Lincoln Electric RANGER IM10030 User manual

RANGER®3 PHASE
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For Machine with Code Number 11619
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November, 2010
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Lincoln arc welding and cutting
equipment i de igned and built
with afety in mind. However,
your overall afety can be
increa ed by proper in tallation ...
and thoughtful operation on your
part. DO NOT I NSTAL L,
OPERATE OR REPAI R THI S
EQUI PMENT WI THOUT READ-
I NG THI S MANUAL AND THE
SAFETY PRECAUTI ONS CON-
TAI NED THROUGHOUT. And,
mo t importantly, think before you
act and be careful.
• Sales and Service through Subsidiaries and istributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.

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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. o 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 vaporiz-
ing on contact with hot engine parts and
igniting. o 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. o not put your hands near the engine fan.
o 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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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.
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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. o 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. o not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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iesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
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 iesel Engines The Above For Gasoline Engines

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 A SI 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.
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 oltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced oltage 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. ever dip the electrode in water for cooling.
3.h. ever 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.
ii
SAFETY
ii
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 TL limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
stances, 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 spe-
cific 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 vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
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.

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. ational
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. ational
Electrical Code and the manufacturer’s recommendations.
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. ever 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.
WELDING and CUTTING
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.
Remember that welding sparks and hot
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” (A SI
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 though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
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.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow FPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from FPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
iii
SAFETY
iii
Refer to http://www.lincolnelectric.com/safety for additional safety information.

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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:
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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. ans 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 ray-
onnement 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. es 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, pan-
talons 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.
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 lev-
age, 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.
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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 debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

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Thank You for selecting a &*!). 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!
'514D89C$@5B1D?BC"1>E1<3?=@<5D5<I 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:
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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 ate Code_________________________________________________________________
Serial Number____________________________________________________________________________
ate Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
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.
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- 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
,U()1DGGG<9>3?<>5<53DB933?=Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
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The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

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Technical Specifications.......................................................................................................A-1
Safety Precautions ........................................................................................................A-2
Machine Grounding.......................................................................................................A-2
Spark Arrester ...............................................................................................................A-2
Towing...........................................................................................................................A-2
Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Fuel, Oil, Battery Connections ......................................................................................A-3
Welding Cable Connections..........................................................................................A-4
Angle of Operation ........................................................................................................A-4
Lifting, Additional Safety Precautions............................................................................A-4
High Altitude Operation .................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Location and Ventilation................................................................................................A-5
Stacking ........................................................................................................................A-5
Connection of Wire Feeders .........................................................................................A-5
Connection of Tig Module .............................................................................................A-5
Additional Safety Precautions .......................................................................................A-5
Welding Operation Output, Auxiliary Power Receptacles, and Plugs .................................A-6
Motor Starting and Extension Cord Length Table ................................................................A-6
Electrical evice Used with the Ranger 3 Phase .................................................................A-7
Auxiliary Power While Welding, Standby Power Connections ............................................A-8
Premises Wiring ...................................................................................................................A-9
________________________________________________________________________________
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Safety Precautions ...............................................................................................................B-1
General escription..............................................................................................................B-1
Welder Controls Function and Operation .............................................................................B-1
Range, Polarity Control Switch and Fuel Consumption .......................................................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
Scratch Start TIG (Constant Current) Welding .............................................................B-4
Wire Feed Welding Processes (Constant Voltage)......................................................B-5
Arc Gouging ..................................................................................................................B-5
Summary of Welding Processes ...................................................................................B-5
________________________________________________________________________________
335CC?B95C (53D9?>
Optional Equipment...............................................................................................C-1
Recommended Equipment....................................................................................C-2
________________________________________________________________________
"19>D5>1>35 (53D9?>
Safety Precautions ................................................................................................ -1
Routine Engine Maintenance .......................................................................... -1, 2
Engine Adjustments............................................................................................... -3
Slip Rings .............................................................................................................. -3
Battery Maintenance ....................................................................................... -3
Engine Maintenance Parts.............................................................................. -3
________________________________________________________________________
)B?E2<5C8??D9>7(53D9?>
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
________________________________________________________________________
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Wiring and Connection iagramsF-1,F-2
imension Print .............................................................................................................F3
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C Constant Current 225A/25V/40%
C Constant Current 210A / 25V / 100%
C Constant Voltage 200A / 20V / 100%
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11,500 Watts Preak, 10,000 Watts continuous 3 Phase 60Hz AC, 480V
9,000 Watts Continuous, 60 Hz AC
10,500 Watts Peak, 8500 Watts Continuous Single Phase 60 Hz AC
120/240 Volts
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Kohler
CH23S
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2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
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High Idle 3700
Full Load 3500
Low Idle 2200
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41.1(674)
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Fuel:
12 Gal (45.4 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
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23 HP @
3600 RPM
(D1BD9>7
(ICD5=
12V C
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
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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(2) 120VAC uplex (5-20R)
(1) 120/240VAC ual Voltage
Full KVA (14-50R)
(1) 480V AC (16-20R)
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20AMP for Engine Battery
Charging Circuit
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Two 20AMP for Two uplex Receptacle
(2) 50AMP for ual Voltage
(1) 15 AMP for 3 Phase (3 Pole)
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30.00** in. 21.50 in 42.25 in.
762.0 mm 546.0 mm 1073.0 mm
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Full Pressure Hydraulic Mechanical Fuel Pump with Mechanical Governor
with Full Flow Filter Additional electric fuel lift pump
5% Regulation on K2382-4.
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Low noise Muffler: Top outlet Shutdown on low oil
ual Element Automatic Idler can be rotated. Made from pressure.
long life, aluminized steel.
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** Top of enclosure, add 6.00”(152mm) for exhaust.
514 lbs. (233kg)

