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Multi-Process Gasoline Engine Driven Welder and Power Generator
For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
RANGER
10909, 10939
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
9
™
Copyright © 2003 Lincoln Global Inc.
IM753-A
January, 2003
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Related Manuals for Lincoln Electric RANGER 9 IM753-A
Summary of Contents for Lincoln Electric RANGER 9 IM753-A
- Page 1 Multi-Process Gasoline Engine Driven Welder and Power Generator 10909, 10939 For use with machines having Code Numbers: This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...
- Page 2 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.
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Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
- Page 6 QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation........................Section A Technical Specifications ....................A-1,A-2 Installation Instructions......................A-3 Undercarraiges......................A-3 Safety Precautions ......................A-3 Spark Arrester .......................A-3 Machine Grounding .......................A-3 Welding Output Cables ....................A-4 Additional Safety Precautions ..................A-3 Pre-Operation Engine Service....................A-4 Oil ..........................A-4 Fuel ..........................A-4 Engine Coolant......................A-4 Battery Connections ......................A-4 Exhaust Deflector ......................A-4 High Altitude Operation ....................A-5 Electrical Connections ......................A-6... - Page 8 TABLE OF CONTENTS Page Maintenance ....................Section D Safety Precautions ....................D-1 Engine Adjustments....................D-1 Overspeed Is Hazardous..................D-1 Routine Maintenance.....................D-1 Oil........................D-1 Engine Oil Change ..................D-1 Engine Oil Refill Capacities................D-2 Oil Filter Change .....................D-2 Slip Rings......................D-2 Air Cleaner ......................D-2 Battery Charging .....................D-3 Battery......................D-3 Hardware ......................D-3 Engine Maintenance Parts................D-3 ________________________________________________________________________ Troubleshooting ....................Section E...
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Page 9: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 9 (K1420-3,K1421-3) INPUT - GASOLINE ENGINE Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) Starting Capacities @ 3600 RPM SPEED Bore x Stroke in.(mm) System Ranger 9 2 Cylinder 20.5 HP High Idle 39.9 cu in 12V Battery Fuel: 9 gal. -
Page 10: Specifications
INSTALLATION AC STICK / TIG (CC) OUTPUT SPECIFICATIONS A 225 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC STICK / TIG (CC) OUTPUT A 210 OUTPUT RANGE B 50 OUTPUT RANGE 50 100 150 200 250 300 350 400 450 OUTPUT AMPS HIGH 0 50 100 150 200 250 300 350 400... -
Page 11: Installation Instructions
INSTALLATION INSTALLATION INSTRUCTIONS 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 SAFETY PRECAUTIONS ground. See further connection instructions in the section entitled “Standby Power Connections”, as well WARNING as the article on grounding in the latest U.S. -
Page 12: Welding Output Cables
INSTALLATION • Typical conditions of use, i.e., travel speed; rough- WELDING OUTPUT CABLES ness of surface on which the trailer will be operated; With the engine off, connect the electrode and work environmental conditions; like maintenance. cables to the studs provided. These connections •... -
Page 13: High Altitude Operation
INSTALLATION CONNECTION OF LINCOLN ELECTRIC ANGLE OF OPERATION WIRE FEEDERS 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 WARNING for the engine is 15 degrees from horizontal in any direction. -
Page 14: Remote Outpit Control
INSTALLATION Connection of K428 or K446 LN-25 with • Set the “WELDING TERMINAL” Control switch to the “ALWAYS ON” position. K624-1 42 volt Remote Output Control Module to the Ranger 9 • Set the “IDLER” switch to the “AUTO” position. Requires K626-xx Control Cable. - Page 15 INSTALLATION AUXILIARY POWER 115V DUPLEX RECEPTACLE The Ranger 9 can provide up to 9,000 watts of The 115V auxiliary power receptacles should only be 115/230 volts AC, single phase 60Hz power for contin- used with three wire grounded type plugs or approved uous use.
