Lincoln Electric IM604-B manual

OPERA TOR’S MANUAL Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONT[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

RANGER 8 LPG Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick refer[...]

vi vi T ABLE OF CONTENTS Page SAFETY PRECAUTIONS .......................................................................................i - iv INTRODUCTORY INFORMATION ............................................................................v GENERAL DESCRIPTION ....................................................................................[...]

1 1 RANGER 8 LPG GENERAL DESCRIPTION The Ranger ™ 8 LPG is a twin-cylinder LPG fuel engine driven multiprocess arc welder and AC power genera- tor. It is built in a heavy gauge steel case for durability on the job site. DESIGN FEA TURES AC/DC STICK WELDING (Constant Current) • AC 40 - 225 Amps • DC 40 - 210 Amps • 100% Duty Cycle on All Set[...]

2 2 RANGER 8 LPG Machine Product Name Ordering Information K1616-1 Description Multi-Purpose Arc Welder with 8,000 watts of Auxiliary Power AC Constant Current 225A / 25V / 100% DC Constant Current 210A / 25V / 100% DC Constant Voltage 200A / 20V / 100% Max. O.C.V. 80V Auxiliary Power Welding Output 8000 Watts, 60 Hz AC 70 Amps @ 115V 35 Amps @ 230[...]

3 3 RANGER 8 LPG AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE A B OUTPUT AMPS OUTPUT VOLTS AC 0 50 100 150 200 250 0 10 20 30 40 50 60 70 80 DC STICK / TIG (CC) OUTPUT OUTPUT AMPS OUTPUT VOLTS DC A 210 OUTPUT RANGE B 50 OUTPUT RANGE A B 0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 CV OUTPUT RANGE 0 50 100 150 200 250 30[...]

4 4 RANGER 8 LPG OPTIONAL EQUIPMENT (Field Installed) Four Wheel Undercarriage (K933-1) - Allows move- ment of the Ranger 8 by hand without lifting. Easily assembles to the Ranger 8. Includes two rugged, hard molded wheels and two durable, two ply nylon 4.80/4.00-8 pneumatic tires rated at 30 psi. The spring loaded handle provides convenient, comfo[...]

5 5 RANGER 8 LPG RECOMMENDED EQUIPMENT STICK Accessory Kit (K710) which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield Remote Control Receptacle Kit (K892-1), and Remote Control Kit (K857) are optional for remote current control. TIG Magnum™ TIG Torch Magnum Parts Kit and Argon Gas TIG Module (K930-1) Contact[...]

6 6 RANGER 8 LPG INST ALLA TION INSTRUCTIONS Safety Precautions Machine Grounding Because this portable engine driven welder or gener- ator creates it’s own power, it is not necessary to con- nect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). To prevent dangerous electric shock, other[...]

7 7 RANGER 8 LPG • The stem of the cylinder valve and where the valve is attached to the top of the cylinder. • All other fittings on top of the fuel cylinder. If growing bubbles appear, there is a leak. Re-tighten connection or replace defective component. Retest to make sure that there is no leak. Leak test must be performed each time the fue[...]

8 8 RANGER 8 LPG Battery Connections This welder is shipped with the negative battery cable disconnected. Make sure that the Engine Switch is in the “OFF” position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine. If the battery is discharged and does not have enough power to s[...]

9 9 RANGER 8 LPG Angle of Operation Internal combustion engines are designed to run in a level condition which is where the optimum perfor- mance is achieved. The maximum angle of operation for the engine is 25 degrees from horizontal in any direction. If the engine is to be operated at an angle, provisions must be made for checking and maintain- i[...]

10 10 RANGER 8 LPG Connection of the LN-7 to the Ranger 8 a. Shut the welder off. b. Connect the LN-7 and the K240 contactor kit per instructions on the connection diagram S17742 (can be found in the back of this manual). c. Place the “RANGE” switch to the “WIRE FEED” position and the “POLARITY” switch to the desired polarity. d. Place [...]

a. Welding When the electrode touches the work, the welding arc is initiated and the engine accelerates to full speed. After welding ceases (and no auxiliary power is being drawn), the engine will return to low idle after approximately 10 to 14 seconds. b. Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools i[...]

