Lincoln Electric RANGER 3 PHASE 11079, IM831 User Manual

RANGER™3 PHASE

R

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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 thought­ful operation on your part. DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most

importantly, think before you act
and be careful.

IM831

October, 2004

For Machines with Code Number 11079

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

C US

OPERATOR’S MANUAL

Copyright © 2004 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. 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
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

ARC RAYS 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 and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

Mar ‘95

to

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
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 Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

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 suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

vv

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Machine Grounding.......................................................................................................A-2

Spark Arrester ...............................................................................................................A-2

Towing, Vehicle Mounting .............................................................................................A-2

Vehicle Mounting...........................................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-3

Fuel ...............................................................................................................................A-3

Oil..................................................................................................................................A-3

Battery Connections......................................................................................................A-3

Welding Cable Connections..........................................................................................A-3

Angle of Operation ........................................................................................................A-4

Lifting.............................................................................................................................A-4

High Altitude Operation .................................................................................................A-4

Location and Ventilation................................................................................................A-4

Stacking ........................................................................................................................A-4

Connection of Wire Feeders .........................................................................................A-4

Connection of Tig Module .............................................................................................A-5

Additional Safety Precautions,Welding Operation Output.............................................A-5

Auxiliary Power and Receptacles ................................................................................A-5,A-6

Motor Starting and Extension Cord Length Table ................................................................A-6

Electrical Device Used with the Ranger 10,000 ...................................................................A-7

Auxiliary Power While Welding, Standby Power Connections ............................................A-8

Premises Wiring ...................................................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Controls Function and Operation .............................................................................B-1

Range and Control Dial,Polarity ...........................................................................................B-2

Start in/Shutdown Instructions.....................................................................................................B-3

Starting the Engine........................................................................................................B-3

Safety Precautions ........................................................................................................B-3

Stopping the Engine......................................................................................................B-3

Break-In Period .............................................................................................................B-3

Welding Process ..................................................................................................................B-4

Stick (Constant Current) Welding..................................................................................B-4

TIG (Constant Current) Welding ..................................................................................B-4

Wire Feed Welding Processes (Constant Voltage)......................................................B-4

Arc Gouging ..................................................................................................................B-4

Summary of Welding Processes ...................................................................................B-5

________________________________________________________________________________

Accessories ........................................................................................................Section C

Optional Equipment...............................................................................................C-1

Recommended Equipment....................................................................................C-2

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Engine Oil, Oil Filter and Air Cleaner Maintenance............................D-1,D2

Engine Adjustments...............................................................................................D-3

Slip Rings ..............................................................................................................D-3

Battery Maintenance, Engine Maintenance Parts...........................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Wiring Diagrams & Dimension Print..............................................................Section F

Wiring and Connection Diagrams....................................................................F-1,F-2

Dimension Print......................................................................................................F-3

________________________________________________________________________

Parts List..................................................................................................................P496

________________________________________________________________________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 3 PHASE (K2337-1)

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Operating

Speed (RPM)

Displacement

cu. in.

(cu.cm.)

Starting

System

A-1

Capacities

(K2337-1)

Kohler

CH20S

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic

Ignition

20 HP @

3600 RPM

(Kohler)

High Idle 3700

Full Load 3500

Low Idle 2200

38(624)

Kohler

12VDC
Battery

Electric Start

Group 58

Battery
(435 cold
Cranking

Amps)

RATED OUTPUT @ 104°F (40°C)- WELDER

Welding Output

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

RATED OUTPUT @ 104°F (40°C)- GENERATOR

Auxiliary Power

11,500 Watts Peak,10,500 Watts Continuous, 3 Phase 60 Hz AC,480V

10,500 Watts Peak, 9500 Watts Continuous, Single Phase 60 Hz AC,120V/240V

1

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.1 in. 42.0 in. 538 lbs. (244kg)
770 mm 485 mm 1067 mm

1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.
When welding available auxiliary power will be reduced.

RANGER 3 PHASE

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

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.).

In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth
ground such as a metal water pipe going into the ground for
at least ten feet and having no insulated joints, or to the
metal framework of a building which has been effectively
grounded. The National Electrical Code lists a number of
alternate means of grounding electrical equipment. A
machine grounding stud marked with the symbol is pro­vided on the front of the welder.

SPARK ARRESTER

Some federal, state, or local laws may require that gasoline
engines be equipped with exhaust spark arresters when
they are operated in certain locations where unarrested
sparks may present a fire hazard. The standard muffler
included with this welder does not qualify as a spark
arrester. When required by local regulations, the K894-1
spark arrester must be installed and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the engine
or adversely affect performance.

--------------------------------------------------------------------------------

TOWING

The recommended trailer for use with this equipment for
road, in-plant and yard towing by a vehicle
K957-1. If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment and
usage does not result in a safety hazard nor damage the
welding equipment. Some of the factors to be considered
are as follows:

(1)

is Lincoln’s

WARNING

To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:

• be grounded to the frame of the welder using a

grounded type plug or be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.

-------------------------------------------------------------------------------­When this welder is mounted on a truck or trailer, it’s frame
must be electrically bonded to the metal frame of the vehi­cle. Use a #8 or larger copper wire connected between the
machine grounding stud and the frame of the vehicle.

