Return to Master TOC |
View Safety Info |
Return to Master TOC |
View Safety Info |
Return to Master TOC |
View Safety Info |
Return to Master TOC |
View Safety Info |
RETURN TO MAIN INDEX
SVM 110-A
RANGERTM 9 |
January, 1996 |
For use with machine code numbers 9975 and 9976 |
|
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 thoughtful 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.
SERVICE MANUAL
|
|
|
|
World’s Leader in Welding and Cutting Products |
|
|
Premier Manufacturer of Industrial Motors |
|
|
||
|
|
||
|
|
|
|
Sales and Service through subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
i |
i |
|
|
|
SAFETY |
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents |
|
The engine exhaust from this product contains |
are known to the State of California to cause can- |
|
chemicals known to the State of California to cause |
cer, birth defects, and other reproductive harm. |
|
cancer, birth defects, or other reproductive harm. |
|
|
|
The Above For Diesel Engines |
|
The Above For Gasoline Engines |
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
____________________________________________________
1.c. Do 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 vaporizing on contact with hot engine parts and igniting. Do 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. Do not put your hands near the engine fan. Do 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.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
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. Do 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. Do not work next to welding power source.
Mar ‘95
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
ii |
ii |
SAFETY
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 Voltage (Wire) Welder.
•DC Manual (Stick) Welder.
•AC Welder with Reduced Voltage 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. Never dip the electrode in water for cooling.
3.h. Never 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.
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 ANSI 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.
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 below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. 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 products.
5.c. 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.d. 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.e. Also see item 1.b.
Mar ‘95
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
iii |
iii |
SAFETY
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. 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” (ANSI 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 circuits.
This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
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. Never 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.
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. National
Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Mar ‘95
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
iv |
iv |
SAFETY
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 suivantes:
Sûreté Pour Soudage A L’Arc
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 defonc-
tionnement.
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.Dans 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 rayonnement 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.Des 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, pantalons 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 levage, 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.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
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 debrancher à l’interrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
v |
RETURN TO MAIN INDEX |
v |
|
|
|
|
|
|
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
|
Page |
Safety................................................................................................................................................. |
i-iv |
|
|
Installation............................................................................................................................. |
Section A |
Installation Section Table of Contents ........................................................................................ |
A-1 |
Technical Specifications ............................................................................................................. |
A-2 |
Safety Precautions...................................................................................................................... |
A-3 |
Location and Ventilation ............................................................................................................. |
A-3 |
Pre-operation Engine Service ..................................................................................................... |
A-4 |
Electrical Output Connections.................................................................................................... |
A-5 |
|
|
Operation............................................................................................................................... |
Section B |
Safety Instructions ...................................................................................................................... |
B-2 |
General Description .................................................................................................................... |
B-2 |
Recommended Applications ...................................................................................................... |
B-3 |
Operational Features and Controls ............................................................................................ |
B-3 |
Design Features and Advantages............................................................................................... |
B-3 |
Welding Capability ...................................................................................................................... |
B-4 |
Limitations ................................................................................................................................. |
B-4 |
Controls and Settings ................................................................................................................. |
B-4 |
Engine Operation ........................................................................................................................ |
B-7 |
Welding Operation .................................................................................................................... |
B-10 |
Summary of Welding Processes............................................................................................... |
B-13 |
Auxiliary Power ......................................................................................................................... |
B-14 |
|
|
Accessories........................................................................................................................... |
Section C |
|
|
Maintenance ......................................................................................................................... |
Section D |
Safety Precautions...................................................................................................................... |
D-2 |
Routine and Periodic Maintenance ............................................................................................ |
D-2 |
Major Component Locations...................................................................................................... |
D-9 |
|
|
Theory of Operation ............................................................................................................. |
Section E |
|
|
Troubleshooting and Repair................................................................................................. |
Section F |
|
|
Electrical Diagrams.............................................................................................................. |
Section G |
|
|
Parts Manual................................................................................................................................ |
P-230 |
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
Section A-1 |
Section A-1 |
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications ............................................................................................................. |
A-2 |
Safety Precautions...................................................................................................................... |
A-3 |
Location and Ventilation ............................................................................................................. |
A-3 |
Storing ................................................................................................................................. |
A-3 |
Stacking................................................................................................................................ |
A-4 |
Tilting ................................................................................................................................. |
A-4 |
Lifting ................................................................................................................................. |
A-4 |
High Altitude Operation........................................................................................................ |
A-4 |
Pre-operation Engine Service ..................................................................................................... |
A-4 |
Oil ........................................................................................................................................ |
A-4 |
Fuel....................................................................................................................................... |
A-4 |
Battery Connections............................................................................................................. |
A-4 |
Muffler Relocation ................................................................................................................ |
A-5 |
Spark Arrester ...................................................................................................................... |
A-5 |
Electrical Output Connections.................................................................................................... |
A-5 |
Welding Cable Connections................................................................................................. |
A-6 |
Cable Size and Length ............................................................................................ |
A-6 |
Cable Installation..................................................................................................... |
A-6 |
Machine Grounding .............................................................................................................. |
A-6 |
Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment ....................................... |
A-7 |
Circuit Breakers .................................................................................................................... |
A-7 |
Premises Wiring.................................................................................................................... |
A-7 |
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-2 |
A-2 |
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 9
|
|
|
|
|
|
INPUT - GASOLINE ENGINE |
|
|
|
|
|
|||
Manufacturer |
|
Description |
|
Speed Displacement |
Ignition |
|
Capacities |
|||||||
Onan |
|
2 cyl., |
|
3500 RPM |
47.7 cu. in. |
Electric |
|
Fuel: 9 gal. (34 l) |
||||||
P218® |
|
4 cycle |
|
Full load |
(782 cc) |
|
|
|
|
|
||||
|
|
air-cooled |
|
|
|
|
|
Manual |
|
Oil: 1.8 qt. (1.7 l) |
||||
|
|
gasoline |
|
3700 RPM |
|
choke |
|
|
|
|||||
|
|
18 HP @ |
|
High idle |
|
|
|
|
|
|
||||
|
|
3600 RPM |
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
2200 RPM |
|
|
|
|
|
|
||
|
|
|
|
|
|
Low idle |
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
RATED OUTPUT - WELDER |
|
|
|
|
|
|||
Duty Cycle |
|
|
Amps |
|
Volts at Rated Amperes |
|||||||||
100% Duty Cycle |
|
|
250 AC Constant Current |
|
|
25 |
|
|||||||
100% Duty Cycle |
|
|
250 DC Constant Current |
|
|
25 |
|
|||||||
100% Duty Cycle |
|
|
250 DC Constant Voltage |
|
|
25 |
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
OUTPUT - WELDER AND GENERATOR |
|
|
|
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
Auxiliary Power for |
|||
Welding Ranges |
Max. Open Circuit Voltage Auxiliary Power |
|
Wire Feeders |
|||||||||||
40 - 250 Amps |
|
|
|
80 Volts RMS |
9000 Continuous Watts |
|
42V, 60 Hz, 8 Amps |
|||||||
|
|
|
|
|
@ 3700 RPM |
80 Amps @ 115 V |
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
40 Amps @ 230 V |
|
115V, 60 Hz, 8 Amps |
|||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
PHYSICAL DIMENSIONS |
|
|
|
|
|
|||
Height |
|
|
|
|
Width |
Depth |
|
|
|
Weight |
||||
With Onan Engine: |
|
|
|
|
|
|
|
|
|
|
||||
30.3 in. |
|
|
|
|
19.2 in. |
42.3 in. |
|
|
|
562 lb. |
||||
770 mm |
|
|
|
|
485 mm |
1074 mm |
|
|
|
255 kg |
||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 |
|
RANGER 9 |
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-3 |
A-3 |
INSTALLATION
Read this entire installation section before you start installation.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
•Insulate yourself from the work and ground.
•Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or vent exhaust to the outside.
• Do not stack anything on or near the engine.
MOVING PARTS can injure.
•Do not operate this equipment with any of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
LOCATION AND VENTILATION
Whenever you use the RANGER 9, be sure that clean cooling air can flow through the machine’s gasoline engine and the machine case. Avoid dusty, dirty areas. Also, keep the machine away from heat sources. Do not place the back end of the generator anywhere near hot engine exhaust from another machine. And of course, make sure that engine exhaust is ventilated to an open, outside area.
The RANGER 9 may be used outdoors. Do not set the machine in puddles or otherwise submerge it in water. Such practices pose safety hazards and cause improper operation and corrosion of parts.
Always operate the RANGER 9 with the case roof on and all machine components completely assembled. This will protect you from the dangers of moving parts, hot metal surfaces, and live electrical devices.
WARNING
Damage to the fuel tank may cause fire or explosion. Do not drill holes in the RANGER 9 base or weld to the RANGER 9 base.
STORING
1.Store the machine in a cool, dry place when it’s not in use. Protect it from dust and dirt. Keep it where it can’t be accidentally damaged from construction activities, moving vehicles, and other hazards.
2.If you will be storing the machine for over 30 days, you should drain the fuel to protect fuel system and carburetor parts from gum deposits. Empty all fuel from the tank and run the engine until it stops from lack of fuel. If you prefer, you can treat the gasoline with a stabilizer to prevent deterioration rather than drain the system. Follow the stabilizer manufacturer’s instructions. Add the correct amount of stabilizer for the size of the RANGER 9 fuel tank. Fill the tank with clean, fresh gasoline. Run the engine for two to three minutes to circulate the stabilizer through the carburetor.
3.While the engine is still warm, drain the oil and refill with fresh 10W30 oil. Change the oil filter.
4.Remove the spark plugs and add one to two tablespoons of engine oil or rust inhibitor into each cylinder. Replace the spark plugs but do not connect the plug leads. Crank the engine two or three times to distribute the oil.
5.Clean any dirt and debris from the cylinder and cylinder head fins and other exterior surfaces.
6.Store in a clean, dry area.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-4 |
A-4 |
INSTALLATION
STACKING
RANGER 9 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound.
The gasoline engine is designed to run in a level position for best performance. It can operate at an angle, but this should never be more than 15 degrees in any direction. If you do operate it at a slight angle, be sure to check the oil regularly and keep the oil level at the FULL mark as it would be in its normal level condition. Also, fuel capacity will be a little less at an angle.
LIFTING
The RANGER 9 weighs 562 lbs/255 kg. A lift bail is mounted to the generator stator frame and should always be used when lifting the machine.
WARNING
•Keep hands away from the engine muffler or HOT engine parts.
•Stop the engine when fueling.
•Do not smoke when fueling.
•Remove the fuel cap slowly to release pressure.
•Do not overfill the fuel tank.
•Wipe up spilled fuel and allow the fumes to clear before starting the engine.
•Keep sparks and flame away from the fuel tank.
OIL
The RANGER 9 is shipped with the engine filled with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This
is an added precaution. When full, the oil level should be up to but not over the FULL mark on the dipstick. If it is not full, add enough oil to fill it to the full mark.
For more oil fill and service information, see the MAINTENANCE section of this manual.
HIGH ALTITUDE OPERATION
If you operate the RANGER 9 at altitudes above 5000 feet, you should install a carburetor jet designed for high altitude operation. This will result in better fuel economy, cleaner exhaust, and longer spark plug life. It won’t give increased power. Power is decreased at higher altitudes. Contact the engine manufacturer to obtain these high altitude jet kits (Onan kit part number 146-0458).
FUEL
Fill the fuel tank with clean, fresh, regular grade lead-free gasoline. DO NOT MIX
OIL WITH THE GASOLINE.
The RANGER 9 has a 9 gallon (34.1 litre), bottom mounted fuel tank with a top fill and fuel gauge. See the Operation and Maintenance sections of this manual for more details about fuel.
CAUTION
Do not operate a RANGER 9 with a high altitude jet installed at altitudes below 5000 feet. The engine will run too lean and operate at higher engine temperatures, which can shorten engine life.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the gasoline engine in the Operation and Maintenance sections of this manual before you operate the RANGER 9.
BATTERY CONNECTIONS
– + The RANGER 9 is shipped with the nega- 
tive battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the STOP position and attach the disconnected cable securely to the battery terminal. If the battery is discharged and won’t start the engine, see the battery charging instructions in the Maintenance
section.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-5 |
A-5 |
INSTALLATION
FIGURE A.1 - RANGER 9 OUTPUT CONNECTIONS
|
|
|
|
2 |
3 |
4 |
|
|
|
|
6 |
|
|
|
|
|
|
5 |
7 |
|
|
|
|
|
|
|
|
|
|
|
|
4 |
|
|
|
|
|
3 |
|
8 |
|
|
|
|
|
2 |
DC+ |
|
1 |
|
|
|
|
|
|
RANGE |
90 |
125 |
|
9 |
DC- |
|
50 |
|
1 |
AC |
|||
|
70 |
|
||||
|
|
|
175 |
|
10 max |
|
|
|
|
|
225 AC |
|
|
|
16 to 25 |
|
|
210 DC |
|
|
|
WARNING |
|
|
|
|
|
|
|
LINCOLN |
|
RANGER 9 |
|
|
|
|
ELECTRIC |
|
|
||
|
|
|
|
|
CHOKE |
|
7 |
|
|
|
|
AUTO |
START |
|
|
|
|
|
IDLER |
RUN |
|
|
|
|
|
HIGH |
STOP |
|
|
|
|
|
|
|
6
9
8
MUFFLER RELOCATION
WARNING
Shut off the machine and allow the muffler to cool before touching the muffler.
The RANGER 9 is shipped with the exhaust coming out on the left side. It can be changed to the right side by removing two screws that hold the exhaust port cover in place and installing the cover on the opposite side.
NOTE: Operating the RANGER 9 without the cover in place will not increase the machine output and will result in a higher noise level.
SPARK ARRESTER
Gasoline engine mufflers may emit sparks when the engine is running. Some federal, state, or local laws require spark arresters in locations where unarrested sparks could present a fire hazard.
5
1.OUTPUT RANGE SELECTOR
2.FINE OUTPUT CONTROL
3.CONTROL AT WELDER/REMOTE CONTROL SWITCH
4.WELDING TERMINALS SWITCH
5.POLARITY SWITCH
6.115/230 VOLT, 50 AMP RECEPTACLE
7.115 VOLT, 20 AMP RECEPTACLES (2)
8.WELD OUTPUT TERMINALS (2)
9.GROUND STUD
Standard mufflers and deflectors (like the ones included with the RANGER 9) do not act as spark arresters. When local laws require it, a spark arrester must be installed on the machine and properly maintained. An optional spark arrester kit (K894-1) is available for your RANGER 9. See the Accessories section of this manual for more information.
