Lincoln Electric RANGER IM612 Operator's Manual
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Lincoln Electric RANGER IM612 Operator's Manual

Lincoln Electric RANGER IM612 Operator's Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
IM612
RANGER 8 + DIESEL
™
April, 1998
10533
For use with machines having Code Numbers:
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
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric RANGER IM612

  • Page 1 RETURN TO MAIN MENU IM612 RANGER 8 + DIESEL ™ April, 1998 10533 For use with machines having Code Numbers: 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 ...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Engine Service

    This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Installation...Section A Technical Specifications ...A-1 Installation Instructions..A-2 Location and Ventilation ...A-2 Storing ...A-2 Stacking ...A-2 Angle of Operation ...A-2 Lifting...A-3 Additional Safety Precautions ...A-3 Pre-Operation Engine Service...A-3 Oil ...A-3 Fuel ...A-4 Battery Connections ...A-4 Spark Arrester ...A-4 Electrical Connections ...A-5 Machine Grounding ...A-5 Welding Cable Connections ...A-5...
  • Page 8 Maintenance ...Section D Safety Precautions ...D-1 Routine Maintenance...D-1 Engine Adjustments...D-2 Slip Rings ...D-2 Battery ...D-2 Engine Maintenance Components ...D-2 Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1 Troubleshooting Guide ...E-2 Wiring Diagram & Dimension Print...Section F Parts List ...P314 Series TABLE OF CONTENTS Page...

  • Page 9: Installation

    Displacement High Idle 3700 51.9 cu. in Low Idle 2200 (851 cc) Full Load 3500 Horsepower 18.4 HP @ 3600 RPM RATED OUTPUT - WELDER Volts at Rated Amps Duty Cycle 25 volts 100% 25 volts 100% 20 volts 100%...

  • Page 10: Installation Instructions

    INSTALLATION INSTRUCTIONS 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.

  • Page 11: Lifting

    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 PRECAUTIONS WARNING FALLING EQUIPMENT can cause injury. ● Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

  • Page 12: Fuel

    ● CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting nega- tive cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

  • Page 13: Electrical Connections

    Cable diameters are increased for long cable lengths to reduce voltage drops. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. ACCESSORIES section of this manual for more infor- mation.

  • Page 14: Auxiliary Power Receptacles, Plugs, And Hand-Held Equipment

    AUXILIARY POWER RECEPTACLES, 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.
  • Page 15 CONNECTION OF RANGER 8+ DIESEL TO PREMISES WIRING 230 VOLT POWER 230 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 115/230 VOLT PLUG NEMA TYPE 14-50 50 AMP, 115/230 VOLT...

  • Page 16: Operation

    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 power tools, bat- tery chargers, and lighting;...

  • Page 17: Diesel Engine

    ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the case 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.

  • Page 18: Controls And Settings

    CONTROLS 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.
  • Page 19 10. 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. 12. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.

  • Page 20: Engine Operation

    ------------------------------------------------------------------------ STARTING THE ENGINE CAUTION Remove all loads connected to the AC power recepta- cles and the welder before starting the diesel engine. ------------------------------------------------------------------------ 1. Check for proper oil level on the oil dipstick. 2. Set “IDLER” switch to “AUTO”.

  • Page 21: Break-In Period

    OPERATION WELDING OPERATION 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.

  • Page 22: Welding Process

    WELDING PROCESS 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. Set the “RANGE” switch to a setting that is equal to or slightly greater than the desired welding current.
  • Page 23 CONTROL CABLE PROCESS USED STICK TIG/K930-2/K938-1, K936-( ) /K892-1 (WITH AMPTROL) WIRE FEED, LN-25 WITH INTERNAL CONTACTOR WIRE FEED, LN-7 WITH K240 CONTACTOR KIT OPERATION Summary of Welding Processes ELECTRODE IDLE WHEN NOT MODE WELDING AUTO HIGH Cold AUTO Cold HIGH Cold RANGER 8+ DIESEL...

  • Page 24: Auxiliary Power

    AUXILIARY POWER 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.

  • Page 25: 115/230 Volt Dual Voltage Receptacle

    B-10 115/230 VOLT DUAL VOLTAGE RECEPTACLE 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).

  • Page 26: Accessories

    GENERAL OPTIONS / ACCESSORIES 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 move- ment of the RANGER 8+ DIESEL by hand without lift- ing.

  • Page 27: Semiautomatic Fcaw And Mig Welding Options / Accessories

    ACCESSORIES SEMIAUTOMATIC FCAW AND MIG WELDING OPTIONS / ACCES- 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 for voltage control at the feeder.
  • Page 28 N.B. 3 conductor #16 power cord physically suitable for the instal- lation and plug rated at 115 volts 15 amperes AC. N.C. Plug into 115 volt AC receptacle on welder control panel or other 115 volt AC supply rated at a minimum of 500 volt- amperes.

  • Page 29: Maintenance

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance, and replace them when the maintenance requiring their removal is complete.

  • Page 30: Engine Adjustments

    • CONNECTING A BATTERY CHARGER - Remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated.

  • Page 31: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 32 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welder or output power. Engine will not idle down to low speed. 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.
  • Page 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) C. Engine will not go to high idle when attempting to weld. D. Engine will not go to high idle when using auxiliary power. Engine will not crank or is hard to crank.
  • Page 34 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) G. Engine does not develop full power. 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. TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENTS(S)
  • Page 35 DIAGRAMS RANGER 8+ DIESEL...
  • Page 36 DIAGRAMS RANGER 8+ DIESEL...
  • Page 37 NOTES RANGER 8+...

  • Page 38: Basic Course

    Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 39 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
  • Page 40 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...

This manual is also suitable for:

Ranger 8 + diesel

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