Lincoln Electric SVM207-A User Manual

RANGER®3 Phase

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For use with machine code number: 11079 & 11419

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.

SVM207-A

January, 2011

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

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

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.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.

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.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.

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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.

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.

RANGER® 3 PHASE

ii ii

SAFETY

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.

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.

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 within applicable OSHA PEL and ACGIH
TLV limits 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.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

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.d. 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.

vapors

to

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5.e. 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.f. Also see item 1.b.

RANGER® 3 PHASE

iii iii

SAFETY

WELDING and CUTTING
SPARKS can cause fire or
explosion.

6.a.
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent 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.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

If

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.

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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RANGER® 3 PHASE

iv iv

SAFETY

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.

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:

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.

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

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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
zones où l’on pique le laitier.

RANGER® 3 PHASE

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.

v v

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com­plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national

codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip­ment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

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h) the time of day that welding or other activities are to be carried out.

RANGER® 3 PHASE

vi vi

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con­nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-

1

tions.

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_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

RANGER® 3 PHASE

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv

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

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

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

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

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-496

RANGER® 3 PHASE

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications.............................................................................................................................A-2

Safety Precautions.....................................................................................................................................A-3

Machine Grounding ...................................................................................................................................A-3

Spark Arrestor............................................................................................................................................A-3

Towing .......................................................................................................................................................A-3

Vehicle Mounting .......................................................................................................................................A-4

Pre-Operation Service ...............................................................................................................................A-4

Welding Output Cables..............................................................................................................................A-5

Angle of Operation.....................................................................................................................................A-5

Lifting .........................................................................................................................................................A-5

TABLE OF CONTENTS - INSTALLATION SECTION

Fuel ... ..................................................................................................................................................A-4

Oil .........................................................................................................................................................A-4

Battery Connections .............................................................................................................................A-4

High Altitude Operation..............................................................................................................................A-5

Muffler Relocation......................................................................................................................................A-5

Location/Ventilation....................................................................................................................................A-6

Connection of Wire Feeders......................................................................................................................A-6

Additional Safety Precautions....................................................................................................................A-6

Welder Operation.......................................................................................................................................A-6

Auxiliary Power ..........................................................................................................................................A-7

Motor Starting ............................................................................................................................................A-8

Stand-by Power Connections ....................................................................................................................A-8

Auxiliary Power While Welding..................................................................................................................A-8

Connection of RANGER® 3PHASE to Premises Wiring (Drawing) ..........................................................A-9

Extension Cord Recommendations .........................................................................................................A-10

Electrical Devices used w/RANGER® 3 PHASE ....................................................................................A-10

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RANGER® 3 PHASE

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER® 3 PHASE (K2337-1 & K2337-2)

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Operating

Speed (RPM)

Displacement

cu. in.

(cu.cm.)

Starting

System

Capacities

K2337-1

Kohler

CH20S

K2337-2

Kohler

CH23S

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic

Ignition

RATED OUTPUT @ 104°F (40°C)- WELDER

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

20 HP @

3600 RPM

23 HP @

3600 RPM

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

High Idle 3700

Full Load 3500

Low Idle 2200

Welding Output

Auxiliary Power

38(624)

Kohler

CH20S

41(674)

Kohler

CH23S

1

12VDC
Battery

Electric Start

Group 58

Battery

(435 cold

cranking

amps)

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

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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

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.1 in. 42.3 in. 538 lbs.
770 mm 485 mm 1074 mm (244kg)

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.

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RANGER® 3 PHASE

A-3 A-3

INSTALLATION

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.

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

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.

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

See additional warning information at the

front of this operator’s manual.

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

MACHINE GROUNDING

Because this portable engine driven welder / 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.).

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.

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

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

(1)

is

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

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

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RANGER® 3 PHASE

A-4 A-4

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; rough­ness 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.

VEHICLE MOUNTING

INSTALLATION

FUEL

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

(1)

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

WARNING

• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in or weld to the RANGER®®
10,000 or the RANGER®® 10,000
PLUS base.

WARNING

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 manufacture’s instructions.

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

OIL

LUBRICATION  SYSTEM  CAPACITY

(INCLUDING  FILTER)

Kohler CH20S / CH23S - 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. Make cer­tain that the oil filler cap is tightened securely. Refer to
the engine Owner’s Manual for specific oil recommen­dations.

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.

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

GASOLINE

can cause fire
or explosion.

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

GASOLINE FUEL ONLY

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

CAUTION

BATTERY CONNECTIONS

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

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

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.

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RANGER® 3 PHASE

A-5 A-5

INSTALLATION

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.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

225 Amps

100% Duty Cycle

0-100 Ft.

100-200 Ft.

200-250 Ft.

1 AWG

1 AWG

1/0 AWG

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when
lifting.

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

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

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

HIGH ALTITUDE OPERATION

At higher altitudes, elder output de-rating may be necessary.

For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above 3000ft. (914m).

If operation will consistently be at altitudes above 5,000 ft.
(1525m), 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 give increased
power. Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine manu­facturer.

ANGLE OF OPERATION

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.

LIFTING

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

CAUTION

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

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

Muffler Relocation

WARNING

Shut off welder and allow muffler to cool before touch-

•

ing 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 machine
without the covers in place will result in a higher noise level
and no increase in machine output.)