Where this engine driven welder is connected to premises
wiring such as that in your home or shop, it’s frame must be
connected to the system earth ground. See further connec­tion instructions in the section entitled “Standby Power
Connections”, as well as the article on grounding in the lat­est National Electrical Code and the local code.

RANGER 3 PHASE

1. Design capacity of trailer vs. weight of Lincoln equipment
and likely additional attachments.

2. Proper support of, and attachment to, the base of the

welding equipment so there will be no undue stress to
the framework.

3. Proper placement of the equipment on the trailer to

insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.

4. Typical conditions of use, i.e., travel speed; rough-

ness of surface on which the trailer will be operat­ed; environmental conditions.

5. Conformance with federal, state and local laws

(1) Consult applicable federal, state and local laws regarding specif-

ic requirements for use on public highways.

(1)

A-3

INSTALLATION

A-3

VEHICLE MOUNTING

Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo­nents to fail.

• Only transport this Equipment on serviceable vehicles
which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is sta­ble under conditions of use.

• Do not exceed maximum rated loads for components
such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehi­cle.

• Follow vehicle manufacturer’s instructions.

--------------------------------------------------------------------------------

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instruc­tions supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from
tank.

• Do not leave unattended while fueling.

GASOLINE

can cause fire
or explosion.

• Wipe up spilled fuel and allow
fumes to clear before starting
engine.

• Do not overfill tank, fuel expansion
may cause overflow.

GASOLINE FUEL ONLY

---------------------------------------------------------------------------------

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.

Make certain that the oil filler cap is tightened securely.
Refer to the engine Owner’s Manual for specific oil recom­mendations.

BATTERY CONNECTIONS

-------------------------------------------------------------------------------

This welder is shipped with the negative battery cable dis­connected. Make sure that the Engine Switch is in the
“STOP” 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 start the engine, see the battery charging
instructions in the Battery section.

NOTE: This machine is furnished with a wet charged bat­tery; if unused for several months, the battery may require a
booster charge. Be careful to charge the battery with the
correct polarity.

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work cables
to the studs provided. These connections should be
checked periodically and tightened if necessary. Loose con­nections will result in overheating of the output studs.

When welding at a considerable distance from the welder,
be sure you use ample size welding cables. Listed below
are copper cable sizes recommended for the rated current
and duty cycle. Lengths stipulated are the distance from the
welder to work and back to the welder again. Cable sizes
are increased for greater lengths primarily for the purpose of
minimizing cable voltage drop.

WARNING

• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in the RANGER 3 PHASE base or
weld to the RANGER 3 PHASE base.

CAUTION

Use caution as the electrolyte is a strong acid
that can burn skin and damage eyes.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

225 Amps

100% Duty Cycle

0-100 Ft. (0-31m)

100-200 Ft. (31-61m)

1 AWG

1 AWG

OIL

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Kohler CH20S - 2.0 Quarts (1.9 Liters)

The RANGER 3 PHASE is shipped with the engine
crankcase filled with SAE 10W-30 oil. Check the oil level
before starting the engine. If it is not up to the full mark on
the dip stick, add oil as required.

RANGER 3 PHASE

200-250 Ft. (61-72.m)

1/0 AWG

A-4
ANGLE OF OPERATION

INSTALLATION

Muffler Relocation

A-4

Internal combustion engines are designed to run in a
level condition which is where the optimum perfor­mance 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 checking and maintain­ing the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.

When operating at an angle, the effective fuel capaci­ty will be slightly less than the specified 9 gallons (34
Liters).

LIFTING

The RANGER 3 PHASE weighs approximately 575
lbs.(261kg) with a full tank of gasoline. A lift bail is
mounted to the machine and should always be used
when lifting the machine.

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when lift­ing.

• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

--------------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

If the RANGER 3 PHASE will be consistently operat­ed at altitudes above 5000 ft(1524m), a carburetor jet
designed for high altitudes should be installed. This
will result in better fuel economy, cleaner exhaust,
and longer spark plug life. It will not
power which is decreased at higher altitudes. Engine
horsepower is reduced by 3.5% per 1000
feet(304.8m) for altitudes above 377 feet(115m).

give increased

CAUTION

Do not operate a RANGER 3 PHASE with a high
altitude jet installed at altitudes below 5000
ft.(1524m) This will result in the engine running
too lean and result in higher engine operating
temperatures which can shorten engine life.

-----------------------------------------------------------------------

Contact your local Kohler Authorized Dealer for high
altitude jet kits that are available from the engine
manufacturer.

RANGER 3 PHASE

WARNING

• Shut off welder and allow muffler to cool before

touching muffler.

------------------------------------------------------------------------

The RANGER 3 PHASE is shipped with the exhaust
coming out on the left side. The exhaust can be
changed to the opposite side by removing the two
screws that hold the exhaust port cover in place and
installing the cover on the opposite side. (Operating
the RANGER 3 PHASE without the cover in place will
result in a higher noise level and no increase in
machine output.)

LOCATION / VENTILATION

The welder should be located to provide an unrestrict­ed flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.

STACKING

RANGER 3 PHASE machines cannot be stacked.

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off welder before making any electrical
connections.

-----------------------------------------------------------------------­WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER

The LN-15 has an internal contactor and the electrode
is not energized until the gun trigger is closed. When
the gun trigger is closed the wire will begin to feed
and the welding process is started.

a. Shut the welder off.
b. Set the Polarity switch to the desired polarity,

either DC (-) or DC (+).

c. Attach the single lead from the front of the LN-15

to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.

d. Set the “RANGE” switch to the “WIRE FEED-CV”

position
e. Place the Engine switch in the “Auto Idle” position.
f. Adjust the wire feed speed at the LN-15 and adjust

the welding voltage with the output “CONTROL” at
the welder.

