Lincoln Electric IM831 manual

RANGER ™ 3 PHA SE OPERA TOR’S MANUAL For Machines with Code Number 11079 IM831 October, 2004 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 REPAI[...]

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 Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v 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 reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ..........................[...]

A-1 INST ALLA TION RANGER 3 PHASE A-1 TECHNICAL SPECIFICA TIONS - RANGER 3 PHASE (K2337-1) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.0 in. 538 lbs. (244kg) 770 mm 485 mm 1067 mm RA TED OUTPUT @ 104°F (40°C)- GENERA TOR Welding Output AC Constant Current 225A / 25V / 100% DC Const[...]

A-2 INST ALLA TION RANGER 3 PHASE A-2 SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or generator creates it’s own power, it is not necessary to connect 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 equipment [...]

PRE-OPERA TION SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL The RANGER 3 PHASE is shipped with the engine crankcase filled with SAE 10W-30 oil. Check the oil level before starti[...]

A-4 INST ALLA TION RANGER 3 PHASE A-4 ANGLE OF OPERA TION 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 15 degrees from horizontal in any direction. If the engine is to be operated at an angle, provisions must be made for ch[...]

A-5 INST ALLA TION RANGER 3 PHASE A-5 • Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example, a 60% duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period. Duty Cycle for the RANGER 3 PHASE is 100%. AUXILIAR Y POWER Do not connect any plugs that connect to the power rece[...]

A-6 INST ALLA TION RANGER 3 PHASE A-6 120 V GFCI DUPLEX RECEPTACLES A GFCI (Ground Fault Circuit Interrupter) electrical receptacle is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault. If this situation should occur, the GFCI will trip, removing voltage from the output of the re[...]

A-7 INST ALLA TION RANGER 3 PHASE A-7 TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER 3 PHASE. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electrical [...]

A-8 INST ALLA TION RANGER 3 PHASE A-8 STANDBY POWER CONNECTIONS The RANGER 3 PHASE is suitable for temporary, standby, or emergency power using the engine manu- facturer ’ s recommended maintenance schedule. The RANGER 3 PHASE can be permanently installed as a standby power unit for 240V-3 wire, single phase 40 ampere service. (Connections must b[...]

240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 40 AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE P[...]

WELDER CONTROLS - FUNCTION AND OPERA TION ENGINE SWITCH The engine switch is used to Start the Engine, Select High Idle or Auto Idle while the engine is running, and stop the Engine. When placed in the “ OFF ” position, the ignition circuit is de-energized to shut down the engine. When held in the “ START ” position, the engine starter moto[...]

“ RANGE ” SWITCH The “ Range ” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Never change the “ RANGE ” Switch setting while welding. This will damage the switch. ------------------------------------------------------------------------ “ CONTROL ” D[...]

B-3 OPERA TION B-3 WELDING PROCESS For any electrodes the procedures should be kept within the rating of the machine. For electrode infor- mation see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK ” and "ELECTRODE ” studs. Start the engine. Set the "Polarity ” switch[...]

B-4 OPERA TION B-4 RANGER 3 PHASE SUMMARY OF WELDING PROCESSES CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25 INTERNAL CONTACTOR contactor closes. Welding s[...]

B-5 OPERA TION B-5 ST ARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’ s Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER ENGINE - Always pull the choke control out [...]

C-1 ACCESSORIES C-1 RANGER 3 PHASE OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 Trailer K958-1 Ball Hitch K958-2 L[...]

C-2 ACCESSORIES C-2 RANGER 3 PHASE RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield WIRE FEED LN-25 K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “ cold ” electrode until gun trigger is pressed. Includes [...]

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their removal is complete. Always use the greatest care when working [...]

D-2 MAINTENANCE D-2 Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tempera- ture use, -5 F to 104 F (-20 C to 40 C). See Engine Owner ’ s Manual f[...]

D-3 MAINTENANCE D-3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum. ---[...]

E-1 TROUBLESHOOTING E-1 RANGER 3 PHASE If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair p[...]

E-2 TROUBLESHOOTING E-2 RANGER 3 PHASE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

E-3 TROUBLESHOOTING E-3 RANGER 3 PHASE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATO R B- HOUR METER 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NU MBERS: 7 6 12 1 2 3 4 J1 N.A. B J2 SOLENOID FUEL SHUTOFF OIL PRESSURE TERMINAL BLOCK (SEE CONN.) 209A 209A 224C 210 B B GENERATOR LEAD END (NOTE CAVITY NUMBER S) LOCATING TA[...]

F-2 DIAGRAMS F-2 RANGER 3 PHASE RANGER 3 PHASE R A NG E R 3 P H AS E / / L L N -1 5 AND LN-25 ACROSS T A N D L N -2 5 A C RO S S T H E ARC CONNECT E A R C C O NN E C T IO N DI N D I A G RA M ELECTRIC SHOCK can kill Do not operate with panels open. Disconnect NEGATIVE (-) Bat tery lead before servicing. Do not touch ele ctrical ly live parts. W ARN [...]

F-3 DIAGRAMS F-3 RANGER 3 PHASE M 20397 A.01 26.5 9 30.2 7 9.09 9.09 17.0 0 21.2 2 8.80 30.0 0 42.0 0 22.1 5 10.3 3 CE NTER OF GR A V ITY WITH OIL I N ENGI NE A ND FULL FUEL TAN K 9.31 CEN TE RL I NE O F S HA FT 9.59 10.1 9 OIL FIL TER REMO VAL[...]

NOTES RANGER 3 PHASE[...]

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 •[...]