Lincoln Electric IM511 User Manual [en, de, es, fr]

Multi-Process Gasoline Engine Driven Welder and Power Generator

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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 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.

RANGER

IM511-D

OCTOBER, 2000

Date of Purchase: Serial Number: Code Number: Model: Where Purchased:

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel 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.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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.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.

___________________________________________________

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.

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

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 coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors 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.

vapors

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

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.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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

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 defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

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.

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 noninflammables.

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

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 àleurplace.

Mar. ‘93

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!

Please Examine Carton

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

and Equipment For Damage Immediately

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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

Connection of Wire Feeders .........................................................................................13

Connection of K428 or K446 with K624-1 Remote Output Module ..............................13

Connection of K449 to the Ranger 9 ............................................................................13

Connection of LN-7 or LN-8 to the Ranger 9................................................................14

Connection of the LN-742 to the Ranger 9 ...................................................................14

Connection of the Magnum Spool Gun and SG Control Module to the Ranger 9........14

Remote Output Control .................................................................................................14

High Frequency Generator for TIG welding applications .............................................14

Operating Instructions .....................................................................................................15-17

Additional Safety Precautions .......................................................................................15

Welder Operation ..........................................................................................................15

Welder Controls, Functions, and Operation................................................................15-16

Engine Operation........................................................................................................16-17

Welding Processes .....................................................................................................17-18

Auxiliary Power ...........................................................................................................19-20

Standby Power Information and Connection to Premises Wiring Diagram ............... 20-21

Maintenance....................................................................................................................22-23

General Instructions ......................................................................................................22

Engine Adjustments ......................................................................................................22

Slip Rings ......................................................................................................................22

Battery ...........................................................................................................................23

Hardware.......................................................................................................................23

Troubleshooting ...............................................................................................................24-27

General Troubleshooting ...............................................................................................24

Electronic Idler Troubleshooting ....................................................................................25

Output System Troubleshooting..................................................................................26-27

Wiring Diagram ...............................................................................................................28-30

Connection Diagrams......................................................................................................31-35

Dimension Print .................................................................................................................36

Parts Pages ...............................................................................................................P230 Series

GENERAL DESCRIPTION

AC STICK / TIG (CC) OUTPUT

OUTPUT VOLTS AC

0 50 100 150 200 250 300

350

OUTPUT AMPS

250 OUTPUT RANGE 45 OUTPUT RANGE

DC STICK / TIG (CC) OUTPUT

OUTPUT VOLTS DC

0 50 100 150

200 250 300 350 400 450

OUTPUT AMPS

250 OUTPUT RANGE 45 OUTPUT RANGE

DC WIRE FEED (CV) OUTPUT

OUTPUT VOLTS DC

OUTPUT AMPS

050

100 150

200

250 300

350 400

LOW

MED

HIGH

55 50 45

40 35 30 25

20 15 10

5 0

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.

For AC/DC Stick welding, the range is 40-250 Amps. There is a 100% duty cycle on all settings. The Output selector covers six ranges with remote output control for fine current adjustment. For use with a broad range of AC and DC electrodes including Fleetweld®5P.

For DC Semi-automatic wire feed welding, three constant voltage wire feed welding settings are available giving a range of 40-250 Amps at 100% duty cycle. Excellent performance will be obtained with a broad range of Innershield®and Outershield electrodes (FCAW). Excellent arc characteristics are available with MIG (GMAW). An output contactor is provided for optimum semiautomatic welding.

SPECIFICATIONS

AC and DC Tig welding can be done at all constant current output settings.

The auxiliary power is provided by a 9,000 Watt, AC 115/230 Volt, 60 Hertz generator. It will operate AC power tools. It will also power a 1.5 HP motor (if started under no load). It is capable of lighting ninety 100 Watt incandescent bulbs, and can also be used for standby emergency power.

The Ranger 9 CSA machine (K1420-2) has four 15 amp circuit breakers for 115V auxiliary receptacles and two 50 amp circuit breakers for 230V receptacles. This machine is CSA approved.

- 7 -

SPECIFICATIONS

Machine

Product

Name

Ranger 9

(Onan)

Ranger 9

(Kohler)

* Based on a 10 min. period.

Ordering

Information

K1420-1

K1420-2

CSA(Meets

Canadian

Standards)

K1421-1

CSA

(Meets

Canadian

Standards)

** When welding, available AC auxiliary power will be reduced.

115V will operate either 60Hz or 50/60Hz power tools, lights, etc.

Description

250 Amp

AC/DC

Multi-Process

Arc Welder

with

9,000 Watts AC

Auxiliary

Power

Rated DC Output *

Amps / Volts / Duty Cycle

AC Constant Current

250A / 25V / 100%

DC Constant Current

250A / 25V / 100%

DC Constant Voltage

250A / 25V / 100%

Max OCV @ 3700 RPM

80V

Auxiliary Power for

Wire Feeders

42V, 60 Hz, 8 Amps

115V, 60 Hz, 8 Amps

AC Power **

9,000 Watts

60 Hz. DC

80 Amps @

115V

40 Amps @

230V

Dimensions

& Weight

30.3 x 19.2 x 42.3

(770 x 488 x 1075

598 lbs (272 kg)

30.3 x 19.2 x 42.3

(770 x 488 x 1075

591 lbs (269 kg)

mm)

Engine

Product

Name

Ranger 9

(Onan P218)

Ranger 9

(Kohler Command

CH20S)

Description Horsepower Operating

2 Cylinder

4 Cycle

Air-Cooled

Gasoline Engine.