CAUTION
An incorrect spark arrester may lead to damage to the engine or reduce performance.
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the output range selector, fine output control, polarity switch, control at welder/remote control switch, welding terminals always on/remotely controlled switch 115 and 230 volt receptacles, weld output terminals, and ground stud.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-6 |
A-6 |
INSTALLATION
WELDING CABLE CONNECTIONS
CABLE SIZE AND LENGTH
Be sure to use welding cables that are large enough. The correct size and length becomes especially important when you are welding at a distance from the welder.
Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.
TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
|
|
Cable Size for 250 Amp |
Cable Size for 250 Amp |
|
Cable Length |
40% Duty Cycle |
100% Duty Cycle |
|
0-50 feet (0-15 meters) |
2 AWG |
1 AWG |
|
50-100 feet (15-39 meters) |
2 AWG |
1 AWG |
|
100-150 feet (30-46 meters) |
1 AWG |
1 AWG |
|
150-200 feet (46-61 meters) |
1 AWG |
1 AWG |
|
200-250 feet (61-76 meters) |
1/0 AWG |
1/0 AWG |
|
|
|
|
CABLE INSTALLATION
Install the welding cables to your RANGER 9 as follows. See Figure A.1 for the location of parts.
1.The gasoline engine must be OFF to install welding cables.
2.Remove the flanged nuts from the output terminals.
3.Connect the electrode holder and work cables to the weld output terminals. The terminals are identified on the case front.
4.Tighten the flanged nuts securely.
5.Be certain that the metal piece you are welding (the “work”) is properly connected to the work clamp and cable.
6.Check and tighten the connections periodically.
Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the Accessories section of this manual for more information.
For more information on welding, see WELDING OPERATION and SUMMARY OF WELDING PROCESSES in the Operations section of this manual.
MACHINE GROUNDING
Because the RANGER 9 creates its own power from its gasoline-engine driven generator, you do not need to connect the machine frame to an earth ground. However, for best pro-
tection against electrical shock, connect a heavy gauge wire (#8 AWG or larger) from the ground stud located on the bottom of the output panel (see Figure A.1) to a suitable earth ground such as a metal pipe driven into the ground.
CAUTION
•Loose connections will cause the output terminals to overheat. The terminals may eventually melt.
•Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.
WARNING
Do not ground the machine to a pipe that carries explosive or combustible material.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-7 |
A-7 |
INSTALLATION
When the RANGER 9 is mounted on a truck or a trailer, the machine generator ground stud MUST be securely connected to the metal frame of the vehicle. See Figure A.1. The ground stud is marked
with the ground symbol.
If the RANGER 9 is connected to premises wiring such as a home or shop, it must be properly connected to the system earth ground. See the PREMISES WIRING section of this manual for details.
PREMISES WIRING
The RANGER 9 is suitable for temporary, standby, or emergency power using the engine manufacturer’s recommended maintenance schedule. With its threewire grounded neutral generator, it can be permanently installed as a standby power unit for 230 volt, threewire, single phase 40 ampere service.
AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT
The control panel of the RANGER 9 features two auxiliary power receptacles: See Figure A.1.
•Two 20 amp, 115 volt duplex (double outlet) receptacles.
•One 50 amp 115/230 volt simplex (single outlet) receptacle.
Through these receptacles the machine can supply up to 9,000 rated continuous watts of single-phase, 60 Hz AC power. The machine output voltages fall within ± 10% of the rated voltage.
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriter’s Laboratories (UL) approved double insulation system with a two-blade plug. Lincoln offers an accessory plug kit that has the right type of plugs. See the Accessories section of this manual for details.
If you need ground fault protection for hand-held equipment, refer to the Accessories section of this manual for the K896-1 GFCI Receptacle kit.
CIRCUIT BREAKERS
Canadian Standards Association (CSA) versions of the RANGER 9 are
equipped with 50 amp circuit breakers on the 115/230 V receptacle and 15
amp circuit breakers on the 115 V receptacles for overload protection. Under high heat a breaker may tend to trip at lower loads than it would normally.
CAUTION
Never bypass the circuit breakers. Without overload protection, the RANGER 9 could overheat and/or cause damage to the equipment being used.
WARNING
Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that:
•The installation complies with the National Electrical Code and all other applicable electrical codes.
•The premises is isolated and no feedbacking into the utility system can occur. Certain state and local laws require the premises to be isolated before the generator is linked to the premises. Check your state and local requirements.
•A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter.
The following information and the connection diagram, Figure A.2, can be used as a guide by the electrician for most applications to premises wiring.
1.Install a double pole, double throw switch between the power company meter and the premises disconnect. The switch rating must be the same as or greater than the premises disconnect and service overcurrent protection.
2.Take the necessary steps to assure that the 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 the 230 volt auxiliary is 40 amperes. Loading above 40 amperes
will reduce output voltage below the allowable
– 10% of rated voltage. This may damage appliances or other motor-driven equipment.
3.Install a 50 amp 115/230 volt plug (NEMA type 14-
50)to a double pole circuit breaker using No. 8, 4 conductor cable of the desired length. (The 50 amp 115/230 volt plug is available in the optional power plug kit. See the Accessories section for details.)
4.Plug this cable into the 50 amp 115/230 volt receptacle on the RANGER 9 case front.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
A-8 |
A-8 |
INSTALLATION
FIGURE A.2 - CONNECTION OF RANGER 9 TO PREMISES WIRING
|
|
230 VOLT |
|
230 Volt |
|
GROUNDED CONDUCTOR |
|
POWER |
115 VOLT |
||
60 Hz. |
|||
|
|||
COMPANY |
|
||
3-Wire |
115 VOLT |
||
METER |
|||
Service |
|||
|
|||
|
|
||
|
|
NEUTRAL |
|
|
|
BUS |
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
|
|
|
|
PREMISES |
|
|
40 AMP |
GROUND |
DISCONNECT AND |
|
|
SERVICE |
||
|
|
230 VOLT |
||
|
|
|
OVERCURRENT |
|
|
|
|
|
|
|
|
DOUBLE |
|
PROTECTION |
|
|
|
|
|
50 AMP, 115/230 |
|
POLE |
|
|
230 VOLTS |
CIRCUIT |
|
|
|
VOLT PLUG |
|
|
||
BREAKER |
|
|
||
NEMA TYPE 14-50 |
|
|
|
|
|
|
|
|
|
|
|
GND |
|
|
|
|
|
N |
|
50 AMP, 115/230 VOLT
RECEPTACLE
NOTE: No. 8 COPPER CONDUCTOR CABLE
SEE NATIONAL ELECTRIC CODE FOR
ALTERNATE WIRE SIZE RECOMMENDATIONS.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Master TOC
Section B-1 Section B-1
TABLE OF CONTENTS |
|
- OPERATION SECTION - |
|
Operation............................................................................................................................... |
Section B |
Safety Instructions ...................................................................................................................... |
B-2 |
General Description .................................................................................................................... |
B-2 |
Recommended Applications ...................................................................................................... |
B-3 |
Welder ................................................................................................................................. |
B-3 |
Generator ............................................................................................................................. |
B-3 |
Operational Features and Controls ............................................................................................ |
B-3 |
Design Features and Advantages............................................................................................... |
B-3 |
Welding Capability ...................................................................................................................... |
B-4 |
Limitations ................................................................................................................................. |
B-4 |
Controls and Settings ................................................................................................................ |
B-4 |
Welder/Generator Controls .................................................................................................. |
B-5 |
Gasoline Engine Controls..................................................................................................... |
B-7 |
Engine Operation ........................................................................................................................ |
B-7 |
Before Starting the Engine .................................................................................................. |
B-8 |
Starting the Engine .............................................................................................................. |
B-8 |
Stopping the Engine ............................................................................................................ |
B-8 |
Break-in Period .................................................................................................................... |
B-8 |
Welding Operation .................................................................................................................... |
B-10 |
General Information............................................................................................................ |
B-10 |
AC/DC Constant Current Stick Welding ...................................................................... |
B-10 |
AC/DC TIG (Constant Current) Welding....................................................................... |
B-11 |
DC Wire Feed Welding................................................................................................. |
B-12 |
Summary of Welding Processes............................................................................................... |
B-13 |
Auxiliary Power ......................................................................................................................... |
B-14 |
General Information............................................................................................................ |
B-14 |
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-2 |
B-2 |
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your RANGER 9.