Note: LN-15 Control Cable model will not work with

the RANGER 3 PHASE.

Output “CONTROL” must be set above 3.

A-5

CONNECTION OF THE LN-25 TO THE RANGER 3

PHASE

• Shut the welder off.

•

Connect the electrode cable from the LN-25 to
the

“ELECTRODE” terminal of the welder.
Connect the work cable to the “TO WORK” termi­nal of the welder.

• Position the welder “Polarity” switch to the
desired polarity, either DC (-) or DC (+).

• Position the “RANGE” switch to the “WIRE
FEED” position.

• Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.

• Place the engine switch in the “AUTO” position.

• Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL”
at the welder.

NOTE: The welding electrode is energized at all
times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.

CONNECTION OF K930-2 TIG MODULE TO THE
RANGER 3 PHASE.

The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.

Note: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if the
RANGER 3 PHASE is used with any other high fre­quency equipment, the bypass capacitor must be
installed, order kit T12246.

INSTALLATION

INSTRUCTIONS

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air
flow.

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%.

RANGER 3 PHASE

Constant Current 225 Amps AC @ 25 Volts

210 Amps DC @ 25 Volts

Constant Voltage 200 Amps DC @ 20 Volts

AUXILIARY POWER

CAUTION

Do not connect any plugs that connect to the
power receptacles in parallel.

------------------------------------------------------------------------

Start the engine and set the “IDLER” control switch to
the “High Idle” mode. Set the “CONTROL” to 10.
Voltage is now correct at the receptacles for auxiliary
power. This must be done before a tripped GFCI
receptacle can be reset properly. See the MAINTE­NANCE section for more detailed information on test­ing and resetting the GFCI receptacle.

The RANGER 3 PHASE can provide both three phase
and single phase power, up to 11,500 watts of 480
volts AC, three phase 60Hz power for peak use, and
up to 10,500 watts of 480 volts AC, three phase 60Hz
power for continuous use, up to 10,500 watts of
120/240 volts AC, single phase 60Hz power for peak
use, and up to 9,500 watts of 120/240 volt AC, single
phase 60Hz power for continuous use. The front of
the machine includes four receptacles for connecting
the AC power plugs; one 20 amp 480 volt 3 phase
NEMA receptacle, one 50 amp 120/240 volt NEMA
14-50R receptacle and two 20 amp 120 volt NEMA 5­20R receptacles. Output voltage is within +/-10% at all
loads up to rated capacity. Do not use 3 phase power
and single phase power simultaneously.

Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Owner’s Manual.

WELDER OPERATION

WELDER OUTPUT

• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.

RANGER 3 PHASE

120/240 VOLT DUAL VOLTAGE RECEPTACLE

The 120/240 volt receptacle can supply up to 40 amps
of 240 volt power to a two wire circuit, up to 40 amps
of 120 volts power from each side of a three wire cir­cuit (up to 80 amps total). Do not connect the 120 volt
circuits in parallel. Current sensing for the automatic
idle feature is only in one leg of the three wire circuit
as shown in the following column.

A-6

GND

120 V

120 V*

240 V

*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)

GND

480 V

Y

(FOR ALL SINGLE AND

X

Z

THREE PHASE LOADS)

INSTALLATION

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 receptacle. If a GFCI receptacle is tripped see the
MAINTENANCE section for detailed information on
testing and resetting it. A GFCI receptacle should be
properly tested at least once every month.

The 120V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.

The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle.

480 Volt 3 Phase Receptacle with Ground

The 480 volt receptacle can supply 12.6 amps of 3
phase power, or up to 15 amps of single phase
power. A NEMA plug L16-20P is required to use this
receptacle. The ground (GND) connection is connect­ed to the machine frame, it is NOT the neutral of the
three phase connection, and should under no circum­stances be connected to the neutral of any 3 phase
load. Do not connect 480V 3 phase to single phase
premises wiring.

If 480 volt single phase load is to be run, the X lead
must be one of the leads in the circuit in order for the
automatic idle to function. Using a NEMA plug L16­20P, connect either X and Y or X and Z to the recep­tacle, as well as the machine ground.
All auxiliary power is protected by circuit breakers with
the following values:

The 120V has 20 amp circuit breakers for each
duplex receptacle. The 240V has 50 amp circuit
breakers for each hot lead going the 240V receptacle.
The 480V 3 phase circuit breakers / switch has a 3
phase, 15 amp circuit breaker.

Ground Wire

Periodically check the ground wire at plugs, power
cords and auxiliary loads to ensure that the grounding
circuit is intact and connected.

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a

1.5 hp motor is approximately 20 amperes (10
amperes for 240 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stated
is not exceeded. This may necessitate 240V operation
only.

The 480 volt 3 phase output of the RANGER 3
PHASE is capable of running most 480VAC 3 phase
motors up to 10HP. A 10HP motor must be started
with no load on the motor and no other load connect­ed to the machine, since the full load current of a
10HP 480VAC 3 phase motor is approximately 12.5
amps. Refer to the reconnect phase output to any
load, the ground at the 3 phase receptacle is NOT the
neutral of 3 phase connection, and should under no
circumstance be connected to the neutral of any 3
phase load.