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RANGER® 3 PHASE

A-6 A-6

INSTALLATION

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

the RANGER® 3PHASE.

a. Shut the welder off.

Connect the electrode cable from the LN-15 to

b.

the

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

c. Set the Polarity switch to the desired polarity, either

DC (-) or DC (+).

d. 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.

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

position

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

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

CONNECTION OF THE LN-25 / LN25PRO / LN-25
PRO DUAL

Note: LN-25PRO Dual Control Cable model will not

work with the RANGER® 3 PHASEe.

a. Shut the welder off.

Connect the electrode cable from the LN-25 to

b.

the

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

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Output “CONTROL” must be set above 3.

c. Position the welder “Polarity” switch to the desired

polarity, either DC (-) or DC (+).

d. Position the “RANGE” switch to the “WIRE FEED”

position.

e. 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.
f. Place the engine switch in the “AUTO” position.
g. 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
any other high frequency equipment is used, a
Bypass Capacitor Kit (T12246) must be
installed in the RANGER® 3 PHASE.

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.

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.

• 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

RANGER® 3 PHASE

A-7 A-7

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

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 5-20R
receptacles. Output voltage is within +/-10% at all
loads up to rated capacity. Do not use 3 phase power
and single phase power simultaneously. All auxiliary
power is protected by cuircuit breakers.

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 Figure A.1.

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 L16-20P plug 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. See Figure A.2.

NOTE: Use of 3-Phase AC power is not recommend-

ed while welding.

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FIGURE A.1

FIGURE A.2

RANGER® 3 PHASE

A-8 A-8

INSTALLATION

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 breaker / switch is 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.

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.)

4. Plug this cable into the 50 amp 120/240V recepta-

cle on the RANGER® 3 PHASE case front.

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 A.1

SIMULTANEOUS WELDING AND POWER***

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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

(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 A.1).

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

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Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Max. Stick or Wire

Feed Setting None 00

145 Stick Setting 4500 38 23

90 Stick Setting 6500 54

NO WELDING 9500 80

* 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 power is not recommended

while welding.

RANGER® 3 PHASE

Factor) @ 120V

** 27

** 40

*-or- @ 240V

A-9 A-9

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

INSTALLATION

Figure A.3

CONNECTION OF RANGER® 3 PHASE TO PREMISES WIRING

WARNING

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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

A-10 A-10

INSTALLATION

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 capaci-

tative 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.

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

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

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 machine

RANGER® 3 PHASE Extension Cord Length Recommendations

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

Current

(Amps)

15
20
15
20
40

Voltage

Volts

120
120
240
240
240

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)

175
138
350
275
150

(53)
(42)

(107)

(84)
(46)

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

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RANGER® 3 PHASE

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Starting/Shutdown Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

TABLE OF CONTENTS - OPERATION SECTION

Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

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RANGER® 3 PHASE

B-2 B-2

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.

• 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.

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.

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.

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RANGER® 3 PHASE

B-3 B-3

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)

90 Max.

145 Max.

210DC/225AC Max.

15 to 25V

50 to 90 Amps

70 to 145 Amps

120 to 210 (DC) 225(AC)

Up to 200 Amps

CAUTION

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

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

“ CONTROL” DIAL

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

CH20S or CH23S

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)

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RANGER® 3 PHASE

B-4 B-4

OPERATION

WELDING PROCESS

For any electrodes the procedures should be kept with­in the rating of the machine. For electrode information

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

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

electrode recommended for use with
the RANGER 3 PHASE is NR®-212-MP. The electrode
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

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
3/16 200 - 250 Amps

).

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RANGER® 3 PHASE

B-5 B-5

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”

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” on the dial.

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RANGER® 3 PHASE

B-6 B-6

OPERATION

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.

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.

Remove all loads connected to the AC power recepta­cles. Use the choke control as follows:

KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.

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.

The engine manufacturer’s recommendation for the
running time until the first oil change is 5 Hours

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

.

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RANGER® 3 PHASE

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

TABLE OF CONTENTS - ACCESSORIES SECTION

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RANGER® 3 PHASE

C-2 C-2

ACCESSORIES

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.

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 mov­ing 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.

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. 400 Amp.
Capacity.

K875 ACCESSORY KIT - Includes 20 ft (6.1m) #6 electrode
cable, headshield, filter plate, work clamp , electrode holder
and sample pack of mild steel electrodes 150 Amp. Capacity.
lug, 15ft. (4.6) #6 work cable

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 6-50R
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.

K1745-1 WELDING GAS CYLINDER LPG TANK
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.

K802R 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.

K802N 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.

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.

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

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RANGER® 3 PHASE

C-3 C-3

ACCESSORIES

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 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.

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.

TIG

PRO TORCH®TIG Torch

• K1783-9 PTA 26V TIG Torch

Magnum Parts Kit and Argon Gas

• KP509 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.)

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

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RANGER® 3 PHASE

C-4 C-4

NOTES

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RANGER® 3 PHASE

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

TABLE OF CONTENTS - MAINTENANCE SECTION

Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Air Cleaner/General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

GFCI Test & Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

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

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Engine Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

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RANGER® 3 PHASE