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Multi-Process Gasoline Engine Driven Welder and Power Generator
For use with machines having Code Number 10378, 10379, 10539, 10540 and 10550
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,
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
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OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
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Copyright © 2000 Lincoln Global Inc.
IM511-D
OCTOBER, 2000
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Summary of Contents for Lincoln Electric RANGER IM511-D
- Page 1 RANGER Multi-Process Gasoline Engine Driven Welder and Power Generator For use with machines having Code Number 10378, 10379, 10539, 10540 and 10550 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 ...
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Page 2: California Proposition 65 Warnings
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. 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.
- 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 instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 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 •••...
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Page 7: Table Of Contents
Safety Precautions ...ii-iv Introductory Information...v General Description ...7 Specifications ...7-8 Optional Features ...9 Recommended Equipment ...10 Installation Instructions...11-12 Machine Grounding ...11 Spark Arrester ...11 Trailers ...11-12 Pre-Operation Service ...12 Oil ...12 Fuel ...12 Battery Connection...12 Welding Output Cables ...12 Location/Ventilation ...12 Operation ...13-14 High Altitude Operation ...13 Muffler Relocation ...13... -
Page 9: General Description
GENERAL DESCRIPTION The Ranger ™ 9, is a twin cylinder gasoline engine driven multi-process arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site. RECOMMENDED PROCESSES AND EQUIPMENT The Ranger 9 can be used for AC/DC Stick welding (CC), DC Semiautomatic wire feed welding (CV), AC/DC Tig welding (CC), and also offers a 9,000 Watt AC 115/230 Volt, 60 Hertz power generator. -
Page 10: Specifications
SPECIFICATIONS Machine Product Ordering Description Name Information Ranger 9 K1420-1 250 Amp (Onan) AC/DC K1420-2 Multi-Process CSA(Meets Arc Welder Canadian Standards) with 9,000 Watts AC Auxiliary Ranger 9 K1421-1 Power (Kohler) (Meets Canadian Standards) * Based on a 10 min. period. ** When welding, available AC auxiliary power will be reduced. -
Page 11: Optional Features
OPTIONAL FEATURES K768-2 Two Wheel Undercarriage For in-plant and yard towing. (For highway use, consult applicable federal, state, and local laws regarding possible requirements for brakes, lights, fenders, etc.) Two 4.80 x 12" four-ply tubeless tires. Bed-plate mounting. Has stand for tow bar and grips for hand pulling. -
Page 12: Recommended Equipment
RECOMMENDED EQUIPMENT STICK K702 Accessory Kit which includes: • Electrode holder and cable • Work clamp and cable • Headshield K857 Remote Control Kit is optional for remote current control. Magnum ™ TIG Torch Magnum Parts Kit and Argon gas K930-1 TIG Module K936-1 Control Cable Optional:... -
Page 13: Installation Instructions
INSTALLATION INSTRUCTIONS 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 14: Trailers
Typical conditions of use, i.e., travel speed; rough- ness of surface on which the trailer will be operated; environmental conditions; like maintenance. Conformance with federal, state and local laws. ( ) Consult applicable federal, state and local laws regarding specific requirements for use on public highways. PRE-OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc-... -
Page 15: Operation
(Operating the Ranger 9 without the cover in place will result in a higher noise level and no increase in machine output.) Connection of Lincoln Electric Wire Feeders WARNING Shut off welder before making any electrical connections. -
Page 16: Connection Of Ln-7 Or Ln-8 To The Ranger 9
d. Set the “POLARITY” switch to either WIRE FEED DC+ or WIRE FEED DC- as required by the electrode being used. e. Set the “RANGE” switch to either HIGH, MED or LOW as required by the process. f. Set the “WELDING TERMINAL” Control switch to the “ALWAYS ON”... -
Page 17: Operating Instructions
OPERATING INSTRUCTIONS Additional Safety Precautions Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow. Read carefully the Safety Precautions page in the Instruction Manual before operating this machine. Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual. -
Page 18: Engine Operation
“CONTROL AT WELDER / REMOTE CONTROL” Switch The toggle switch on the control panel labeled “CONTROL AT WELDER” and “REMOTE CONTROL” gives the operator the option of controlling the output at the welder control panel or at a remote station. Remote connections are made at the 6-pin or 14-pin amphenol connector. -
Page 19: Welding Processes
Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine. Stop the engine by placing the “Engine” switch in the “OFF” position. A fuel shut off valve is not required on the Ranger 8 because the fuel tank is mounted below the engine. - Page 20 Recommended Outershield electrodes are: .045 (1.1mm), .052 (1.3mm) and 1/16 (1.6mm) Outershield 71 and 1/16” (1.16mm) Outershield 70. Request Lincoln publication GS-200 for additional information. Some recommended solid wires for MIG welding are: .030 (0.8mm), .035 (0.9mm) and .045 (1.1mm) L-50 and L-56.