SAFETY INSTRUCTIONS
WARNING
WARNING
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Do not attempt to use this equipment until you have |
|
ENGINE EXHAUST can kill. |
thoroughly read all the operation and maintenance |
|
|
|
|
|
manuals supplied with your machine. They include |
|
• Use in open, well ventilated areas or |
important safety precautions; detailed engine starting, |
|
vent exhaust to the outside. |
operating, and maintenance instructions; and parts |
|
• Do not stack anything on or near the |
lists. |
|
|
|
engine. |
|
|
|
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
•Insulate yourself from the work and ground.
•Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause 
fire or explosion.
•Keep flammable material away.
•Do not weld on containers that have held combustibles.
MOVING PARTS can injure.
•Do not operate this equipment with any of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
GENERAL DESCRIPTION
The RANGER 9 is a gasoline-engine driven, multiprocess 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 to operate AC power tools, battery chargers, and lighting; it can also be used to provide standby power. As a welder it provides 250 amps of AC current for welding with AC stick electrodes or 250 amps of DC current for DC stick welding. The RANGER 9 can also perform AC/DC TIG welding and DC semiautomatic wire feed welding.
The RANGER 9 is powered by the Onan P218 Performer® air-cooled, twin-cylinder engine.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-3 |
B-3 |
OPERATION
RECOMMENDED APPLICATIONS
WELDER
The RANGER 9 provides excellent constant current AC/DC welding output for stick (SMAW) welding and for TIG welding, and it offers constant voltage output for DC semiautomatic wire feed welding. For more details on using the machine as a welder, see WELDING OPERATION in the Operation section of this manual.
GENERATOR
The RANGER 9 gives AC generator output for medium use demands. For more details on operating the generator, see AUXILIARY POWER in the Operation section of this manual.
DESIGN FEATURES AND
ADVANTAGES
•9,000 watts of auxiliary power
•Enhanced constant voltage capability with low (1221 volts), medium (15-27 volts), and high (18-35 volts) range settings for greater control of wire feed applications.
•Built-in contactor with front panel selection of “cold” or “hot” welding terminals: Cold (WELDING TERMINALS REMOTELY CONTROLLED) – Closing wire feeder trigger switch or amptrol causes contactor to close and engine to accelerate to high idle. Hot (WELDING TERMINALS ALWAYS ON) – The contactor is closed and welding begins when electrode touches work; engine automatically goes to high idle.
OPERATIONAL FEATURES AND CONTROLS
The RANGER 9 was designed for simplicity. Therefore, it has very few operating controls. Three switches are used for welding operations:
•A nine-position output range selector switch selects current output for constant current stick or TIG applications and constant voltage wire feed applications.
•A fine output control switch for fine adjustment of current or voltage within the selected output range
•A three-position polarity switch for selecting DC+, DCor AC welding output.
•A two-position toggle switch for selecting between CONTROL AT WELDER or REMOTE CONTROL (Remote control connections are made at either the 6 pin or the 14 pin amphenol connector.
•A two-position toggle switch for selecting between control of the output contactor by the RANGER 9 (WELDING TERMINALS ALWAYS ON) or control of the output contactor by a cable from a wire feeder gun (WELDING TERMINALS REMOTELY CONTROLLED).
The gasoline engine control is a three-position toggle switch for START, RUN, and STOP and a two-position “IDLER” switch that selects engine speed for welding or auxiliary power applications. See ENGINE OPERATION in the Operation section of this manual for details about starting, running, stopping, and breaking in the gasoline engine.
•Constant current AC/DC Stick welding (SMAW) process capability with output range from 40-250 amps (AC) or 40-250 amps (DC).
•Constant voltage DC Semiautomatic Wire Feed Welding with output range from 40-250 amps.
•Constant current AC/DC TIG Welding with output across the entire range of settings.
•Polarity switch for selecting DC+, DC-, or AC welding output.
•Separate ground stud for safe connection of case to earth ground.
•Single 50 amp, 230 volt, full 9 kVA auxiliary power receptacle.
•Double duplex 20 amp, 115 volt auxiliary power receptacles.
•Electric starting.
•Battery Charging Ammeter.
•Engine Hour Meter for determining periodic maintenance.
•Top-of-the-line 18 HP Onan P218 Performer® engine.
•Durable, heavy-gauge steel case.
•Built-in feet for easy mounting to truck bed or trailer.
•Bottom-mounted 10 gallon (38.0 litre) fuel tank with convenient top fill and fuel gauge.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-4 |
B-4 |
OPERATION
•Quiet engine muffler with reversible exhaust feature for right or left side.
•All copper alternator windings and high quality insulation for dependable long life.
•Automatic engine shutdown protection for low oil pressure.
•Automatic engine idler goes to low idle 10 to 14 seconds after welding for greater fuel economy; includes high idle switch.
LIMITATIONS
•The RANGER 9 is not recommended for any processes besides those that are normally performed using stick welding (SMAW), TIG welding, MIG (GMAW) welding and Innershield® (FCAW) welding. Specific limitations on using the RANGER 9 for these processes are described in the WELDING OPERATION section of this manual.
•The RANGER 9 is not recommended for pipe thawing.
•Standard Remote Control Receptacle provides
interface for Lincoln remote control accessories. • During welding, generator power is limited and out-
Both 6 pin and 14 pin amphenols are provided for |
put voltages can drop. Therefore, DO NOT OPER- |
|
ease in hooking up wire feeders. |
ATE ANY SENSITIVE ELECTRICAL EQUIPMENT |
|
• Canadian Standard Association (CSA) approved |
WHILE YOU ARE WELDING. See Table B.4 for per- |
|
missible simultaneous welding and auxiliary power |
||
models available; include integrated generator out- |
||
loads. |
||
put overload protection through two 50 amp circuit |
||
|
||
breakers. |
|
WELDING CAPABILITY
The RANGER 9 is rated 250 amps, 25 volts constant current AC or 250 amps, 25 volts constant current DC (250 amps 25 volts constant voltage DC) at 100% duty cycle on a ten-minute basis.
The current is continuously variable from 40 to 250 amps AC or 40 to 250 amps DC. The RANGER 9 can weld with all 3/32 and most 1/8 inch and 1/16 diameter Lincoln AC stick electrodes. Wire feed processes using wire diameters from .030 to .068 inch are possible, depending on the specific process and wire feeder. (See LIMITATIONS.)