Aluminum Alloy

Block with Cast Iron

Liners, Electronic

Ignition

18 HP

@ 3600 RPM

20 HP

@ 3600 RPM

Full Load:

3500 RPM

High Idle:

3700 RPM

Low Idle:

2200 RPM

Speeds

Displacement Ignition Capacities

47.7 cu in (782 cc)

38.1 cu in (624 cc)

12V Battery, 430

Cold Cranking

Amps, Toggle Start

Switch, Charging

Ammeter, Manual

Choke

Fuel:

9 Gal (34 L)

Lubricating Oil:

1.8 Qts (1.7 L)

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts (1.9 L)

- 8 -

OPTIONAL FEATURES

A) 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. Overall width 43.06" (1.09 m).

B) K886-1 Canvas Cover

To protect the Ranger 9 when not in use. Made from attractive red canvas material that is flame retardant, mildew resistant, and water repellent.

C) K894-1 Spark Arrester Kit

Includes a heavy gauge steel, approved spark arrester and clamp for easy mounting to muffler exhaust pipe.

D) K896-1 GFCI Receptacle Kit

Includes two UL approved 115 Volt ground fault circuit interrupter duplex type receptacles with covers and installation instructions. Replaces the two factory installed 115 Volt duplex receptacles. Each receptacle of each GFCI duplex is rated at 15 Amps but the maximum total current from each GFCI duplex is limited to 20 amps.

E) K930-1 TIG Module

G) K934-1 Bracket for Mounting a Gas Cylinder to a

K933-1 Undercarriage

Easily mounts on the back of the K933-1 Four Wheel Undercarriage to carry a welding gas cylinder.

H) K889-2 Two Wheel Undercarriage

For moving by hand. Two 4.00" x 8" industrial tires. Overall width 29" (.74m).

I) K857 Remote Control

Consists of a control box with 25' (7.5 m) of four conductor cable. Permits remote adjustment of output voltage.

J) K893-1 Caster for Two Wheel Undercarriage

Mounts to the front of the K889-2 Two-Wheel Undercarriage to allow easy movement on smooth surfaces. Includes a 6" diameter hard rubber wheel with a convenient toe-on, toe-off locking brake.

K) K702 Accessory Kit

Accessory Set includes 35 ft. 2 AWG electrode cable, 30 ft. 2 AWG work cable, headshield with number 12 filter, work clamp, and Cooltong®300 electrode holder. Cables are rated at 250 Amps, 40% duty cycle.

Provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications. Compact case is designed for easy carrying, complete with handle. High frequency bypass is built in. The K939-1 Docking Kit is available for mounting the TIG Module on top of the Ranger 9. The K936-1 control cable is required.

F) K933-1 Four Wheel Undercarriage

Allows movement of the Ranger 9 by hand without lifting. Easily assembles to the Ranger 9. It includes two rugged, hard molded wheels and two durable pneumatic tires. The spring loaded handle provides convenient, comfortable steering. The k934-1 Bracket is available for mounting a gas cylinder on the undercarriage.

L) K802-R Power Plug Kit

Provides four 115 Volt plugs rated at 15 Amps each and one dual voltage, full KVA plug rated at 115/230 Volts, 50 amps.

M) K802-N Power Plug KIt

Provides four 115 Volt plugs rated at 20 Amps each and one dual voltage, full KVA plug rated at 115/230 Volts, 50 Amps. (Not for use with K1420-2 CSA machine and machines with GFCI receptacles.)

- 9 -

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.

TIG

Magnum™TIG Torch Magnum Parts Kit and Argon gas K930-1 TIG Module K936-1 Control Cable

Optional:

K939-1 TIG Module Docking Kit K963 Hand Amptrol K870 Foot Amptrol K814 Arc Start Switch

™

WIRE FEED

LN-25 (K428 or K446) with K624-1 42 Volt Remote Output Control Module - Requires K626-xx Control Cable. Provides "cold" electrode until gun trigger is pressed. Voltage control is at the feeder. K446 LN-25 includes gas solenoid.

LN-25 (K449) Includes internal contactor for across the arc operation (no control cable). Provides "cold" electrode until gun trigger is pressed. Includes gas solenoid. K444-1 Remote Voltage Control Kit is required for voltage control at the feeder.

LN-742 (K617-1 or K618-1) or LN-742H (K617-2 or K618-2), requires K619-xx Input Cable Assembly. Provides "cold" electrode until gun trigger is pressed. Includes gas solenoid. K589-1 Remote Control Kit connects to the LN-742 to provide remote voltage and wire speed control or K857 Remote Voltage Control Kit connects to the Ranger 9 for voltage control at the feeder.

LN-7 (K521) or LN-7 GMA (K440), requires K584-xx Input Cable Assembly. Provides "cold" electrode until gun trigger is pressed. K440 LN-7 GMA included gas solenoid. K8567 Remote Voltage Control Kit is required for voltage control at the feeder. Ranger 9 must be operated at "HIGH" idle.

Magnum Gun is required for gas-shielded welding. Innershield Gun is required for gas-less welding.

- 10 -

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.