Current

(Amps)

Voltage

Volts
15
20
15
20
40

120
120
240
240
240

RANGER 3 PHASE Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Load

(Watts)

1800
2400
3600
4800
9500

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

30
60

Maximum Allowable Cord Length in ft. (m) for Conductor Size

(9)

(18)

40
30
75
60

Conductor size is based on maximum 2.0% voltage drop.

(12)

(9)
(23)
(18)

150
100

75
50

50

(23)
(15)
(46)
(30)
(15)

125

88
225
175

90

(38)
(27)
(69)
(53)
(27)

RANGER 3 PHASE

175
138
350
275
150

(53)
(42)

(107)

(84)
(46)

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

A-7

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 control. regulation can cause the capac-

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain

INSTALLATION

TABLE lll

itative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe
operation. DO NOT RUN

THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.

maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

A-7

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required,
and liabilities still exist. DO

NOT USE THESE DEVICES
WITH A RANGER 3 PHASE

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect­ed to the RANGER 3 PHASE.

RANGER 3 PHASE

A-8

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time).
Also, the “Output Control” is set at “10” for maximum
auxiliary power.

TABLE I

SIMULTANEOUS WELDING AND POWER***

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Factor) @ 120V

Max. Stick or Wire

Feed Setting None 0 0

145 Stick Setting 4500 38 23

90 Stick Setting 6500 54

INSTALLATION

*-or- @ 240V

** 27

A-8

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 3 PHASE by installing
a 40 amp 240V double pole circuit breaker.
Maximum rated load for the 240V auxiliary is 40
amperes. Loading above 40 amperes will reduce
output voltage below the allowable -10% of rated
voltage which may damage appliances or other
motor-driven equipment.

3. Install a 50 amp 120/240V plug (NEMA type 14-50)
to the Double Pole Circuit Breaker using No. 8, 4
conductor cable of the desired length. (The 50 amp
120/240V plug is available in the optional plug kit.)

NO WELDING 9500 80

** 40

* Each duplex receptacle is limited to 20 amps.
**Not to exceed 40A per 120VAC branch circuit when

splitting the 240 VAC output.

***Use of 3-Phase AC poower is not recommended

while welding.

STANDBY POWER CONNECTIONS

The RANGER 3 PHASE is suitable for temporary,
standby, or emergency power using the engine manu­facturer’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.

WARNING

4. Plug this cable into the 50 amp 120/240V recepta­cle on the RANGER 3 PHASE case front.

(Connections must be made by a licensed electri­cian who can determine how the 120/240V power
can be adapted to the particular installation and
comply with all applicable electrical codes.) The
following information can be used as a guide by
the electrician for most applications (refer also to
the connection diagram shown in Figure 1.)

-------------------------------------------------------------------------

RANGER 3 PHASE

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 POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES

SERVICE OVERCURRENT

PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

A-9

INSTALLATION

Figure 1

CONNECTION OF RANGER 3 PHASE TO PREMISES WIRING

A-9

WARNING

Connection of RANGER 3 PHASE to premises
wiring must be done by a licensed electrician and
must comply with the National Electrical Code and
all other applicable electrical codes. See the
Installation Section for important information
about not using the 480V 3 Phase Receptacle for
connection to Single Phase Premises Wiring.

RANGER 3 PHASE

B-1

OPERATION

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door

closed and the side panels in place.

B-1

WELDER CONTROLS - FUNCTION AND
OPERATION

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 motor is energized.

When in “HIGH IDLE” ( ) position, the engine will
run continuously at high idle.

• Read carefully the Safety Precautions page

before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The RANGER 3 PHASE is a twin-cylinder, gasoline
driven, multiprocess arc welder and AC power gener­ator. It is built in a heavy gauge steel case for durabili­ty on the job site.

When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:

• 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.

• Auxiliary Power
With the engine running at low idle and auxiliary

power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles,
the engine will accelerate to high speed. If no
power is being drawn from the receptacles (and
not welding) for 10-14 seconds, the idler reduces
the engine speed to low idle.

RANGER 3 PHASE

B-2

OPERATION

“ 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.

Process Range Setting Current Range

STICK/TIG
(constant current)
(3 range settings)

WIRE FEED

(constant voltage)

(one range setting)

Never change the “RANGE” Switch setting while
welding. This will damage the switch.

------------------------------------------------------------------------

“ CONTROL” DIAL

90 Max.

145 Max.

210DC/225AC Max.

15 to 25V

CAUTION

50 to 90 Amps

70 to 145 Amps

120 to 210 (DC) 225(AC)

Up to 200 Amps

B-2

Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and weld­ing voltage control with the Range switch set in the
wire feed mode.

POLARITY SWITCH

Provides three selectable welding polarities:
AC, DC+ & DC-

CAUTION

Never change the Polarity switch setting while
welding. This will damage the switch.