CONTROLS AND SETTINGS
All generator/welder controls are located on the Output Control Panel of the machine case front. Gasoline engine choke control, idler control, and start/stop controls are also on the case front. See Figure B.1 and the explanations that follow.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-5 |
B-5 |
OPERATION
FIGURE B.1 – OUTPUT PANEL CONTROLS
|
|
|
|
2 |
4 |
5 |
6 |
|
|
|
|
6 |
|
|
|
|
|
|
|
5 |
7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
4 |
|
|
|
|
|
|
3 |
|
8 |
|
|
|
|
|
|
2 |
DC+ |
|
|
1 |
|
|
|
|
|
|
|
RANGE |
90 |
125 |
|
9 |
DC- |
|
|
50 |
|
1 |
AC |
|
|||
|
70 |
|
|
||||
|
|
|
175 |
|
10 max |
|
|
|
|
|
|
225 AC |
|
|
|
|
16 to 25 |
|
|
210 DC |
|
|
|
|
WARNING |
|
|
|
|
|
|
|
|
LINCOLN |
|
RANGER 9 |
|
|
|
|
|
ELECTRIC |
|
|
|
||
|
|
|
|
|
CHOKE |
|
|
7 |
|
|
|
|
AUTO |
START |
|
|
|
|
|
|
IDLER |
RUN |
|
|
|
|
|
|
HIGH |
STOP |
|
|
|
|
|
|
|
|
|
8
3
1.OUTPUT RANGE SELECTOR
2.FINE OUTPUT CONTROL
3.POLARITY SWITCH
4.CONTROL AT WELDER/REMOTE CONTROL SWITCH
5.WELDING TERMINALS ALWAYS ON/
WELDING TERMINALS REMOTELY CONTROLLED SWITCH 6 WIRE FEEDER POWER CIRCUIT BREAKER
7.115 VOLT, 20 AMP RECEPTACLES (2)
8.115/230 VOLT, 50 AMP RECEPTACLE
9.WELD OUTPUT TERMINAL (TO WORK)
10.WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER)
11.GROUND STUD
12.14 PIN AMPHENOL
13.6 PIN AMPHENOL
11 
9 |
12 |
13 |
10 |
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1.OUTPUT RANGE SELECTOR: Selects continuous current output for constant current stick or TIG applications (blue settings) and constant voltage wire feed applications (red settings). The amperages on the dial correspond to the maximum amperages for each corresponding range setting.
Never change the range switch setting while welding since this could damage the switch.
2.FINE OUTPUT CONTROL: Allows fine adjustment of current or voltage within the selected output range.
3.POLARITY SWITCH: Selects DC+, DCor AC welding output. Color codings aid in the proper selection of stick (blue) or wire feed (red) polarity setting. The color setting of the polarity switch must match the color setting of the OUTPUT RANGE SELECTOR. Never change the polarity switch setting while welding since this could damage the switch.
4.CONTROL AT WELDER/REMOTE CONTROL SWITCH: Allows the operator to control welding output at the welding control panel or at a remote station. Remote connections are made at the 6 pin or 14 pin amphenol connector.
5.WELDING TERMINALS ALWAYS ON/WELDING TERMINALS REMOTELY CONTROLLED SWITCH: Allows control of the RANGER 9 output contactor. In the ALWAYS ON position, the switch closes the output contactor, and welding begins when an arc is struck between the electrode and the workpiece. In the REMOTELY CONTROLLED position, the switch places control of the contactor at the wire feeder. The contactor closes when the wire feeder gun trigger or amptrol switch closes and opens when it is released.
6.WIRE FEEDER POWER CIRUIT BREAKER: Opens the wire feeder circuit and disables the feeder if a fault is detected in the circuit.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-6
OPERATION
7.20 AMP, 115 VOLT DUPLEX RECEPTACLES: Connection point for supplying 115 volt power to operate one or two electrical devices.
8.50 AMP, 230 VOLT RECEPTACLE: Connection point for supplying 230 volt power to operate one electrical device.
9.WELD OUTPUT TERMINAL (TO WORK) WITH FLANGE NUT: Provides the connection point for the work cable.
10.WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH FLANGE NUT: Provides the connection point for the electrode holder.
11.GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.
12.14 PIN AMPHENOL: For attaching wire feeder control cables to the RANGER 9.
13.6 PIN AMPHENOL: For attaching optional remote control equipment to the RANGER 9.
RANGER 9
B-6
RANGER 9
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-7 |
B-7 |
OPERATION
FIGURE B.2 – GASOLINE ENGINE CONTROLS
|
|
|
|
6 |
|
|
|
|
|
5 |
|
|
|
|
|
7 |
|
|
|
|
4 |
|
|
|
|
3 |
|
8 |
|
|
|
|
2 |
|
DC+ |
|
|
|
|
|
|
RANGE |
90 |
125 |
1 |
9 |
DC- |
70 |
|
AC |
|||
|
|
175 |
|
10 max |
|
|
50 |
|
|
|
|
|
|
|
|
|
|
|
|
|
225 AC |
|
|
16 to 25 |
|
|
210 DC |
|
|
1. |
ENGINE CHOKE CONTROL |
|
|
|
2. |
IDLER CONTROL SWITCH |
WARNING |
|
1 |
3. |
START/STOP SWITCH |
LINCOLN |
RANGER 9 |
|
4. |
ENGINE HOUR METER |
|
||
ELECTRIC |
5 |
|||
5. |
BATTERY CHARGING SYSTEM METER |
|
|
|
|
|
|
CHOKE |
|
|
|
|
|
4 |
|
|
|
AUTO |
START |
|
|
|
|
|
|
|
|
IDLER RUN |
|
|
|
|
HIGH |
STOP |
|
|
|
|
|
2 3
GASOLINE ENGINE CONTROLS
See Figure B.2 for the location of the following features:
1.ENGINE CHOKE CONTROL: Provides a richer air/fuel mixture for cold engine starting conditions. See the topic ENGINE OPERATION, below, for details on setting the choke.
2.IDLER CONTROL SWITCH: Adjusts the running speed of the engine. The switch has two positions, HIGH and AUTO. In HIGH, the engine runs continuously at high idle. In AUTO, the idler control works as follows:
Stick Welding, “WELDING TERMINALS ALWAYS ON” mode: The engine accelerates to high speed when the electrode touches the work and strikes a welding arc. The engine returns to low idle approximately 10-14 seconds after welding stops, as long as no auxiliary power is being drawn.
Wire Welding, “WELDING TERMINALS ALWAYS ON” mode: The engine accelerates to high speed when the wire feeder gun trigger or amptrol is closed. The engine returns to low idle approximately 10-14 seconds after the gun trigger is released and the welding stops, provided that no auxiliary power is being drawn.
Auxiliary Power: The engine accelerates to high speed when power is drawn at the receptacles for lights or tools. The engine returns to low idle approximately 10-14 seconds after demand for auxiliary power stops.
3.START/STOP SWITCH: Has three positions, START, RUN, and STOP. When the switch is held in the START position, the starter motor cranks over the engine – release the switch once the engine starts. The STOP position stops the engine.
NOTE: If you place the switch in the START position when the engine is running, you may damage the ring gear or starter motor.