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ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

Spark Arrester

Some federal, state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, the K894-1 arrester must be installed and properly maintained.

CAUTION

Use of an incorrect arrester may lead to engine damage or performance loss.

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Machine Grounding

Because this portable engine driven welder or generator creates it’s own power, it is not necessary to connect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.).

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:

a. be grounded to the frame of the welder using a

grounded type plug, or

b. be double insulated.

When this welder is mounted on a truck or trailer, it’s frame must be securely connected to the metal frame of the vehicle.

Where this engine driven welder is connected to premises wiring, such as that in your home or shop, it’s frame must be connected to the system earth ground. See further connection instructions in the section entitled Standby Power Connections in this manual, as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

Undercarriages

The recommended undercarriage for use with this equipment for in-plant and yard towing by a vehicle is Lincoln’s K768-2. If the user adapts a non-Lincoln undercarriage, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

(

)

Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

1. Design capacity of undercarriage vs. weight of

Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue stress to the framework.

3. Proper placement of the equipment on the

undercarriage to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

-11 -

(1)

4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; like maintenance.

(

)

5. Conformance with federal, state and local laws.

)

(

Consult applicable federal, state and local laws regarding

specific requirements for use on public highways.

Battery Connection

This welder is shipped with the negative battery cable disconnected. Make sure that the Engine Switch is in the “STOP” position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine. If the battery is discharged and does not have enough power to start the engine, see the Maintenance-Battery section of this manual for battery charging instructions.

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instruc-

tions supplied with this machine.

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WARNING

GASOLINE

explosion.

• Stop engine while fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Keep sparks and flame away from tank.

• Wipe up spilled fuel and allow fumes to clear

before starting engine.

Oil

The Ranger 9 is shipped with the engine crankcase filled with SAE 10W-30 oil. Check the oil level before starting the engine. It if is not up to the full mark on the dipstick, add oil as required. Make certain that the oil filter cap is tightened securely. Refer to the engine Operators Manual for specific oil recommendations.

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Onan P218 - 1.8 Quarts (1.7 Liters)

Kohler CH20S - 2.0 Quarts (1.9 Liters)

Fuel

Fill the fuel tank with clean, fresh lead-free gasoline. The capacity is approximately 9 gallons (34 liters). Observe the fuel gauge while filling to prevent overfilling.

fuel can cause fire or

Welding Output Cables

With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if necessary.

Listed below are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

0-50 Ft.

50-100 Ft.

100-150 Ft.

150-200 Ft.

200-250 Ft.

250 Amps

40% Duty Cycle

2 AWG

1 AWG

1/0 AWG

250 Amps

100% Duty Cycle

1 AWG

1/0 AWG

Location / Ventilation

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid heated air coming out of the back of the welder recirculating back to the cooling air inlets below the exhaust. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

WARNING

Damage to fuel tank may cause fire or explosion. Do NO the Ranger 9 base.

------------------------------------------------------------------------

T drill holes in the Ranger 9 base or weld to

-12 -

Angle of Operation

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of operation for the engine is 15 degrees from horizontal in any direction. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase.

When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 10 gallons.

High Altitude Operation

Connection of Lincoln Electric Wire Feeders

WARNING

Shut off welder before making any electrical connections.

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Connection of K428 or K446 LN-25 with K624-1 42 volt Remote Output Control Module to the Ranger 9.

Requires K626-xx Control Cable. Provides “cold” electrode until gun trigger is pressed and also provides voltage control at the feeder. The K446 LN-25 includes a gas solenoid. See the appropriate connection diagram in rear of this manual.

If the Ranger 9 will be consistently operated at altitudes above 5,000 feet, a carburetor jet designed for high altitudes should be installed. This will result in better fuel economy, cleaner exhaust, and longer spark plug life. It will not is decreased at higher altitudes. Engine horsepower is reduced by 3.5% per 1000 feet for altitudes above 377 feet. High altitude jet kits are available from the engine manufacturer. Order Onan kit part number 146-0458.

give increased power which

a. Shut off the welder.

b. Connect the electrode cable from the LN-25 to the

c. Connect the control cable from the LN-25 to the

d. Attach the single lead from the front of the LN-25

CAUTION

Do not operate a Ranger 9 with a high altitude jet installed at an altitude below 5,000 ft. This will result in the engine running too lean and result in higher engine temperatures which can shorten engine life.

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Muffler Relocation

e. Set the “POLARITY” switch to either WIRE FEED

WARNING

Shut off welder and allow muffler to cool before touching muffler.

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The Ranger 9 is shipped with the exhaust coming out on the left side of the machine. The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and installing the cover on the opposite side. (Operating the Ranger 9 without the cover in place will result in a higher noise level and no increase in machine output.)

f. Set the “RANGE” switch to either HIGH, MED or

g. Set the “WELDING TERMINALS” Control switch to

h. Set the “IDLER” switch to the “AUTO” position.

Connection of the K449 LN-25 to the Ranger 9.

“ELECTRODE” stud of the welder. Connect the work cable to the “TO WORK” stud of the welder.

14 pin amphenol on the Ranger 9.

to the work using the spring clip on the end of the lead.

This is a control lead to supply the current to the wire feeder motor; it does not carry welding current.

DC+ or WIRE FEED DC- as required by the electrode being used.