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Because this portable engine driven welder or genera-
tor creates it’s own power, it is not necessary to con-
nect it’s frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).
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------------------------------------------------------------------------
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 connect-
ed 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 enti-
tled “Standby Power Connections”, as well as the arti-
cle 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 insulat-
ed 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.
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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 K1898-1 spark arrester must be
installed and properly maintained.
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The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(1) is
Lincoln’s K2635-1. 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. esign 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.
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Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel sight gauge in the base of the machine
while filling to prevent overfilling.
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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 cer-
tain that the oil filler cap is tightened securely. Refer to
the engine Owner’s Manual for specific oil recommen-
dations.
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------------------------------------------------------------------------
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.
#$): 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 bat-
tery with the correct polarity.
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)
(1) Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
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LUBRICATION SYSTEM CAPACITY
(INCLU ING FILTER)
Kohler CH23S - 2.0 Quarts (1.9 Liters)
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-----------------------------------------------------------------------
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------------------------------------------------------------------------
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<?14C
O9CDB92ED521<1>351>4C53EB5<?14CC?F5893<5
9CCD12<5E>45B3?>49D9?>C?6EC5
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O"?E>D5AE9@=5>D21C5D?=5D1<254?B6B1=5?6
F5893<5
O?<<?GF5893<5=1>E613DEB5BVC9>CDBE3D9?>C
------------------------------------------------------------------------
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With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces-
sary. 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.
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Internal combustion engines are designed to run in a
level condition which is where the optimum perfor-
mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintain-
ing 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 12 Gal. (45 L).
!)#
The RANGER® 3 PHASE weighs approximately
587lbs. (266.3kg) with a full tank of gasoline. A lift bail
is mounted to the machine and should always be used
when lifting the machine.
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At higher altitudes, Welder output de-rating may be
necessary. For maximum rating, de-rate the welder
output 3.5% for every 1000 ft. (305m) above 3000 ft.
(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.
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1<D9DE45C25<?G6D=)89CG9<<B5CE<D9>
D855>79>5BE>>9>7 D??<51>1>4 B5CE<D9> 89785B
5>79>5?@5B1D9>7D5=@5B1DEB5CG893831>C8?BD5>
5>79>5<965
------------------------------------------------------------------------
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Using the clamp provided secure the outlet pipe to the
outlet tube with the pipe positioned such that it will
direct the exhaust in the desired direction. Tighten
using a 9/16” socket or wrench.
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145AE1D5<96D9>731@139DI
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851FI1335CC?BICE381CDB19<
5B?B71C3I<9>45B
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31EC59>:EBIO?>?D?@5B1D5=1389>5G89<5
CEC@5>4546B?=<96D219<
------------------------------------------------------------------------
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The welder should be located to provide an unrestrict-
ed 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.
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RANGER® 3 PHASE machines cannot be stacked.
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,''(
(8ED?66G5<45B256?B5=1;9>71>I5<53DB931<
3?>>53D9?>C
------------------------------------------------------------------------
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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.
• Shut the welder off.
•
Connect the electrode cable from the LN-15 to the
“ELECTRO E” terminal of the welder. Connect the
work cable to the “TO WORK” terminal of the
welder.
• Connect Electrode leads appropriately to acquire
desired polarity, either C (-) or 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.
• Set the “RANGE” switch to the “WIRE FEE -CV”
position
• Place the Engine switch in the “Auto Idle” position
when welding with MIG wire instead of self-shielded
core wire, weld starts can be improved by setting
the idle mode to “HIGH”.
• Adjust the wire feed speed at the LN-15 and adjust
the welding voltage with the output “CONTROL” at
the welder.
Output “CONTROL” must be set above 3
when welding with MIG wire instead of self-shielded
core wire, weld starts can be improved by setting
the idle mode to “HIGH”
.
#$) LN-15 Control Cable model will not work with
the RANGER® 3 PHASE.
• Position the “RANGE” switch to the “WIRE FEE
CV” 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 I LE” posi-
tion.
• When welding with MIG wire instead of self-
shielded core wire, weld starts can be improved
by setting the idle mode to “HIGH”
.
• Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL”
at the welder.
#$) The welding electrode is energized at all
times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.
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• Shut the welder off.
•
Connect the electrode cable from the LN-25 to
the
“ELECTRO E” terminal of the welder.
Connect the work cable to the “TO WORK” termi-
nal of the welder.
• Attach working and electrode leads appropriately
to acquire desired polarity, either C (-) or C (+).
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'#'P%(
The TIG Module is an accessory that provides high
frequency and shielding gas control for C GTAW
(TIG) welding. See IM528 supplied with the TIG
Module for installation instructions.
#$) 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 fre-
quency equipment, the bypass capacitor must be
installed, order kit T12246.
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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.
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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). o 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.
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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.
+?<D%81C5'535@D13<5G9D8B?E>4
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 (GN ) connection is connect-
ed to the machine frame, it is #$) the neutral of the
three phase connection, and should under no circum-
stances be connected to the neutral of any 3 phase
load. ?>?D3?>>53D+@81C5D?C9>7<5@81C5
@B5=9C5CG9B9>7
GND
120V
120V*
240V
*CurrentSensingforAutomaticIdle.
(ReceptacleviewedfromfrontofMachine)
GND
120 V
120 V*
240 V
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
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,!'$*)%*)
• Maximum Open Circuit Voltage at 3700 RPM is 80
Volts RMS.
• uty 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. uty
Cycle for the RANGER® 3 PHASE is 100%.
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------------------------------------------------------------------------
Start the engine and set the “I LER” 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 "#)
## 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. ?>?DEC5@81C5
@?G5B1>4C9>7<5@81C5@?G5BC9=E<D1>5?EC<I All
auxiliary power is protected by cuircuit breakers.
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'#'P%(
?>CD1>DEBB5>D 210 Amps C @ 25 Volts
?>CD1>D+?<D175 200 Amps C @ 20 Volts
'#'%(HD5>C9?>?B4!5>7D8'53?==5>41D9?>C
(Use the shortest length extension cord possible sized per the following table.)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Conductor size is based on maximum 2.0% voltage drop.
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
Current
(Amps)
15
20
15
20
40
Voltage
Volts
120
120
240
240
240
Load
(Watts)
1800
2400
3600
4800
9500
30
60
(9)
(18)
40
30
75
60
(12)
(9)
(23)
(18)
75
50
150
100
50
(23)
(15)
(46)
(30)
(15)
125
88
225
175
90
(38)
(27)
(69)
(53)
(27)
175
138
350
275
150
300
225
600
450
225
(91)
(69)
(183)
(137)
(69)
(53)
(42)
(107)
(84)
(46)