------------------------------------------------------------------------

RANGER 3 PHASE APPROXIMATE FUEL CONSUMPTION

KOHLER

20 H.P. COMMAND

Low Idle - No Load

2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
225 Amps @ 25 Volts
DC CC Weld Output
210 Amps @ 25 Volts
DC CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power Single Phase
9,500 Watts
Auxiliary Power 3 Phase
10,500 Watts

.35 Gallons/Hour

(1.34 Liters/Hour)

.76 Gallons/Hour

(2.86 Liters/Hour)

1.23 Gallons/Hour
(4.64 Liters/Hour)

1.38 Gallons/Hour
(5.21 Liters/Hour)

1.22 Gallons/Hour
(4.60 Liters/Hour)

1.52 Gallons/Hour)
(5.77 Liters/Hour)

1.64Gallons/Hour)
(6.23 Liters/Hour)

RANGER 3 PHASE

B-3

OPERATION

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 to the desired polarity. The “RANGE”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The “OUTPUT” Control provides fine adjust­ment of the welding current within the select range.
For maximum output within a selected range set the
“OUTPUT” Control at 10. For minimum output within a
selected range set the “OUTPUT” Control at 5. (“OUT­PUT” Control settings below 5 may reduce arc stabili­ty) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUT­PUT” Control near the maximum to achieve the
desired welding current.

RANGE SETTING TYPICAL CURRENT RANGE

ELECTRODE SIZE

90 MAX.

125 MAX.

3/32

1/8

50 TO 90 AMPS

70 TO 145 AMPS

B-3

SETTINGS FOR 1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps

The K930-[ ] TIG Module should be used with the
RANGER 3 PHASE on high idle to maintain satisfac­tory operation. It can be used in the AUTO position
but the delay going to flow idle after welding is ceased
will be increased if the AFTER FLOW CONTROL is
set above 10 seconds.

WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)

®

The Innershield
the RANGER 3 PHASE is NR
trode sizes and welding ranges that can be used with
the RANGER 3 PHASE are shown in the following
table:

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A

electrode recommended for use with

®

-212-MP. The elec-

210(DC)/225(AC)

MAX.

5/32

120 TO 210(DC),

225(AC) AMPS

The RANGER 3 PHASE can be used with a broad
range of AC and DC stick electrodes. See “Welding
Tips 1” included with the RANGER 3 PHASE for elec­trodes within the rating of this unit and recommended
welding currents of each.

TIG (CONSTANT CURRENT) WELDING

The K930-[ ] TIG Module installed on a RANGER 3
PHASE provides high frequency and shielding gas
control for AC and DC GTAW (TIG) welding process­es. The TIG Module allows full range output control.
After flow time is adjustable from 0 to 55 seconds.

When using the RANGER 3 PHASE for AC TIG weld­ing of aluminum, the following settings and electrodes
are recommended:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/16 90 40 - 80 Amps

The RANGER 3 PHASE is recommended for limited
“MIG” welding (GMAW - gas metal arc welding). The
recommended electrodes are.030” and .035”SuperArc
L-50 and L-56. They must be used with a blended
shielding gas such as C25 (75% Argon - 25% CO

2

The welding ranges that can be used with the
RANGER 3 PHASE are shown in the following table:

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.030 80 - 110 75A to 120A
.035 70 - 130 120A to 170A

ARC GOUGING

The RANGER 3 PHASE can be used for limited arc
gouging.

Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:

CARBON DIAMETER (in) CURRENT RANGE (DC, electrode positive)

1/8 30 - 60 Amps
5/32 90 - 150 Amps
3/16 150 - 250 Amps

).

RANGER 3 PHASE

B-4

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.

WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding

TIG, TIG MODULE WITH Yes High Cold Press Arc Start Switch
WITH CONTACTOR KIT contactor closes,
CONTROL CABLE, & ARC welding starts immediately.
START SWITCH

OPERATION

Welding starts immediately
and engine goes to high
idle.

starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”

B-4

WIRE FEED, LN-15 No Auto Cold Press gun trigger.
ACROSS the ARC LN-15 contactor closes,
(has internal contactor) Welding starts immediately

Note: Output Control must
be set above “3”.

RANGER 3 PHASE

B-5

OPERATION

B-5

STARTING/SHUTDOWN INSTRUCTIONS

STARTING THE ENGINE

WARNING

• Do not touch electrically live parts
of electrode with skin or wet
clothing.

• Keep flammable material away.

• Insulate yourself from work and

ground. Wear eye, ear, and body
protection.

• Keep your head out of the fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

Be sure all Pre-Operation Maintenance has been per­formed. 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

when starting the engine; cold, warm or hot.

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.

Stop the engine by placing the Engine switch in the
“OFF” position.

A fuel shut off valve is not required on the RANGER
3 PHASE because the fuel tank is mounted below the
engine.

BREAK-IN PERIOD

It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi­mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS

BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.

The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:

KOHLER

CH20SI

Turn the engine switch to the “start” position and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
and turn the switch to the Auto Idle( / )
position. Do not turn the switch to the “start” position
while the engine is running because this will cause
damage to the ring gear and/or starter motor

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.

RANGER 3 PHASE

5 HRS

The oil filter is to be changed at the second oil
change. Refer to the Engine Owner’s Manual for more
information.

C-1

ACCESSORIES

C-1

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 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack

K889-2 & -3 Two-Wheel Undercarriage - For moving
by hand. Overall Width 29 in (.74m) Both have pneu­matic tires. Puncture proof tires included with K889-3.

K1631-1 Puncture Proof Wheel Kit - For converting
K889-2 or K933-1 to puncture proof pneumatic tires.

K893-1 Caster for Undercarriage - Mounts to the
front of the K889-2 or 3 to allow easy movement on
smooth surfaces. Includes 6” diameter hard rubber
wheel and convenient toe-on, toe-off locking brake.