4.ENGINE HOUR METER: Records engine running time. Use the meter to determine when to perform required maintenance.
5.BATTERY CHARGING SYSTEM METER: Shows whether the charging circuit is performing its job of charging the battery when the engine is running. The meter will register discharge during starting, but then the needle should return to a position slightly toward positive during running. The needle will hold position when the engine stops.
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the RANGER 9 is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed.
Read and understand all safety instructions included in the Onan instruction manual that is shipped with your RANGER 9.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-8 |
B-8 |
OPERATION
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
1. Be sure the machine is on a level surface.
2.Remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick. On the Onan engine, the oil fill cap and dipstick are a unit. See Figure D.1 in the Maintenance section of this manual.
3.Add oil (if necessary) to bring the level up to the full mark. Do not overfill.
Replace the dipstick and tighten it securely.
2. Hold the Engine Switch in the START position. Release the switch when the engine starts. Slowly return the choke control to the full “in” position.
The engine will run at high idle for 10-14 seconds, then go to low idle.
3.Let the engine run at low idle for a few minutes to warm up before you use the RANGER 9 for welding or auxiliary power.
If the engine will not start, see the Troubleshooting section of this manual.
Check and fill the engine fuel tank:
1.Remove the fuel tank cap.
2.Fill the tank approximately 4 inches
(100 mm) from the top of the filler neck to allow for fuel expansion (observe the fuel gauge). DO NOT FILL THE TANK TO THE POINT OF OVERFLOW.
3.Replace the fuel tank cap and tighten securely.
NOTE: Use only fresh, unleaded gasoline with octane rating 87 or higher. Gasoline/alcohol blends are approved for use with your engine as long as the blend does not exceed 10% ethyl alcohol by volume. Other gasoline/alcohol blends are not approved, and their use may damage fuel system and engine parts. NOTE: Purchase gasoline in quantities that will be used within 30 days, to assure freshness.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power receptacles before starting the gasoline engine.
For a “cold” engine:
1.Set the Idler Control Switch in the AUTO position.
Use the Choke Control as follows:
If the engine is cold, pull the choke control out. If the engine is warm or hot, DO NOT use the choke control.
STOPPING THE ENGINE
1.Remove all welding and generator power loads and let the engine cool by running it for several minutes at low idle.
2.Stop the engine by placing the Engine 
Switch in the STOP position.
A fuel shutoff valve is not required on the RANGER 9 because the fuel tank is mounted below the engine.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its “break-in” period. For the gasoline engine on the RANGER 9, break-in is about 50 running hours.
Check the oil at least twice a day during break-in. Change the oil after the first 25 hours of operation. Change the oil filter at the second oil change. For more details, see the Maintenance section of this manual.
CAUTION
During break-in, subject the RANGER 9 to moderate loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several minutes.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-9 |
|
B-9 |
||||||
|
|
OPERATION |
|
|
||||
|
|
TABLE B.1 |
|
|
|
|||
|
|
TYPICAL RANGER 9 FUEL CONSUMPTION |
||||||
|
|
|
|
|
||||
|
|
ONAN P218 PERFORMER |
|
|||||
|
|
Low Idle – No Load, 2150 RPM |
|
.40 |
Gallons/hour (1.5 liters/hour) |
|
||
|
|
High Idle – No Load, 3700 RPM |
|
.82 |
Gallons/hour (3.10 liters/hour) |
|
||
|
|
AC CC Weld Output, 250 Amps @ 25 Volts |
|
1.7 |
Gallons/hour (6.5 liters/hour) |
|
||
|
|
DC CC Weld Output, 250 Amps @ 25 Volts |
|
1.7 |
Gallons/hour (6.5 liters/hour) |
|
||
|
|
DC CV Weld Output, 250 Amps @ 25 Volts |
|
1.7 |
Gallons/hour (6.5 liters/hour) |
|
||
|
|
Auxiliary Power, 9000 kVA |
|
1.7 |
Gallons/hour (6.5 liters/hour) |
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 |
|
RANGER 9 |
|
||
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-10 |
B-10 |
OPERATION
WELDING OPERATION
GENERAL INFORMATION
WARNING
•Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Do not breathe welding fumes or gases.
• Use ventilation or exhaust to remove welding fumes from the breathing area.
To use the RANGER 9 for AC/DC Constant Current Stick Welding:
1.Remove the flange nuts from output terminals and place the work and electrode welding cables over the terminals. See Figure B.3. Replace and tighten the flange nuts securely. Be sure the connections are tight.
2.Select the appropriate electrode. See “Welding Tips 1” included with your RANGER 9.
3.Attach the work clamp securely to the work you are welding.
4.Insert the electrode into the electrode holder.
5.Set the IDLER CONTROL to AUTO and start the gasoline engine. See ENGINE OPERATION in this section of the manual.
• Keep flammable material away.
• Wear eye, ear, and body protection.
The RANGER 9 can deliver from 40 to 250 amps of constant current for AC/DC stick welding or from 40 to 250 amps of constant voltage current for DC semiautomatic wire feed welding. AC/DC TIG welding is possible across the entire range from 40 to to maximum rated output. Output can be adjusted by setting the POLARITY SWITCH, the OUTPUT RANGE dial, and the FINE CONTROL dial on the output control panel to the settings that are best for your selected welding process.
6.Set the OUTPUT RANGE dial to a setting equal to or slightly higher than the welding current recommended for the electrode being used.
7.Set the POLARITY SWITCH to the desired polarity.
8.Set the FINE OUTPUT CONTROL. Use a setting that results in the highest output at the lowest setting of the RANGE switch for the application.
9.Strike an arc and begin welding.
After you finish welding:
1.Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2.Allow the electrode and work to cool completely.
3.Remove the work clamp from the work.
4.Remove any remaining piece of electrode from the electrode holder.
5.If you are finished using the RANGER 9 for welding, disconnect the welding cables from the weld output terminals. Reattach the flange nuts and leave them on the terminals.
FIGURE B.3 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
|
|
|
4 |
6 |
|
1 |
|
|
|
|
5 |
|
|
|
|
|
|
7 |
|
|
|
|
|
3 |
8 |
|
1. OUTPUT CONTROL PANEL |
|
|
|
175 |
DC+ |
|
|
|
|
|
2 |
|
|
|
RANGE |
90 |
125 |
1 |
9 |
DC- |
|
70 |
|
AC |
|
|||
|
50 |
|
|
10 max |
|
2. ELECTRODE CABLE |
|
|
|
225 AC |
|
|
|
16 to 25 |
|
|
210 DC |
|
|
|
|
|
|
|
|
|
3. ELECTRODE HOLDER |
WARNING |
|
|
|
|
|
4. ELECTRODE |
|
LINCOLN |
|
|
RANGER 9 |
|
5. OUTPUT TERMINALS |
|
ELECTRIC |
|
|
|
||
|
|
|
|
CHOKE |
|
6. WORK |
|
|
|
|
|
7. WORK CLAMP |
|
|
|
|
|
|
|
|
|
|
|
|
IDLER |
RUN |
8. WORK CABLE |
|
|
|
|
AUTO |
START |
|
|
|
|
|
HIGH |
STOP |
|
|
|
|
|
|
|
2
8 |
|
|
|
|
5 |
|
|
4 |
7 |
6 |
3 |
|
|
|
RANGER 9 |
|
RANGER 9 |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-11 |
B-11 |
OPERATION
To Use the RANGER 9 for AC/DC TIG (Constant Current) Welding:
1.Connect the K930-1 TIG Module to the RANGER 9. Follow the installation instructions provided with the kit. Also be sure to follow the special machine grounding instructions given in the manual.