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 L16-20P, 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 fol-
lowing values:
The 120V has 20 amp circuit breakers for each duplex recepta-
cle. 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.
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Periodically check the ground wire at plugs, power cords and
auxiliary loads to ensure that the grounding circuit is intact and
connected.
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TABLE lll
ELECTRICAL DEVICE USE WITH THE RANGER® 3 PHASE.
)I@5 ?==?><53DB931<5F935C %?CC92<5?>35B>C
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 capacitative
elements to fail. Surge protection,
transient protection, and additional
loading is recommended for 100%
fail-safe operation. DO NOT RUN
THESE DEVICES WITHOUT ADDI-
TIONAL 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 maxi-
mum output torque, but they SHOUL
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 pro-
tection 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.
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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 approxi-
mately 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 capa-
ble 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 #$) the neutral of 3 phase connec-
tion, and should under no circumstance be connected to the
neutral of any 3 phase load.
GND
480V
Y
(FORALLSINGLEAND
XZ
THREEPHASELOADS)
GND
480 V
Y
(FOR ALL SINGLE AND
XZ
THREE PHASE LOADS)

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The RANGER® 3 PHASE is suitable for temporary,
standby, or emergency power using the engine manu-
facturer’s recommended maintenance schedule.
The RANGER® 3 PHASE can be permanently
installed as a standby power unit for 240V-3 wire, sin-
gle phase 40 ampere service.
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------------------------------------------------------------------------
1. Install a double pole, double throw switch between
the power company meter and the premises dis-
connect.
Switch rating must be the same or greater than the
customer’s premises disconnect and service over-
current 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 break-
er. 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 ouble 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.
,'##
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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.
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$ED@ED(5<53D?B %5B=9CC92<5%?G5B %5B=9CC92<5EH9<91BI
(5DD9>7 ,1DDC*>9DI%?G5B EBB5>D9>=@5B5C
13D?B +?B+
Max. Stick or Wire
Feed Setting None 00
145 Stick Setting 4500 38** 23
90 Stick Setting 6500 54** 27
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 Power is not recommended while
welding