K933-1 Four Wheel Undercarriage - For Hand
Moving. Rear pneumatic tires, front molded wheels.

K802-N Power Plug Kit - Provides four 120V plugs
rated at 20 amps each and one dual voltage, full KVA
plug rated at 120/240V, 50 amps.

K704 Accessory Kit - Includes 35 ft (10.7m) 2/0 AWG elec­trode cable, 30 ft. (9.1m) 2/0 AWG work cable, headshield
Filterplate, work clamp and electrode holder. 450 Amp.
Capacity.

K894-1 Spark Arrester Kit - Includes a heavy gauge steel,
approved spark arrester and clamp for easy mounting to
muffler exhaust pipe.

K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
(which accepts 4-prong plugs) and converts it to a NEMA 6­50R receptacle, (which accepts 3-prong plugs.)

T12153-9 Full-KVA Power Plug - One dual voltage plug
rated at 120/240V, 50 amps.

K930-2 TIG Module - Provides high frequency and shield­ing gas control.for AC and DC GTAW (TIG) welding applica­tions. Its compact case is designed foe easy carrying, com­plete with a handle. High frequency bypass is built in
Requires K938-1 Contactor Kit, K936-4 Control Cable, and
K814 Arc Start Switch.

K934-1 Cylinder Brackets ­transporting one welding gas cylinder.

K1737-1 FOUR WHEEL ALL-TERRAIN UNDER­CARRIAGE - For moving by hand at construction

sites. Heavy duty puncture resistant pneumatic tires.
K1770-1 UNDERCARRIAGE (FACTORY) - For mov-

ing by hand on a smooth surface. One or two gas
cylinders can be mounted on the rear of the undercar­riage with the installation of K1745-1 Cylinder
Holder(s). Heavy duty puncture resistant pneumatic
tires and front caster.

K1745-1 GAS CYLINDER HOLDER

Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.

K1788-1 ROLL CAGE - Gives added damage protection.
Attaches to K1737-1, K1770-1, and K957-1.

K886-1 Canvas Cover -To protect the RANGER 3
PHASE when not in use. Made from attractive red
canvas material which is flame retardant, mildew
resistant, and water repellent.

For use with K933-1.

For

K938-1 Contactor Kit - For use with TIG Module, Provides a
“cold” electrode until the triggering device (Arc Start Switch)
is pressed.

K936-4 Control Cable - Connects TIG Module to RANGER
3 PHASE. (9 Pin to 115V Plug)

K814 Arc Start Switch - Attaches to the TIG torch for conve­nient finger control.

K937-45 Control Cable Extension - Allows TIG Module to be
operated at distances up to 200ft. from the power source.
Available in 45ft. (13.7m) Sections.

K844-1 Water Valve Kit - For use with water cooled TIG
torch, Installs inside of TIG Module.

K939-1 Docking Kit - For Mounting the K930-2 TIG Module
on top of the RANGER 3 PHASE.

K875 Accessory Kit - Includes 20 ft (6.1m) #6 electrode
cable, headshield, filter plate, work clamp , electrode holder
and sample packof mild steel electrodes 2w Amp. Capacity.

lug, 15ft. (4.6) #6 work cable

K802-R Power Plug Kit- provides four 120V plugs
rated at 15 amps each and one dual voltage, Full
KVA plug rated at 120/240V, 50 amps.

RANGER 3 PHASE

C-2

RECOMMENDED EQUIPMENT

ACCESSORIES

C-2

STICK

K704 Accessory Kit which includes:

• Electrode Holder & Cable

• Work Clamp & Cable

• Headshield

FEED

WIRE

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 gas
solenoid. Requires Drive Roll Kit and Weld Power
Cable.

Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.

TIG

Magnum™ TIG Torch

•K 26V 2 Cable Pro Torch

Magnum Parts Kit and Argon Gas

•K509 Parts Kit

K930-2 TIG Module (Requires)

• Requires K938-1 Contactor Kit,

• K936-4 Control Cable, and

• K814 Arc Start Switch

Optional TIG Module Accessory:

• K939-1 Docking Kit

• K937-45 Control Cable Extensions (45ft.)

• K844-1 Water Valve Kit

LN-15

K449 LN-15 - Includes internal contactor for across
the arc operation (no control cable). Provides “cold”
electrode until gun trigger is pressed. Includes gas
solenoid. Requires Drive Roll Kit and Weld Power
Cable.

Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Magnum
Innershield Gun and wire bushing is required for gas­less welding.

RANGER 3 PHASE

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

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 mainte­nance requiring their removal is complete.
Always use the greatest care when working near
moving parts.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts

or electrode with skin or wet
clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas

or vent exhaust outside.

CAUTION

Make certain that the oil filler cap is securely tight­ened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.

------------------------------------------------------------------------

• OIL - Maintenance schedule for changing the oil and
oil filter after break-in :

Kohler
CH20S

Oil 100 Hrs.

Oil Filter 200 Hrs.

The above schedule is for normal operating condi­tions. More frequent oil changes are required with
dusty, high temperature and other severe operating
conditions. Refer to the maintenance section of the
Engine Owner's Manual for more information.

NOTE: Engine life will be reduced if the oil and oil
filter are not changed according to the manufacturer’s
recommendation.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information

throughout this operator’s manual and
the Engine manual as well.