2.Refer to the instruction manual with the TIG module (IM 528) for operation with a RANGER 9 and proper machine settings.
3.Set the OUTPUT RANGE dial to the appropriate setting for the electrode you are using. Refer to IM -528 with the TIG module or refer to Table B.2 for AC TIG welding.
4.Set the POLARITY SWITCH to the desired polarity.
5.Do not AC TIG weld on the 250 AC range setting. The output current may exceed the rating of the RANGER 9.
6.Start the arc and begin welding.
NOTE: When using the RANGER 9 for AC TIG welding of aluminum, the TIG Module is to be set for CONTINUOUS HF.
After you finish welding:
1.Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2.Allow the electrode and work to cool completely.
3.Remove the work clamp from the work.
TABLE B.2 - AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS
Settings for Pure Tungsten
|
Tungsten Diameter (inches) |
Range Switch Settings |
Appropriate Current Range |
|
|
1/8 |
90 or 120 |
160 - 200 Amps |
|
|
3/32 |
45 or 90 |
45 - 140 Amps |
|
|
1/16 |
45 or 90 |
45 - 100 Amps |
|
|
|
|
|
|
Settings for 1% Thoriated Tungsten
|
Tungsten Diameter (inches) |
Range Switch Settings |
Appropriate Current Range |
|
|||
|
1/8 |
90, 120, or 180 |
160 - 250 Amps |
|
|||
|
3/32 |
45, 90, or 120 |
100 - 180 Amps |
|
|||
|
1/16 |
45 or 90 |
60 - 120 Amps |
|
|||
|
|
|
|
|
|
|
|
|
RANGER 9 |
|
|
|
|
RANGER 9 |
|
|
|
|
|
|
|
||
|
|
|
|
|
|
||
|
|
|
|
|
|
||
|
|
|
|
|
|
||
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-12 |
B-12 |
OPERATION
To Use the RANGER 9 for DC Wire Feed Welding (Constant Voltage):
1.Connect one of the following: the LN-25, LN-7, LN-8, or LN-742 Wire Feeder. Follow the installation instructions in the ACCESSORIES section of this manual.
2.Some recommended Innershield electrodes are: NR-211MP, NR-311, NR-203 series, as well as Lincore® 33 and 55 hardfacing electrodes. Diameters from .035 (0.9mm) up to and including 5/64” (2.0mm) can be used. 5/64” (2.0mm) NS3M can be used in limited applications. Cable length and other conditions can affect the ultimate results of this application. Request Lincoln publication N-675 for additional information.
Recommended Outershield electrodes are .045,
.052, and 1/16 Outershield 71 and 1/16 Outershield 70. Request Lincoln publication GS-200 for additional information.
For MIG welding, the recommended electrodes are .030, .035 and .045 L-50 and L-56. You must use a blended shielding gas such as C25 (75% Argon, 25% CO2). Request Lincoln publication GS-100 for additional information.
3.Set the IDLER CONTROL to “AUTO” for the LN-25 or LN-742 or “HIGH” for the LN-7 or LN-8 and start the gasoline engine. See ENGINE OPERATION in this section of the manual.
4.Set the OUTPUT RANGE dial to either HIGH, MED, or LOW depending on your wire size and speed.
5.Set the POLARITY SWITCH to either WIRE FEED DC+ or WIRE FEED DC- (red), depending on the electrode.
6.Set the FINE OUTPUT CONTROL to a setting that gives the most stable arc for the application.
7.Strike an arc and begin welding.
After you finish welding:
1.Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2.Allow the work to cool completely. The wire gun and wire are “cold.”
3.Remove the work clamp from the work.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-13 |
B-13 |
OPERATION
SUMMARY OF WELDING
PROCESSES AND MACHINE
SETTINGS
Table B.3 summarizes the requirements for various welding processes you can perform with the RANGER 9.
|
|
TABLE B.3 - 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 |
|
No |
|
Auto |
|
At Welder |
|
Always on |
|
Hot |
|
Touch electrode to work. |
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Welding starts immedi- |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
ately and engine goes to |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
high idle. |
TIG - CC |
|
Yes |
|
Auto |
|
Remote |
|
Remote |
|
Cold |
|
Press Amptrol. Welding |
||
K930-1/K936-1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
starts immediately. |
(With Amptrol) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Wire Feed - CV, |
|
Yes |
|
Auto |
|
Remote |
|
Remote |
|
Cold |
|
Press gun trigger, |
||
LN-25 with 42V |
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 contactor |
Remote Control Kit |
|
|
|
|
|
|
|
|
|
|
|
|
|
closes. Welding starts |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
immediately and engine |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
goes to high idle. |
Wire Feed - CV |
|
No |
|
Auto |
|
At Welder |
|
Always on |
|
Cold |
|
Press gun trigger, LN-25 |
||
LN-25 with internal |
|
|
|
|
|
|
|
|
|
|
|
|
|
contactor closes. Weld- |
contactor |
|
|
|
|
|
|
|
|
|
|
|
|
|
ing starts immediately |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
and engine goes to high |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
idle. |
Wire Feed - CV |
|
Yes |
|
Auto |
|
Remote |
|
Remote |
|
Cold |
|
Press gun trigger, |
||
LN-742 |
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 contactor |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
closes. Welding starts |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
immediately and engine |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
goes to high idle. |
Wire Feed - CV, |
|
Yes |
|
High |
|
Remote |
|
Remote |
|
Cold |
|
Press gun trigger, |
||
LN-7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 contactor |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
closes. Welding starts |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
immediately. |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 |
|
RANGER 9 |
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-14 |
B-14 |
OPERATION
AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation.
Powering Motors
You can start most 1.5 HP, single-phase electric motors if there is no load on the motor or other load connected to the RANGER 9. After starting, the motor may be run at full load. Larger motors (up to 2 HP) may be started and run as long as you don’t exceed the current rating of the receptacle. This may mean that only 230 volt motors of this size may be operated.
Using Auxiliary Power and Welding at the
Same Time
GENERAL INFORMATION
The RANGER 9 generator is rated at 9000 continuous watts. It provides both 115 volt and 230 volt power. You can draw up to 80 amps total from the 115 volt receptacles, but no more than 20 amps (15 amps CSA) from each receptacle at once. See Tables B.4A and B.4B. Up to 40 amps can be drawn from the single 230 volt receptacle.
The current rating of any plug used must be at least equal to the current load being drawn from the receptacle. Do not try to connect the receptacles in parallel.
Electrical loads in watts are calculated by multiplying the voltage rating of the load by the number of amps it draws. (This information is given on the load device nameplate.) For example, a device rated 115 volts, 2 amps will need 230 watts of power (115 x 2 = 230).
You can use Table B.6, GENERATOR POWER APPLICATIONS, to determine the wattage requirements of some common types of loads you can power with the RANGER 9. Be sure to read the notes at the bottom of the table.
It is possible to weld and use the RANGER 9 for auxiliary power at the same time. However, the size of the loads you can power is reduced when you weld. See Table B.5 in this section of the manual for a list of permissible simultaneous welding and load ratings. The table assumes that power is being drawn from either a 115 volt or the 230 volt receptacle, but not both at the same time.