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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 I LE” ( ) position, the engine will
run continuously at high idle.
When in “AUTO I LE” ( / ) position, the
engine will run continuously and the idler operates as
follows:
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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.
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With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
00-150 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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1>4@1BDC<9CDC
------------------------------------------------------------------------
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"1>E1<
------------------------------------------------------------------------
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The RANGER® 3 PHASE is a twin-cylinder, gasoline
driven, multiprocess arc welder and AC power gener-
ator. It is built in a heavy gauge steel case for durabili-
ty on the job site.

R '#S(,)
The “Range” switch is used to select one of four
amperage ranges with generous overlap for Stick/TIG
welding, or one Wire Feed welding range.
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G5<49>7)89CG9<<41=175D85CG9D38
------------------------------------------------------------------------
R $#)'$!S!
Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and weld-
ing voltage control with the Range switch set in the
wire feed mode.
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.40 Gallons/Hour
(1.50 Liters/Hour)
.7 Gallons/Hour
(2.8 Liters/Hour)
1.3 Gallons/Hour
(4.9 Liters/Hour)
1.2 Gallons/Hour
(4.5 Liters/Hour)
1.52 Gallons/Hour)
(5.77 Liters/Hour)
1.64 Gallons/Hour)
(6.23 Liters/Hour)
Low Idle - No Load
2400 RPM
High Idle - No Load
3700 RPM
C CC Weld Output
210 Amps @ 25 Volts
C CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power Single Phase
9500 Watts
Auxiliary Power 3 Phase
10,500 Watts
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STICK/TIG
(constant current)
(3 range settings)
WIRE FEE
(constant voltage)
(1 range setting)
90 Max.
145 Max.
225 MAX
15 to 25V
40 to 90 Amps
70 to 145 Amps
120 to 225 Amps
Up to 200 Amps

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Be sure all Pre-Operation Maintenance has been per-
formed. Also, read the Engine Owner’s Manual before
starting for the first time.
Remove all loads connected to the AC power recepta-
cles. Use the choke control as follows:
$!'## - <G1IC 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. o 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.
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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.
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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 (approxi-
mately 50 running hours).
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The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:
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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KOHLER
CH23S
5 HRS

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For any electrodes the procedures should be kept
within the rating of the machine. For electrode infor-
mation see the appropriate Lincoln publication.
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Connect welding cables to the "TO WORK” and
"ELECTRO E” 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 adjust-
ment 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. (“OUT-
PUT” Control settings below 5 may reduce arc stabili-
ty) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUT-
PUT” Control near the maximum to achieve the
desired welding current.
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!)'$(/
The RANGER® 3 PHASE can be used with a broad
range of C stick electrodes. See “Welding Tips 1”
included with the RANGER® 3 PHASE for electrodes
within the rating of this unit and recommended weld-
ing currents of each.
(')()'))$#()#)*''#)
,!#
The RANGER® 3 PHASE can be used for Scratch-Start of C
TIG welding applications. To initiate a weld, the course and fine
output control knobs must be set for the desired current. The
tungsten electrode is then scratch on the work which establish-
es the arc.
To stop the arc, simply lift the TIG torch away from the work
piece. The tungsten may then be scratched on the work piece
to restrike the arc.
If a high frequency start is desired, the K930-2 TIG Module can
be used with the RANGER® 3 PHASE. The settings are refer-
enced.
The RANGER® 3 PHASE and any high frequency generating
equipment must be properly grounded. See the K930-2 TIG
Module operating manuals for complete instructions on installa-
tion, operation and maintenance.
When using the TIG Module, the OUTPUT control on
the RANGER® 3 PHASE is used to set the maximum range of
the CURRENT CONTROL on the TIG Module or an Amptrol if
connected to the TIG Module.
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90 MAX.
145 MAX.
225 MAX.
3/32
1/8
5/32
40 TO 90 AMPS
70 TO 145 AMPS
120 TO 225 AMPS
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Tungsten Electrode CEN (-) CEP (+) Approximate Argon Gas Flow TIG TORCH
iameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten
.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)
0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and C applications.
(3) CEP is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6 mm)
# 5 = 5/16 in. (8 mm)
# 6 = 3/8 in. (10 mm)
# 7 = 7/16 in. (11 mm)
# 8 = 1/2 in. (12.5 mm)
#10 = 5/8 in. (16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures
and high duty cycles.