------------------------------------------------------------

Read the Safety Precautions in the front of this manual
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 when starting, operating, or repairing the
equipment.

ROUTINE MAINTENANCE

• At the end of each day’s use, refill the fuel tank to

minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and
add oil if indicated.

RANGER 3 PHASE

ENGINE OIL CHANGE

Drain the oil while the engine is warm to assure rapid
and complete draining.

• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable contain­er.

• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

With oil filter replacement:

• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

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 con­tainer to be sure it includes the letters SG or SH.

MAINTENANCE

D-2

• Refer to the maintenance section of the Engine

Owner’s Manual for the maintenance schedule,
spark plug servicing, cooling system servicing, and
fuel filter replacement.

SAE 10W-30 is recommended for general, all-tempera­ture use, -5 F to 104 F (-20 C to 40 C).

See Engine Owner’s Manual for more specific informa­tion on oil viscosity recommendations.

Wash your hands with soap and water after handling
used oil.

Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.

Do not throw it in the trash, pour it on the ground or
down a drain.

OIL FILTER CHANGE

1. Drain the engine oil.

2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.

3. Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.

4. Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil fil­ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.

5. Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.

6. Start the engine and check for oil filter leaks.

7. Stop the engine, and check the oil level. If neces­sary, add oil to the upper limit mark on the dipstick.

• Blow out the machine with low pressure air period­ically. In particularly dirty locations, this may be
required once a week.

• Output Ranger Selector and Polarity Switches:

Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the han­dle from maximum to minimum setting twice each
morning before starting to weld.

GFCI RECEPTACLE TESTING AND RESET­TING PROCEDURE

The GFCI receptacle should be properly tested at
least once every month or whenever it is tripped. To
properly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully remove

any load and check it for damage.

• If the equipment has been shut down, it must be

restarted.

• The equipment needs to be operating at high idle

speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be

tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI recep-

tacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other

product (such as a lamp) into the GFCI receptacle
and turn the product "ON".

• Push the "Test" button located on the GFCI recepta-

cle. The night-light or other product should go
"OFF".

• Push the "Reset" button, again. The light or other

product should go "ON" again.

AIR CLEANER AND OTHER MAINTENANCE

• Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling the
foam pre-filter is every 25 hours and replacement of
the air cleaner filter every 100 hours. More frequent
servicing is required with dusty operating condi­tions. Refer to the maintenance section of the
Engine Owner’s Manual for more information.

RANGER 3 PHASE

If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI is not working prop­erly or has been incorrectly installed (miswired). If
your GFCI is not working properly, contact a qualified,
certified electrician who can assess the situation,
rewire the GFCI if necessary or replace the device.

D-3

MAINTENANCE

D-3

ENGINE ADJUSTMENTS

OVERSPEED IS HAZARDOUS

WARNING

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.

------------------------------------------------------------------------

Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary.If brushes are
to be replaced, clean slip rings with a fine emery
paper.

CAUTION

Do not attempt to polish slip rings while engine is
running.

------------------------------------------------------------------------

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
last.

• CONNECTING A BATTERY CHARGER - Remove bat­tery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When rein­stalling, connect negative cable last. Keep well venti­lated.

• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.

BATTERY

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, disconnect the negative battery cable
first and then the positive battery cable before
attaching the charger leads. Failure to do so
can result in damage to the internal charger
components. When reconnecting the cables,
connect the positive cable first and the negative
cable last.

HARDWARE

Both English and Metric fasteners are used in this
welder.

ENGINE MAINTENANCE PARTS

KOHLER C20S

KOHLER 1205001

Oil Filter FRAM PH3614*
Air Filter KOHLER 4708303

Element FRAM CA79
Air Filter KOHLER 2408302

Pre-Cleaner
Fuel Filter KOHLER 2505002

FRAM G1

Spark Plugs CHAMPION RC12YC
(Resistor (.030” GAP)

Type)

* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.

RANGER 3 PHASE

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

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.

RANGER 3 PHASE

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-2

RECOMMENDED

COURSE OF ACTION

No auxiliary power from the GFCI
receptacle.

Engine will not go to high idle when
using auxiliary power.

No welder output power.

Engine will not idle down to low
speed.

Engine will not go to high idle when
attempting to weld.

1. GFCI Receptacle may have
tripped. Follow “GFCI
Receptacle Testing and
Resetting Procedure” in the
MAINTENANCE section of this
manual.

1. GFCI may be tripped-see above

2. No voltage signal from the
current sensor.

3. Auxiliary power load less than
100 to 150 watts.

4. Faulty P.C. Board.

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 Field rectifier (D2).

7. Faulty P.C. Board.

1. Idler switch on High Idle.

2. Insufficient voltage present
between terminals #213 and
#5E. (Voltage should be 12V
DC).

3. External load on welder or
auxiliary power.

4. Faulty wiring in solenoid circuit.

5. Faulty idler solenoid.

6. Faulty P.C. Board.

1. Poor work lead connection to
work.

2. No voltage signal from the
current sensor.

3. No open circuit voltage on
output studs.

4. Faulty P.C. Board.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

CAUTION

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.

RANGER 3 PHASE

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-3

RECOMMENDED

COURSE OF ACTION

Engine will not crank or is hard to
crank.

Engine shuts down.

Engine does not develop full power.

Engine is hard to start.