NOTE: For simultaneous welding and power, set the OUTPUT CONTROL at “10” for maximum auxiliary power. At settings below “10,” only incandescent loads should be connected to the auxiliary receptacles.
To use the generator as an auxiliary power supply:
1.Start the gasoline engine. See ENGINE OPERATION in this section of the manual.
2.Set the IDLER CONTROL to the desired operating mode, HIGH or AUTO. Set the OUTPUT CONTROL to “10.” See Figure B.1.
3.Plug the load(s) into the appropriate 115 volt or 230 volt power receptacle.
NOTE: The 115 volt auxillary power receptacles should only be used with three-wire grounded type plugs or approved double insulated devices with two-wire plugs.
TABLE B.4A
MAXIMUM CURRENT DRAW FROM 115V DUPLEX
RECEPTACLES – NO WELDING
|
K1420-1 |
K1420-2 (CSA) |
||
Load From |
Each |
Total |
Each |
Total |
115V/230V |
Half of |
from |
Half of |
from |
Dual Voltage |
Each 115V |
Both 115V |
Each 115V |
Both 115V |
Receptacle |
Duplex |
Duplexes |
Duplex |
Duplexes |
0 |
20* |
78 |
15 |
60 |
2.2 KW |
20* |
60 |
15 |
60 |
4.5 KW |
20* |
40 |
15 |
40 |
6.7 KW |
20* |
20 |
15 |
20 |
9.0 KW |
0 |
0 |
0 |
0 |
|
|
|
|
|
*NEMA 5-20P plug required for 20 amp draw.
TABLE B.4B
MAXIMUM CURRENT DRAW FROM OPTIONAL 115V GFCI DUPLEX RECEPTACLES – NO WELDING
|
K1420-1* |
K1420-2** |
||
Load From |
Each |
Total |
Each |
Total |
115V/230V |
Half of |
from |
Half of |
from |
Dual Voltage |
Each 115V |
Both 115V |
Each 115V |
Both 115V |
Receptacle |
Duplex |
Duplexes |
Duplex |
Duplexes |
0 |
15 |
40 |
15 |
30 |
2.2 KW |
15 |
40 |
15 |
30 |
4.5 KW |
15 |
40 |
15 |
30 |
6.7 KW |
15 |
20 |
15 |
20 |
9.0 KW |
0 |
0 |
0 |
0 |
|
|
|
|
|
*Maximum current draw from each 115V GFCI Duplex is 20 amps. **Maximum current draw from each 115V GFCI Duplex is 15 amps.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
|
B-15 |
|
|
OPERATION |
|
B-15 |
|
|||
|
|
|
|
|
|
|
|
|||
|
|
|
TABLE B.5 - SIMULTANEOUS WELDING AND AUXILIARY POWER |
|
|
|||||
|
|
|
|
|
|
|
||||
|
Output Selector |
|
Welding |
Permissible Power in Watts |
Permissible Auxiliary Current |
|
||||
|
Setting |
|
Output |
|
|
(Unity Power Factor) |
in Amperes |
|
||
|
|
|
|
|
|
|
|
@ 115V |
@230V |
|
|
250 |
|
250 |
|
|
None |
— |
— |
|
|
|
200 |
|
200 |
2500 |
22 |
11 |
|
|||
|
160 |
|
160 |
3700 |
32 |
16 |
|
|||
|
120 |
|
120 |
5000 |
44 |
22 |
|
|||
|
90 |
|
90 |
6000 |
52 |
26 |
|
|||
|
45 |
|
45 |
7500 |
65 |
32.5 |
|
|||
|
|
CV Low |
|
200 |
5000 |
43 |
21.5 |
|
||
|
|
|
|
60 |
7500 |
65 |
32.5 |
|
||
|
|
CV Medium |
|
250 |
2750 |
40 |
20 |
|
||
|
|
|
|
80 |
6500 |
56 |
28 |
|
||
|
|
CV High |
|
250 |
1200 |
10 |
5 |
|
||
|
|
|
|
100 |
6000 |
52 |
26 |
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
RANGER 9 |
|
RANGER 9 |
|
||
|
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
Return to Section TOC |
Return to Master TOC |
B-16 |
|
|
|
B-16 |
|||||
|
|
|
OPERATION |
|
|
|
|||
|
|
|
|
TABLE B.6 |
|
|
|
||
|
|
|
TYPICAL GENERATOR POWER APPLICATIONS |
|
|
|
|||
|
|
|
|
|
|
|
|
|
|
|
|
|
Suggested Power Applications |
|
Running Watts |
|
*Start-up Watts |
|
|
|
|
|
*Air Compressor - 3/4 HP |
|
1,250 |
|
3,100 - 5,000 |
|
|
|
|
|
*Airless Sprayer - 1/3 HP |
|
600 |
|
1,500 - 2,400 |
|
|
|
|
|
Chain Saw |
|
1,200 |
|
|
|
|
|
|
|
Circular Saw |
|
1,200 |
|
|
|
|
|
|
|
Coffee Maker |
|
1,000 |
|
|
|
|
|
|
|
*Deep Freezer |
|
500 |
|
750 - 2,000 |
|
|
|
|
|
*Electric Motor - 1 HP |
|
1,000 |
|
2,500 - 4,000 |
|
|
|
|
|
Electric Range (1 element) |
|
1,500 |
|
|
|
|
|
|
|
Electric Skillet |
|
1,250 |
|
|
|
|
|
|
|
*Furnace Fan - 1/3 HP |
|
1,200 |
|
3,000 - 4,800 |
|
|
|
|
|
Portable Grinder (4 1/2”) |
|
600 |
|
|
|
|
|
|
|
Portable Grinder (7”) |
|
2,000 |
|
|
|
|
|
|
|
Halogen Work Light |
|
500 |
|
|
|
|
|
|
|
Hand Drill - 1/4” |
|
500 |
|
|
|
|
|
|
|
Hand Drill - 3/8” |
|
700 |
|
|
|
|
|
|
|
1500 Watt Heater |
|
1,750 |
|
|
|
|
|
|
|
Hedge Trimmer |
|
450 |
|
|
|
|
|
|
|
Light Bulb |
|
100 |
|
|
|
|
|
|
|
Reciprocating Saw |
|
900 |
|
|
|
|
|
|
|
Radial Arm Saw |
|
2,600 |
|
|
|
|
|
|
|
Radio |
|
50 |
|
|
|
|
|
|
|
*Refrigerator/Freezer (small) |
|
600 |
|
1,500 - 2,400 |
|
|
|
|
|
Slow Cooker |
|
200 |
|
|
|
|
|
|
|
*Submersible Pump - 1 HP |
|
1,000 |
|
2,500 - 4,000 |
|
|
|
|
|
*Sump Pump |
|
600 |
|
1,500 - 2,400 |
|
|
|
|
|
Toaster |
|
1,100 |
|
|
|
|
|
|
|
Weed Trimmer |
|
500 |
|
|
|
|
|
|
|
Lincoln 100 or 125 Amp Wire Feeder/Welder |
|
4,000 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
NOTES:
Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in the table, multiply RUNNING WATTS by 2.
Multiple loads can be used as long as the total load does not exceed 9,000 watts. Be sure to start the largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to start.
RANGER 9 |
|
|
RANGER 9 |
|
|
||
|
|
||
|
|
Loading...