LOW as required by the process.

the “REMOTELY CONTROLLED” position.

a. Shut off the welder.

b. Connect the electrode cable from the LN-25 to the

“ELECTRODE” stud of the welder. Connect the work cable to the “TO WORK” stud of the welder.

c. Attach the single lead from the front of the LN-25 to

work using the spring clip on the end of the lead. This is a control lead to supply the current to the wire feeder motor; it does not carry welding current.

-13 -

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” position.

g. Set the “IDLER” switch to the “AUTO” position.

Connection of the LN-7 or LN-8 to the Ranger 9.

a. Shut off the welder.

b. Connect the LN-7 or LN-8 per the instructions on

the appropriate connection diagram in the rear of this manual.

c. Set the output control toggle switch to appropriate

position: “CONTROL REMOTE” for LN-8 and LN-7 with K857 attached; “CONTROL AT WELDER” for LN-7 with no remote voltage control.

d. Set “POLARITY” switch to either WIRE FEED DC+

or WIRE FEED DC-.

e. Set the “RANGE” switch to either HIGH, MED or

LOW as required by the process.

f. Set the “WELDING TERMINALS” Control switch to

the “REMOTELY CONTROLLED” position.

g. Set the “IDLER” switch to the “HIGH” idle position.

Connection of the Magnum Spool Gun and SG Control Module to the Ranger 9

a. Shut off the Welder.

b. Connect per the instructions on the appropriate

connection diagram in the rear of this manual.

c. Set the output control toggle switch to “CONTROL

AT WELDER” when not using remote control.

d. Set the “POLARITY” switch to WIRE FEED DC+.

e. Set the “RANGE” switch to either HIGH, MED or

LOW as required by the process.

f. Set the “WELDING TERMINALS” Control switch to

the “REMOTELY CONTROLLED” position.

g. Set the “IDLER” switch to the “HIGH” idle position.

Remote Output Control

The Ranger 9 has a 6-pin and a 14-pin Amphenol connector. These connectors are located above the output studs. The 6-pin connector is intended to be used with the optional K857 Remote Output Control or in the case of TIG welding applications, with the Foot or Hand Amptrol. The 14-pin connector is used to connect a wire feeder control cable. If the wire feeder has a built-in power source output control, do not connect a remote output control to the 6-pin connector. When remote output control is used, the output control toggle switch is to be set at “CONTROL REMOTE”.

Connection of the LN-742 to the Ranger 9

a. Shut off the welder.

b. Connect per the instructions on the appropriate

connection diagram in rear of this manual.

c. Set the output control toggle switch to

“CONTROL AT WELDER” when not using remote control. When the LN-742 has a K589-1 remote control attached, set output control to “REMOTE”.

d. Set “POLARITY” switch to either WIRE FEED

DC+ or WIRE FEED DC-.

e. Set “RANGE” switch to either HIGH, MED or

LOW as required by the process.

f. Set the “WELDING TERMINAL” control switch to

“REMOTELY CONTROLLED” position.

g. Set the “IDLER” switch to the “AUTO” position.

High Frequency Generator for TIG welding applications

The K930-1 TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding. See IM528 supplied with the TIG Module for installation instructions.

Note: The TIG Module does not require the use of a high frequency bypass capacitor. If any other high frequency accessory is used with the Ranger 9, a bypass capacitor (Order Kit T12246) must be installed in the Ranger 9.

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OPERATING INSTRUCTIONS

Welder Controls - Function and Operation

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.

Welder Operation

Welder Output

Constant 250 amps AC @ 25 volts Current 250 amps DC @ 25 volts

Constant 250 amps DC @ 25 volts Voltage

RANGER 9

• Maximum Open Circuit Voltage at 3700 RPM is 80 volts.

• Duty Cycle: 100% for both welding and auxiliary power.

Explanation of Symbols that Appear on this Equipment

OFF

Low Idle

High Idle

ENGINE “ON-OFF” Switch

When placed in the “ON” position, this switch energizes the engine ignition circuit. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine.

ENGINE “START” Push-Button Switch

Energizes engine starter motor.

“POLARITY” Switch

Three STICK/TIG (constant current) polarity settings:

DC+, DC- and AC

Two wire feed (constant voltage) settings:

DC+ and DC-

Ranger 9 Approximate Fuel Consumption

Low Idle - No Load

2200 RPM

High Idle - No Load

3700 RPM

AC CC Weld Output

250 Amps @ 25 Volts

DC CC Weld Output

250 Amps @ 25 Volts

DC CV Weld Output

250 Amps @ 25 Volts

Auxiliary Power

9000 kVA

ONAN P218

PERFORMER

.4 gallons/hour

(1.5 liters/hour)

.8 gallons/hour

(3.1 liters/hour)

1.6 gallons/hour

(6.2 liters/hour)

1.8 gallons/hour

(7.0 liters/hour)

1.7 gallons/hour

(6.5 liters/hour)

1.8 gallons/hour

(7.0 liters/hour)

KOHLER

CH20S

.4 gallons/hour

(1.5 liters/hour)

1.0 gallons/hour

(3.9 liters/hour)

1.5 gallons/hour

(5.7 liters/hour)

1.7 gallons/hour

(6.5 liters/hour)

1.6 gallons/hour

(6.2 liters/hour)

1.7 gallons/hour

(6.5 liters/hour)

NOTE: The setting of this switch must match the

color band setting of the Range Switch (both switches must be set for the same welding process).