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Page 16: Standby Power Connections
INSTALLATION STANDBY POWER CONNECTIONS • Install a double pole, double throw switch between the power company meter and the premises The Ranger 9 is suitable for temporary, standby, or disconnect. emergency power using the engine manufacturer’s rec- Switch rating must be the same or greater than ommended maintenance schedule. - Page 17 INSTALLATION CONNECTION OF RANGER 9 TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR POWER 230 Volt 115 VOLT 60 Hz. COMPANY 3-Wire 115 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
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Page 18: Operation
OPERATION SAFETY INSTRUCTIONS WARNING Read and understand this entire section before oper- ating your RANGER 9. ARC RAYS can burn. • Wear eye, ear, and body protection. WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance ENGINE EXHAUST can kill. -
Page 19: Auxiliary Power
OPERATION LN-25 (K449) Includes internal contactor for across RECOMMENDED PROCESSES AND the arc operation (no control cable). Provides “cold” electrode until gun trigger is pressed. Includes gas EQUIPMENT solenoid. K444-1 Remote Voltage Control Kit is The Ranger ™ 9 can be used for AC/DC Stick welding required for voltage control at the feeder. -
Page 20: Fuel Consumption
OPERATION Ranger 9 Approximate Fuel Consumption ONAN P220 KOHLER 20 H.P. CH20S Low Idle - No Load .5Gallons/Hour .4 Gallons/Hour 2200 RPM (1.9 Liters/Hour) (1.5 Liters/Hour) High Idle - No Load .9 Gallons/Hour 1.0 Gallons/Hour 3700 RPM (3.4 Liters/Hour) (3.8 Liters/Hour) AC CC Weld Output 1.6 Gallons/Hour 1.5 Gallons/Hour... -
Page 21: Idler Switch
OPERATION With the switch in the “REMOTELY CONTROLLED” USE the choke control as follows: position, the contactor is open at LOW idle and HIGH ONAN ENGINE - If the engine is cold, pull the idle until a control cable is attached to the welder choke control out. -
Page 22: Welding Processes
OPERATION WELDING PROCESSES SETTINGS FOR PURE TUNGSTEN STICK (Constant Current) Welding TUNGSTEN RANGE SWITCH APPROXIMATE DIAMETER in.(mm) SETTINGS CURRENT RANGE Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the 1/8(3.2) 90 , 100 - 200 Amps "POLARITY”... -
Page 23: Summary Of Welding Processes
OPERATION SUMMARY OF WELDING PROCESSES PROCESS CONTROL IDLE OUTPUT WELDING ELECTRODE TO START WELDING CABLE MODE CONTROL TERMINALS STATE WHEN USED SWITCH SWITCH NOT WELDING Stick – CC Auto At Welder Always on Touch electrode to work. Welding starts immediately and engine goes to high idle. -
Page 24: Accessories
ACCESSORIES K704 400 AMP Accessory Kit Which Includes: GENERAL OPTIONS / ACCESSORIES • Electrode Holder & Cable • Work Clamp & Cable K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR • Headshield SMALL WELDERS - For road, off-road and In-plant and yard towing. ( For highway use, consult applicable K894-1 Spark Arrester Kit - Includes a heavy gauge federal, state and local laws regarding requirements steel, approved spark arrester and clamp for easy... -
Page 25: Maintenance
MAINTENANCE ROUTINE MAINTENANCE SAFETY PRECAUTIONS At the end of each day’s use, refill the fuel tank to • WARNING minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and Have qualified personnel do the maintenance add oil if indicated. -
Page 26: Engine Oil Refill Capacities
MAINTENANCE SLIP RINGS ENGINE OIL REFILL CAPACITIES A slight amount of darkening and wear of the slip rings Without oil filter replacement: and brushes is normal. Brushes should be inspected • 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler when a general overhaul is necessary. If brushes are •... -
Page 27: Battery Charging
MAINTENANCE BATTERY CHARGING BATTERY WARNING • When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity GASES FROM BATTERY can explode. must be observed. Failure to observe the proper • Keep sparks, flame and cigarettes away polarity could result in damage to the charging from battery. -
Page 28: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 29 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION No welder or output power. Open in miscellaneous leads. Open lead in flashing or field circuit. Faulty rotor. Faulty Potentiometer (R1). Faulty stator Field winding.
- Page 30 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Engine will not go to high idle when No voltage signal from the using auxiliary power. current sensor. Auxiliary power load less than 100 to 150 watts.
- Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Battery does not stay charged Faulty battery. Faulty charging system. 3. Loose or broken lead in charging circuit. Output control on welder not functioning.
- Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Contactor does not pull in when 1. Welding terminal switch in wrong scratch starting when engine goes to position. high idle. 2.
- Page 33 WIRING DIAGRAM RANGER 9...
- Page 34 DIAGRAMS RANGER 9 OPTIONAL K444-1 REMOTE CONTROL TO WORK ELECTRODE N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO CV POSITION. N.C.
- Page 35 DIAGRAMS RANGER 9 TO WORK ELCTRODE -XX INPUT IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.
- Page 36 DIAGRAMS RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM WARNING WARNING Do not operate with panels open. Do not operate with panels open. Keep guards in place. Keep guards in place. Disconnect NEGATIVE (-) BATTERY LEAD Disconnect NEGATIVE (-) BATTERY LEAD Keep away from moving parts.
- Page 37 DIAGRAMS RANGER 9 / LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM WARNING Do not operate with panels open. Keep guards in place. Keep away from moving parts. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Only qualified personnel should install,use or service this equipment.
- Page 38 DIAGRAMS RANGER 9 AND 10LX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM WARNING Do not operate with panels open. Keep guards in place. Keep away from moving parts. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Only qualified personnel should install,use Do not touch electrically live parts.
- Page 39 DIMENSION PRINT RANGER 9...
- Page 40 NOTES RANGER 9...
- Page 41 NOTES RANGER 9...
- Page 42 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 43 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 44 • World's Leader in Welding and Cutting Products • • 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...