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Page 21: Auxiliary Power
Auxiliary Power The Ranger 9 can provide up to 9,000 watts of 115/230 volts AC, single phase 60HZ power for contin- uous use. The front of the machine includes three receptacles for connecting AC power plugs. The K1420-1 has one 50 amp 115/230 volt NEMA 50R receptacle and two 20 amp 115 volt NEMA 5- 20R receptacles. -
Page 22: Standby Power Information And Connection To Premises Wiring Diagram
Most 1.5 HP 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 1.5HP motor is approximately 20 amperes (10 amperes for 230 volt motors). - Page 23 2. Take necessary steps to assure load is limited to the capacity of the Ranger 9 by installing a 40 amp, 230 volt double pole circuit breaker. Maximum rated load for each leg of the 230 volt auxiliary is 40 amperes. Loading above 40 amps will reduce output voltage below the allowable - 10% of rated voltage which may damage appliances or...
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Page 24: Maintenance
MAINTENANCE Safety Precautions WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine . 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. -
Page 25: Battery
Battery Charging WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away. BATTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when boosting, charging or working near battery. To prevent EXPLOSION when: a) Installing a new battery - disconnect the negative cable from the old battery first and connect the negative cable to the new battery... -
Page 26: Troubleshooting
TROUBLESHOOTING ENGINE TROUBLE A. Engine will not crank or is hard to crank. B. Engine will not start or shuts down. C. Engine does not develop full power. D. Battery does not stay charged. CAUSE 1. Battery will not hold a charge. Faulty battery. -
Page 27: Electronic Idler Troubleshooting
IDLER SYSTEM TROUBLE A. Engine will not idle down to low speed. B. Engine will not go to high idle when attempting to weld. I. Scratch Start II. When using wire feeder with con- trol cable plugged into amphenol connector or using amptrol when trigger is depressed. -
Page 28: Output System Troubleshooting
OUTPUT SYSTEM TROUBLE A. No welder or power output. B. Output control on welder not functioning. C. Output control or remote not functioning. D. Wire feeder does not work when connected to welder amphenol. CAUSE 1. Open lead in flashing or field circuit. 2. - Page 29 OUTPUT SYSTEM TROUBLE E. Contactor does not pull in when scratch starting when engine goes to high idle. F. Contactor does not pull in when using a wire feeder with a control cable plugged into amphenol. G. Contactor does not drop out. CAUSE 1.
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Page 30: Wiring Diagram
BLACK WHITE WHITE BLACK BLACK WHITE -28 -... - Page 31 BLACK BLACK WHITE WHITE GREEN GREEN BLACK BLACK BLACK GREEN WHITE BLACK BLACK BLACK BLACK BLACK -29 -...
- Page 32 BLACK BLACK WHITE WHITE GREEN GREEN BLACK BLACK BLACK GREEN WHITE BLACK BLACK BLACK BLACK BLACK -30 -...
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Page 33: Connection Diagrams
RANGER 9 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL ELECTRODE TO WORK N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. - Page 34 RANGER 9 / LN-7 CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL 6 PIN TO WORK ELECTRODE AMPHENOL CAUTION : ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE.
- Page 35 RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL ELECTRODE TO WORK K867 UNIVERSAL ADAPTER PLUG ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION : ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE...
- Page 36 RANGER 9 / LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL TO WORK ELECTRODE CAUTION : ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE.
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Page 37: Connection Diagrams
RANGER 9 AND 10LX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 115V RECEPTACLE RANGER 14 PIN WIRE FEEDER 6 PIN REMOTE RECEPTACLE RECEPTACLE... -
Page 38: Dimension Print
– 36 –... - 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 ● Desconectar el cable de respiración. alimentación de poder de la ●...
- Page 41 • 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...