CAUTION

Never change the “POLARITY” switch setting while welding. This will damage the switch.

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“

RANGE” Switch

STICK/TIG (constant current) 6 45,90,120, range settings 160,200,250

WIRE FEED (constant voltage) 3

LOW,MED,HIGH

range settings

CAUTION

Never change the “RANGE” switch setting while welding. This will damage the switch.

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“

Provides a fine welding current adjustment within the Range Switch settings in the STICK/TIG mode and welding voltage control with the Range switch set in the WIRE FEED mode.

CONTROL”

-15 -

“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.

b. Auxiliary Power - With the engine running at low idle and auxiliary power for lights or tools is drawn (approximately 100-150 watts or greater) from the receptacles, the engine will accelerate to high speed.

”

If no power is being drawn from the receptacles (and not welding) for 10-14 seconds, the idler reduces the engine speed to low idle.

Starting/Shutdown Instructions

Starting the Engine

For remote control, the toggle switch is set in the “REMOTE CONTROL” position.

For control at the welder control panel, the toggle switch is set in the “CONTROL AT WELDER” position.

“WELDING TERMINALS” Switch

The toggle switch labeled “WELDING TERMINALS ALWAYS ON” and “WELDING TERMINALS REMOTELY CONTROLLED” is used to control the operation of the welder output contactor.

With the switch in the “ALWAYS ON” position, the output contactor is closed at LOW and HIGH idle.

With the switch in the “REMOTELY CONTROLLED” position, the contactor is open at LOW idle and HIGH idle until a control cable is attached to the welder amphenol connector from a wire feeder. Under this condition, contactor closes when the wire feeder trigger is depressed and opens when the trigger is released.

“IDLER” Switch

The idler switch has two positions, “HIGH” and “AUTO”.

When in “HIGH” position, the engine will run continuously at high idle.

When in “AUTO” operates as follows:

a. Welding

Low idle and in the “WELDING TERMINALS ALWAYS ON” mode Stick Welding only. welding arc is initiated and the engine accelerates to full speed.

Low idle and in the “WELDING TERMINALS REMOTELY CONTROLLED” mode -Wire Welding Only trigger closes the Ranger 9 output contactor and causes the engine to accelerate to full speed.

After the gun trigger is released and/or welding ceases (and no auxiliary power is being drawn), the engine will return to low idle after approximately 10 to 14 seconds.

When the electrode touches work, the

/ idle position, the idler

Pressing the gun

WARNING

• Do not touch electrically live parts of electrode with skin or wet clothing.

• Keep flammable material away.

• Insulate yourself from work and ground. Wear eye, ear, and body protection.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

Be sure all Pre-Operation Maintenance has been performed. Also, read the Engine Owner’s Manual.

Remove all loads connected to the AC power receptacles. To start the engine, set the “Idler Control” switch in the Automatic ( / ) position.

Use the choke control as follows: Onan Engine - If the engine is cold, pull the choke control out. Do not use the choke if the engine is warm or hot.

Kohler Engine - Always pull the choke control out when starting the engine; cold, warm or hot. Place the “Engine” switch in the “ON” position.

Push the “START” button and crank the engine until it starts. Release the button as soon as the engine starts. Do not push the “START” button while the engine is running because this will cause damage to the ring gear and/or starter motor. After the engine has started, slowly return the choke control to the full “in” position (choke open).

After running at high engine speed for 10-14 seconds, the engine will go to low idle.

Allow the engine to warm up by letting it run at low idle for a few minutes.

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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.

CURRENT RANGES (AC and DC STICK WELDING

- 5 to 10 ON CONTROL DIAL)

RANGE SETTING

ON MACHINE

90 120 160 200 250

ACTUAL

CURRENT RANGE

25 to 45 AMPS

50 to 90 AMPS 60 to 120 AMPS 80 to 160 AMPS

100 to 200 AMPS 140 to 250 AMPS

TIG (Constant Current) Welding

Break-in Period

It is normal for any engine to use a greater amount of oil until the break-in is accomplished. Check the oil level twice a day during the break-in period (approximately 50 running hours)).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS, WITHIN THE RATING OF THE MACHINE. AVOID LONG IDLE RUNNING PERIODS. REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN.

The engine manufacturer’s recommendation for the running time until the first oil change is as follows:

Kohler

CH20S

5 hr

Onan P218

25 hr

The oil filter is to be changed at the second oil change. Refer to the Engine Owner’s Manual for more information.

Welding Processes

Stick (Constant Current) Welding

Connect welding cables to the “TO WORK” and “ELECTRODE” studs. Start the engine. Set the "POLARITY” switch to the desired polarity. Set the output “CONTROL” or remote output control to max (10) and the “RANGE” switch to the setting that is closest to the recommended current for the electrode being used and make a trial weld. A fine adjustment of the welding can be made by adjusting the output “CONTROL” or remote control. For the best arc stability, alw setting of the output or remote control and the lowest setting of the “RANGE” switch.

The Ranger 9 can be used with a broad range of AC and DC stick electrodes. See “Welding Tips 1” included with the Ranger 9 for electrodes within the rating of this unit and recommended welding currents of each. See the following table for welding current ranges:

ays use setting that results in the highest

The Ranger 9 can be used in a wide variety of AC and DC Tungsten Inert Gas (TIG) welding applications for AC TIG welding up to 200 amps and DC TIG welding up to 250 amps.