12 12 RANGER 8 LPG After running at high engine speed for 10-14 seconds, the engine will go to low idle. Allow the engine to warm up by letting it run at low idle for a few minutes. Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine. NOTE: Backfiring may oc[...]

13 13 RANGER 8 LPG Wire Feed Welding Processes (Constant Voltage) The only Innershield ® electrode recommended for use with the Ranger 8 is NR ® -211-MP. The electrode sizes and welding ranges that can be used with the Ranger 8 are shown in the following table: Diameter Wire Speed Approximate (in.) Range In./Min. Current Range .035 80 - 110 75A t[...]

14 14 RANGER 8 LPG The current rating of any plug used with the system must be at least equal to the current load through the associated receptacles (see tables below). Do not attempt to connect power receptacles in parallel. * Maximum current draw from each 115V GFCI Duplex receptacle is 20 amps. 115/230 Volt Dual Voltage Receptacle The 115/230 vo[...]

15 15 RANGER 8 LPG 1. Install a double pole, double throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customer’s premises disconnect and service overcurrent protection. 2. Take necessary steps to assure load is limited to the capacity of the Ranger 8 by installing a 35 amp[...]

16 16 RANGER 8 LPG CAUTION Certain Electrical devices cannot be powered by the RANGER 8 LPG. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE RANGER 8 LPG. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, mi[...]

17 17 RANGER 8 LPG MAINTENANCE Safety Precautions Read the Safety Precautions in the front of this manu- al and the engine instruction manual before working on this machine. Keep all equipment safety guards, covers, and devices in position and in good repair. keep hands, hair, clothing, and tools away from gears, fans, and all other moving parts wh[...]

18 18 RANGER 8 LPG 1. When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover. 2. If the battery requires charging from an external charger, [...]

19 TROUBLESHOOTING 19 RANGER 8 LPG TROUBLE A. No welder or output power. B. Engine will not idle down to low speed. C. Engine will not go to high idle when attempting to weld. CAUSE 1. Open in miscellaneous leads. 2. Open lead in flashing or field circuit. 3. Faulty rotor. 4. Faulty Potentiometer (R1). 5. Faulty stator Field winding. 6. Faulty Fiel[...]

20 TROUBLESHOOTING 20 RANGER 8 LPG TROUBLE D. Engine will not go to high idle when using auxiliary power. E. Engine will not crank or is hard to crank. F. Engine shuts down. G. Engine does not develop full power. H. Engine is hard to start. CAUSE 1. No voltage signal from the current sensor. 2. Auxiliary power load less than 100 to 150 watts. 3. Fa[...]

21 WIRING DIAGRAM 21 RANGER 8 LPG STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID 213 BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D S4 224B 224 213 "S4" SHOWN IN "AUTO" POSITION ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 LEAD COLOR CODE: B = BLACK R = RED W = WHITE N.A. [...]

22 DIAGRAMS 22 RANGER 8 LPG STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID 213 BATTERY AC AC B+ SWI TCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D S4 224B 224 213 "S4" SHOWN IN "AUTO" POSITION ENGINE COMPONENT S 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 N.A. B J5 SOLENOID FUEL SHUTOFF OIL PRESSURE TERMINAL [...]

23 CONNECTION DIAGRAMS 23 RANGER 8 LPG CONNECTION OF RANGER 8 TO LN-7 & K240 CONT ACTOR KIT WARNING: Turn the power off when making connections. N.A. Use power source polarity switch to set for desired electrode polarity. Position the output selector switch on the power source to the CV position. N.B. 3 conductor #16 power cord physically suita[...]

9.29 21.21 21.95 43.80 17.00 26.59 30.28 19.11 9.31 M17215-4 CRM28731 9.09 9.09 UNDERCARRIAGE MOUNTING HOLES 42.25 42.00 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 11.31 FOR OIL FILTER REMOVAL 8.80 30.00 2.75 24 DIMENSION PRINT 24 RANGER 8 LPG DIMENSION PRINT - Ranger 8 LPG (Kohler)[...]

NOTES RANGER 8 LPG[...]

NOTES RANGER 8 LPG[...]

NOTES RANGER 8 LPG[...]

There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location. Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U .S. Funds Only. Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for del[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]