1. Battery will not hold a charge.
Faulty Battery.

2. No or insufficient charging
current.

3. Loose battery cable
connection(s).

1. Out of fuel.

2. Low oil level.

1. Fuel filter clogged.

2. Air filter clogged.

1. Spark plugs do not have
specified gap.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

2. Spark plugs are fouled.

CAUTION

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.

RANGER 3 PHASE

STARTER

CR1

STARTER

SOLENOID

12 VOLT

IDLER

SOLENOID

BATTERY

AC ACB+

SWITCH

REGULATOR

FLYWHEEL ALTERNATOR

B-

HOUR METER

5E

5D

224

ENGINE COMPONENTS

224A

12

3

CONNECTOR PIN NUMBERS:

7

6

12

12

34

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 NUMBERS)

LOCATING TAB

TERMINAL BLOCK

CONNECTION

208

208 (CAVITY #2)

211 (CAVITY #3)

224C (CAVITY #4)

13

2

4

211

IGNITION

MODULE

M20315

215

+

ELECTRICAL SYMBOLS PER E1537

STATOR

REACTOR

S1

WORK

CHOKE

D1

S2

ROTOR

PCB1

W1

W2

C1

S1

R1

R5

C1

L1

-

+

+

R3

STATOR

REACTOR

+

10

8

1

7

12

6

9

7

200A

219

3

ENGINE

CROSS

SUPPORT

GROUND SCREW

GND-E

GND-E

GND-G

200A

219

224

215

76A

5E

75A

77A

J1

8

10

5D

254

R1

OUTPUT

CONTROL

75A

76A

77A

75A

77A

76A

ON UPPER CASEFRONT

-

209

+

R

R

U

V

W

ENGINE

FOOT

GND-D

GND-C

5F

224A

GND-H

TERMINALS

6

5

5L

120V/240V

5K

GND-D

GND-C

J4

J3

J2

GND-G

5L

5K

120V

120V

12

11

11

3A

3A

CB1

50A

50A

CB2

CB3

20A

20A

CB4

3

SILVER COLORED

(WHITE WIRES)

RANGER 3 PHASE

A.02

CCW

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

210

CB7

25A

R = RED OR PINK

B = BLACK OR GRAY

V = VIOLET

U = BLUE

W = WHITE

LEA

D COLOR CODE:

254

3

12

3

4

261

260

LEADS 254 PASSES THRU

TOROID 1 TIME

211

213

208C

6A

6

LEADS 3 AND 6:

2 TURNS THRU TOROID IN

OPPOSITE DIRECTIO NS

6

6

79

J2

S2 E

GND-J

P5

J5

GROUND SCREW

ON LOWER

CASEFRONT

S3

3B

6B

5

6

3

X

Y

Z

Z

X

480 V

3-PHASE

CB1

15 AMP

X

X

Y

Z

6

3

GND-I

Z

Y

SLIP RING NEAREST LAMINATION

6

3

GND-I

GND-I

ELECTRODE

WAC

W1

WAC

X

LEAD X FROM STATOR TO

PASS THROUGH TOROID

ONCE (NOT SHOWN)

IN SAME DIRECTION

AS LEAD 6.

NEUT

HOT

HOT

NEUT

120V

GFCI

GFCI

LEAD X PASSES THRU TOROID

ONCE IN SAME DIRECTION

AS LEAD 6.

213A

213A

F-1

Enhanced Diagram

DIAGRAMS

F-1

RANGER 3 PHASE

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

F-2

RANGER

3

PHASE

/

L

N-15

AND

LN-25

ACROSS

T

H

E

ARC

CONNECT

IO

N

DI

AGRAM

ELECTRIC SHOCK can kill

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

before servicing.

Do not touch ele

ctrically live parts.

WARNING

MOVING PARTS can injure

Keep guards in place.

Keep away from moving parts.

Only qualified personnel should install,use

or service this

equipment.

M20266

A.02

TO WORK

ELECTRODE

TO

ENGINE

WELDER

WORK

LN

LN-15 OR

-25

WI

RE

FEEDER

TO

WORK

ELECTRODE

CABLE

WORK CLIP LEAD

N.A. WELDING

CABL

E

MUST

BE

SIZE

D

FO

R

CURRENT

DUTY

CYCLE

OF

APPLICATION.

N.B.

USE

POLARITY

SWIT

CH

TO

SET

FOR

DESIRE

D

ELECTRODE

POLARITY

.

POSITION

TH

E

OUTPUT

SELECTOR

SWITCH

TO

TH

E

WIRE

FEED

(CV)

POSITION.

DIAGRAMS

W

F-2

N DI

E ARC CONNECT

AND LN-25 ACROSS T

L

/

equipm

or service this

S

RE F

E OU
T

A
O

C

D

CU
R

D F

SIZ
B

M
E

C

PO

.

P

D EL

D

F

S

CH T

S

PO

USE

PO

(

F

W
E

T
T

CABL

W

RANGER 3 PHASE

RANGER 3 PHASE

F-3

DIAGRAMS

CENTER OF GRAVITY WITH OIL IN

ENGINE AND FULL FUEL TANK

A.01

42.00

F-3

M20397

22.15

21.22

8.80 30.00

10.33

30.27

26.59

OIL FILTER REMOVAL

CENTERLINE OF SHAFT

9.59

17.00

9.31

10.19

9.09 9.09

RANGER 3 PHASE

NOTES

RANGER 3 PHASE

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com