The K930-1 TIG Module installed on a Ranger 9 provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding processes. The TIG Module allows full range output control. Afterflow time is adjustable from 0 to 55 seconds.

When using the Ranger 9 for AC TIG welding of aluminum, the TIG Module is to be set for CONTINUOUS HF.

The following settings and electrodes are

recommended:

Pure (EWP)

Tungsten Diameter

1/8

3/32

1/16

“Range”

Switch Settings

90, 120

45, 90

Welding

Current

100 to 200 amps

45 to 140 amps

45 to 100 amps

When AC TIG welding, the actual maximum welding current is 40 to 80 amps higher than the current marked on the RANGE SWITCH dial. This is a result of a lower effective reactance due to the natural rectification that occurs with the AC TIG welding process.

Wire Feed (Constant Voltage) Welding

The Ranger 9 can be used with a broad range of fluxcored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding).

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) NS-3M 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.

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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. Request Lincoln publication GS-100 for additional information.

SUMMARY OF WELDING PROCESS

When using a wire feeder with contactor control, the electrode will be “cold” until the gun trigger is pressed. To start the welding process, position the gun and close the gun trigger. The contactor will close, the arc will be initiated and the engine will accelerate to full speed. To stop welding, release the gun trigger and pull the gun away from the work. With the “IDLER SWITCH” in the “AUTO” position, the engine will go back to low idle in approximately 12 seconds (when no auxiliary power is drawn).

NOTE: The LN-7 and the LN-8 must be operated in

the “HIGH” idle position.

PROCESS

STICK - CC

TIG - CC K930-1/K936-1 (WITH AMPTROL)

WIRE FEED - CV, LN-25 WITH 42V REMOTE CONTROL KIT

WIRE FEED - CV, LN-25 WITH INTERNAL CONTACTOR

CONTROL

CABLE

USED

YES

IDLE

MODE

AUTO

OUTPUT

CONTROL

SWITCH

WELDER

REMOTE

WELDER

WELDING

TERMINALS

SWITCH

ALWAYS

REMOTE

ALWAYS

ELECTRODE

WHEN NOT

WELDING

HOT

COLD

TO START WELDING

Touch electrode to work. Welding starts immediately and engine goes to high idle.

Press Amptrol. Welding starts immediately.

Press gun trigger, Ranger 9 contactor closes. Welding starts immediately and engine goes to high idle.

Press gun trigger, LN-25 contactor closes. Welding starts immediately and engine goes to high idle.

WIRE FEED - CV, LN-742

WIRE FEED - CV, LN-7

YES

AUTO

HIGH

REMOTE

-18 -

REMOTE

COLD

Press gun trigger, Ranger 9 contactor closes. Welding starts immediately and engine goes to high idle.

Press gun trigger, Ranger 9 contactor closes. Welding starts immediately.

Auxiliary Power

GND

115 V

230 V

* Current Sensing for Automatic Idle (Receptacle viewed from front of machine.)

115V Duplex Receptacles

The Ranger 9 can provide up to 9,000 watts of 115/230 volts AC, single phase 60HZ power for continuous 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 1450R receptacle and two 20 amp 115 volt NEMA 520R receptacles. The K1420-2 CSA machine has one 50 amp 115/230 volt NEMA 14-50R receptacle and two 15 amp 115 volt NEMA 5-15R receptacles. Do not connect any plugs that connect to the power receptacles in parallel.

Start the engine and set the “IDLER” control switch to the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptalces for auxiliary power.

115/230 Volt Dual Voltage Receptacle

The 115/230 volt receptacle can supply up to 40 amps of 230 volt power to a two wire circuit, up to 40 amps of 115 volt power from each side of a three wire circuit (up to 80 amps total). Do not circuits in parallel. Current sensing for the automatic idle feature is only in the leg of the three wire circuit as shown below.

connect the 115 volt

The 115V auxiliary power receptacles should only be used with three wire grounding type plugs or approved double insulated tools with two wire plugs.

Maximum Current Draw from 115V Duplex Receptacles - No Welding

K1420-1 K1420-2 (CSA)

LOAD FROM

115V / 230V

DUAL VOLTAGE

RECEPTACLE

2.2 KW

4.5 KW

6.7 KW

9.0 KW

EACH

HALF OF

EACH 115V

DUPLEX

20 *

TOTAL

FROM BOTH 115V DUPLEXES

* NEMA 5-20P plug required for 20 amp draw.

and K1421-1 (CSA)

EACH

HALF OF

EACH 115V

DUPLEX

TOTAL

FROM BOTH 115V DUPLEXES

Maximum Current Draw from Optional 115V GFCI Duplex Receptacles - No Welding

LOAD FROM

115V / 230V

DUAL VOLTAGE

RECEPTACLE

K1420-1*

(WITH GFCI’S)

EACH

HALF OF

EACH 115V

DUPLEX

BOTH 115V

TOTAL

FROM

DUPLEXES

K1420-2

(WITH GFCI’S)

EACH

HALF OF

EACH 115V

DUPLEX

** and

K1421-1

BOTH 115V

DUPLEXES

TOTAL

FROM

2.2 KW

4.5 KW

6.7 KW

9.0 KW

* Maximum current draw from each 115V GFCI Duplex is 20 amps. ** Maximum current draw from each 115V GFCI Duplex is 15 amps.

