Lincoln Electric IM612 manual

RANGER 8 + DIESEL ™ OPERA TOR’S MANUAL IM612 April, 1998 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THI[...]

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

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

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

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

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

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

vii T ABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance..............................................................[...]

A-1 INST ALLA TION RANGER 8+ DIESEL A-1 TECHNICAL SPECIFICA TIONS - RANGER 8+ DIESEL (K1632-1) Make/Model Description Speed (RPM) Displacement Starting Capacities System Ruggerini 2 cylinder High Idle 3700 51.9 cu. in 12VDC battery Fuel: 9.0 gal. RD 201 4 Cycle Low Idle 2200 (851 cc) 34.0 L Diesel Engine Air Cooled Diesel Full Load 3500 w/Direct In[...]

RANGER 8+ DIESEL A-2 INST ALLA TION A-2 INST ALLA TION INSTR UCTIONS SAFETY PRECA UTIONS Only qualified per sonnel should install, use, or ser vice this equipment. LOCA TION AND VENTILA TION Whenever you use the RANGER 8+ DIESEL, be sure that clean cooling air can flow through the machine’s diesel engine and the machine case. Avoid dusty, dirty a[...]

RANGER 8+ DIESEL A-3 INST ALLA TION A-3 LIFTING The RANGER 8+ DIESEL weighs approximately 695 lbs/315 kg. A lift bail is mounted to the machine frame and should always be used when lifting the machine. ADDITIONAL SAFETY PRECA UTIONS FALLING EQUIPMENT can cause injury. ● Do not lift this machine using lift bale if it is equipped with a heavy acces[...]

RANGER 8+ DIESEL A-4 INST ALLA TION A-4 FUEL Fill the fuel tank with clean No. 2, diesel fuel only. Do not fill to the top of the filler neck to allow room for expansion. The RANGER 8+ DIESEL has a 9 gallon (34 liter) fuel tank with a top fill and fuel gauge mounted on the fuel tank. See the OPERATION and MAINTENANCE sec- tions of this manual for m[...]

RANGER 8+ DIESEL A-5 INST ALLA TION A-5 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of this manual for the location of the 115 and 230 volt recep- tacles, weld output terminals, circuit breakers and ground stud. MA CHINE GROUNDING Because the RANGER 8+ DIESEL creates its own power from its diesel-engine driven generator, and if t[...]

RANGER 8+ DIESEL A-6 INST ALLA TION A-6 A UXILIAR Y PO WER RECEPT A CLES, PLUGS, AND HAND-HELD EQUIPMENT The control panel of the RANGER 8+ DIESEL fea- tures three auxiliary power receptacles: See Figure B.1. • Two 15 amp, 115 volt duplex (double outlet) recepta- cles. • One 50 amp 115/230 volt simplex (single outlet) receptacle. Through these [...]

RANGER 8+ DIESEL A-7 INST ALLA TION A-7 Connection of RANGER 8+ DIESEL to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 230 VOLT 115 VOLT 115 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND [...]

B-1 OPERA TION RANGER 8+ DIESEL B-1 GENERAL DESCRIPTION The RANGER 8+ DIESEL is a diesel-engine driven, multi-process AC and DC arc welder and AC power generator for commercial and residential applications. As a generator it can supply up to 9,000 continuous watts of 115/230 volt, 60 Hz, single-phase AC power at unity power factor to operate AC pow[...]

B-2 OPERA TION B-2 DIESEL ENGINE Ruggerini - RD 201 features: • Air cooled, twin cylinder. • Direct injection. • Crankcase in diecast aluminium. • Forced lubrication with oil pump. • Spin on oil filter. • Centrifugal speed governor. • Automatic mechanical fuel supplement. RECOMMENDED APPLICA TIONS WELDER The RANGER 8+ DIESEL provides [...]

B-3 OPERA TION B-3 CONTR OLS AND SETTINGS All generator/welder controls are located on the Output Control Panel of the machine case front. Diesel engine idler control, and start/stop controls are also on the case front. See Figure B.1 and the expla- nations that follow. FIGURE B.1 OUTPUT P ANEL CONTROLS MA CHINE CONTROLS See Figure B.1 for the loca[...]