-19 -

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). The motor may be run at full load when plugged into only one side of the duplex receptacle. Larger motors through 2HP can be run provided the receptacle rating as previously stated is not exceeded. This may necessitate 230V operation only.

It must be noted that the above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are permitted by the following table. The permissible currents shown assume that current is being drawn from either the 115 volt or 230 volt supply (not both at the same time).

Standby Power Connections

The Ranger 9 is suitable for temporary, standby or emergency power using the engine manufacturer's recommended maintenance schedule.

The Ranger 9 can be permanently installed as a standby power unit for 230 volt, 3-wire, 40 ampere service. Connections must be made by a licensed electrician who can determine how the 115/230 volt power can be adapted to the particular installation and comply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications (refer also to the Premises Wiring diagram shown).

NOTE: Voltage and permissible watts decrease as

“CONTROL” is adjusted to settings less than

10. It is recommended that at settings less than 10, only incandescent lighting loads be connected to the auxiliary power receptacles.

Output

Selector

Setting

Welding

Output

IMPORTANT: When the Ranger 9 is connected to

a 230 volt, 3-wire line, the unit should be operated with the idler switch in the “HIGH” idle position to avoid load sensing problems. If the machine is set for automatic idle, the 230 volt circuit will sense loads and cause the engine to accelerate to high idle. However, since only one line of the circuit senses current, 115 volt power drawn from only one line to neutral may result in the engine not going to high idle.

1. Install the double pole, double throw switch

Permissible

Power Watts

(Unity Power

Factor)

between the power company meter and the premises disconnect.

Switch rating must be the same or greater than the customer’s premises disconnect and service overcurrent protection.

Permissible

Auxiliary Current in

Amperes @ 115V

Permissible

Auxiliary Current in

Amperes @ 230V

MAR 95

250 200 160 120

90 45

CV LOW

CV MEDIUM

CV HIGH

250 200 160 120

90 45

200

250

250 100

NONE

2500 3700 5000 6000 7500

5000 7500

2750 6500

1200 6000

-20 -

22 32 44 52 65

43 65

40 56

10 52

11 16 22 26

32.5

21.5

32.5

20 28

2. Take necessary steps to assure load is

230 Volt

60 Hz.

3-Wire

Service

POWER

COMPANY

METER

230 VOLT

115 VOLT

LOAD

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 8 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

230 VOLT

GROUNDED CONDUCTOR

40 AMP

230 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.

50 AMP, 115/230

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 115/230 VOLT

RECEPTACLE

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 other motor-driven equipment.

3. Install a 50 amp 115/230 volt plug (NEMA Type 14-50) to the Double Pole Circuit Breaker using No. 8, 4 connector cable of the desired length. (The 50 amp 115/230 volt plug is available in the optional plug kit).

4. Plug this cable into the 50 amp 115/230 volt receptacle on the Ranger 9 case front.

CONNECTION OF RANGER 9 TO PREMISES WIRING

-21 -

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. Always use the greatest care when working near moving parts.

Do not put your hands near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

Engine Adjustments

WARNING

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum.

------------------------------------------------------------------------

Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop.

Routine Maintenance

1. At the end of each day’s use, refill the fuel tank to minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated.

2. OIL

The above schedule is for normal operating conditions. More frequent oil changes are required with dusty, high temperature, and other severe operating conditions. Refer to the maintenance section of the Engine Owner’s Manual for more information.

- Maintenance schedule for changing the oil

and oil filter after break-in:

Oil

Oil Filter

Kohler

CH20S

100 hr

200 hr

Onan

P218

50 hr

100 hr

CAUTION

Engine life will be reduced if the oil and oil filter are not changed according to the manufacturer’s recommendation.

-----------------------------------------------------------------------

3. Air Cleaner maintenance schedule for cleaning and re-oiling the foam pre-filter is every 25 hours and replacement of the air cleaner filter every 100 hours. More frequent servicing is required with dusty operating conditions. Refer to maintenance section of the Engine Owner’s Manual for more information.

4. Refer to the maintenance section of the Engine Owner’s Manual for the maintenance schedule for spark plug servicing, cooling system servicing, and fuel filter replacement.

- With normal operating conditions, the

CAUTION

Make certain that the oil filler cap is securely tightened after checking or adding oil. If the cap is not tight, oil consumption can increase significantly which may be evidenced by white smoke coming from the exhaust.

------------------------------------------------------------------------

5. Blow out the machine with low pressure air periodically. In particularly dirty locations, this may be required once per week.

6. Output Ranger Selector and Polarity Switches:

Switch contacts should not be greased. To keep contacts clean, rotate the switch through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld.

-22 -

Battery Charging

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an

ignition switch, turn it off when engine is not running.

• To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug.

------------------------------------------------------------------------

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 last.

b) Connecting a battery charger - remove the

battery from the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last.

c) Using a booster - connect the positive lead to

the battery first, then connect the negative lead to the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:

a) Installing a new battery. b) Using a booster.

1. When replacing, jumping or otherwise

connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover.

2. If the battery requires charging from an

external charger, disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads. Failure to do so can result to damage to the internal charger components. When re-connecting the cables, connect the positive cable first and the negative cable last.