B-4 OPERA TION B-4 1 0 . WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH FLANGE NUT: Provides the con- nection point for the electrode holder cable. 11. WELD OUTPUT TERMINAL (TO WORK) WITH FLANGE NUT: Provides the connection point for the work cable. 1 2 . GROUND STUD: Provides a connection point for connecting the machine case to earth ground for [...]

B-5 OPERA TION B-5 RANGER 8+ DIESEL ENGINE OPERA TION DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the RANGER 8+ DIESEL is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maxi- mum rated speed.[...]

B-6 OPERA TION B-6 RANGER 8+ DIESEL BREAK-IN PERIOD Any engine will use a small amount of oil during its “break-in” period. For the diesel engine on the RANGER 8+ DIESEL, break-in is about 50 running hours. Check the oil every four hours during break-in. Change the oil after the first 20 hours of operation, then at 100 hours of operation, then [...]

B-7 OPERA TION B-7 RANGER 8+ DIESEL WELDING PR OCESS STICK (CONST ANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity” switch to the desired polarity. Set the “RANGE” switch to a setting that is equal to or slightly greater than the desired welding current.[...]

B-8 OPERA TION B-8 RANGER 8+ DIESEL Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. TIG/K930-2/K938-1, Yes HIGH Cold Press Amptrol, contactor K936-( ) /K892-1 closes, welding (WITH AMPTROL[...]

B-9 OPERA TION B-9 RANGER 8+ DIESEL A UXILIAR Y PO WER The RANGER 8+ DIESEL can provide up to 9,000 watts of 115/230 volts AC, Single phase 60 HZ power for continuous use. The front of the machine includes three receptacles for connecting AC power Plugs, one 50 amp 115/230 volt NEMA 14-50R receptacle and two 15 amp 115 volt NEMA 5-15R receptacles. [...]

B-10 OPERA TION B-10 RANGER 8+ DIESEL 115/230 V OL T DU AL V OL T A GE RECEPT A CLE The 115/230 volt receptacle can supply up to 40 amps of 230 volt power to a two wire circuit, up to 40 amps of 115 volt power from each side of the three wire cir- cuit, (up to 80 amps total). Do not connect the 115 volt circuits in parallel. Current sensing for the[...]

C-1 A CCESSORIES C-1 GENERAL OPTIONS / A CCESSORIES The following options/accessories are available for your RANGER 8+ DIESEL from your local Lincoln Distributor. K957-1 Two-Wheel Trailer - For in-plant and yard towing. Suitable for road towing with optional fender and light kit. Load capacity is 1150 lbs. K933-1 Four-Wheel Undercarriage - Allows m[...]

C-2 A CCESSORIES C-2 SEMIA UT OMA TIC FCA W AND MIG WELDING OPTIONS / A CCES- SORIES 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. Remote control Receptacle Kit (K892-1) and Remote voltage Control Kit (K444-1) are required [...]

RANGER 8+ DIESEL A CCESSORIES - CONNECTION DIA GRAMS C-3 C-3 CONNECTION OF RANGER 8+ DIESEL T O LN-7 & K240 CONT A CT OR KIT WARNING: Turn the power off when making connections. N.A. Use power source polarity switch to set for desired electrode polarity. Position the output selector switch on the power source to the CV position. N.B. 3 conducto[...]

D-1 MAINTENANCE D-1 R OUTINE MAINTENANCE 1. 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 and air cleaner oil levels and add oil if indicated. Make certain that the oil filler cap is securely tight- ened after[...]

D-2 MAINTENANCE D-2 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum. Adj[...]

RANGER 8+ DIESEL E-1 TR OUBLESHOO TING E-1 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. CA UTION This Troubleshooting Guide is provided to help you locate and rep[...]

E-2 TR OUBLESHOO TING E-2 RANGER 8+ DIESEL Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PRO[...]

E-3 TR OUBLESHOO TING E-3 RANGER 8+ DIESEL Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PRO[...]

E-4 TR OUBLESHOO TING E-4 RANGER 8+ DIESEL Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PRO[...]

F-1 DIA GRAMS F-1 RANGER 8+ DIESEL      WIRING DIA GRAM - RANGER 8+ DIESEL M19107 12-11-97 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[...]

F-2 DIA GRAMS F-2 RANGER 8+ DIESEL            M19108 12-11-97 MAXIMUM O VERALL DIMENSIONS: LENGTH: 48.12 IN. WIDTH: 19.09 IN. HE[...]

NO TES RANGER 8+[...]

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

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