HARDWARE

Both English / Metric fasteners are used in this welder.

Engine Maintenance Parts

ONAN P218 KOHLER CH20S

Oil Filter ONAN 122-0645 KOHLER 1205001

FRAM PH3614 FRAM PH3614*

Air Filter ONAN 140-2628-01 KOHLER 4708303 Element FRAM CA140PL FRAM CA79

Air Filter ONAN 140-1496 KOHLER 2408302 Pre-Cleaner

Fuel Filter ONAN 149-2005 KOHLER 2505002

FRAM G1 FRAM G1

Spark Plugs ONAN 167-0263 CHAMPION RC12YC (Resistor CHAMPION RS14YC (.030” GAP)

Type) (.025” GAP)

* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.

-23 -

TROUBLESHOOTING

ENGINE

TROUBLE

A. Engine will not crank or is hard to

crank.

B. Engine will not start or shuts down.

CAUSE

1. Battery will not hold a charge. Faulty battery.

2. No or insufficient charging current.

3. Loose battery cable connection(s).

4. Lead #216A from solenoid to start switch broken.

5. Spark plugs fouled.

1. Low oil pressure.

2. Out of fuel.

3. Fault in fuel system.

4. #216 lead from start switch to P.C. board broke / (Onan engine).

5. Oil pressure switch faulty.

6. Generator terminal block connection faulty.

7. Faulty P.C. Board (Onan engine).

WHATTODO

1. Replace with known good one.

2. Check connection of lead from voltage regulator on engine to charging ammeter and battery lead #208 and #209.

3. Check and tighten connection at battery, at starter, at engine foot, or at frame.

4. Repair.

5. Replace spark plugs.

1. Check oil level and add oil as req’d.

2. Add fuel to tank.

3. Repair.

4. Repair.

5. Replace

6. Repair. Check leads #208, 224A, 224B, 212.

7. Replace.

C. Engine does not develop full

power.

D. Battery does not stay charged.

1. Fuel filter clogged.

2. Air filter clogged.

1. Faulty battery.

2. Faulty charging system.

3. Loose or broken lead in charging circuit.

1. Replace.

2. Replace.

1. Replace with a new battery.

2. Refer to Engine Operators Manual for charging system service.

3. Refer to wiring diagram and check related leads, especially #208 and #209 leads.

-24 -

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

CAUSE

1. Idler switch in “HIGH” idle position.

2. External load on welder or auxiliary power.

3. Mechanical problem in idler solenoid linkage.

4. Idler solenoid position out of adjustment.

5. Faulty wiring in solenoid circuit.

6. Contactor circuit #2 or #4 closed or shorted. Engine goes to high idle when contactor circuit closes.

7. Faulty idler solenoid.

8. Low voltage at 224D to ground stud. (Voltage should be 12-14V DC).

9. Faulty P.C. Board PCB1.

1. Poor work lead connection to work.

2. “WELDING TERMINALS” switch in wrong position.

3. No open circuit voltage on output studs.

4. Faulty P.C. Board PCB1.

WHATTODO

1. Set switch to “AUTO” position.

2. Remove all external loads.

3. Repair.

4. Adjust solenoid as necessary.

5. Check for broken leads #224D,

214.

6. Refer to wiring diagram. Check related leads and amphenol connectors.

7. Replace with known good one.

8. Check wiring, battery and battery charging circuits.

9. Replace P.C. Board with known good one.

1. Make sure work clamp is tightly connected to clean base metal.

2. Switch must be in “ALWAYS ON” position to scratch start.

3. Check leads #247 and #250 for breaks. Check Switch S6 for faults.

4. Replace P.C. Board with known good one.

II. When using wire feeder with con-

trol cable plugged into amphenol connector or using amptrol when trigger is depressed.

C. Engine will not go to high idle

when using auxiliary power.

1. “WELDING TERMINALS” switch in wrong position.

2. Faulty wiring.

1. No signal from current sensor.

2. Auxiliary power lead less than 100 watts.

3. Faulty idler P.C. Board

-25 -

1. Switch must be in “REMOTELY CONTROLLED” position.

2. Refer to schematic. Check wiring in #2 and #4 circuit.

1. Check for broken leads in idler sensing circuit. #3 lead.

2. Idler may not respond with less than 100 watt load. Set idler switch to high idle.

3. Replace P.C. Board with known good one.

OUTPUT SYSTEM

TROUBLE

A. No welder or power output.

B. Output control on welder not

functioning.

CAUSE

1. Open lead in flashing or field circuit.

2. Faulty rotor.

3. Faulty stator field.

4. Faulty field rectifier D2.

5. Output contactor does not pull in.

6. Faulty P.C. Board.

1. Output control switch in wrong position.

2. Output control switch defective.

3. Output control potentiometer defective.

4. Faulty wiring.

5. Faulty P.C. Board

WHATTODO

1. Refer to wiring diagram and check related leads. (#7 & #9; #200, #201 and #219)

2. Lift brushes and check rotor continuity between slip rings. (Should be approx. 7.3Ω)

3. Disconnect lead #7 at D2 and check for continuity between leads #7 and #9.

4. Replace with known good one.

5. Refer to wiring diagram and check related leads and contactor.

6. Replace P.C. Board with known good one.

1. Place switch in “Output Control at Welder”.

2. Check and replace switch if faulty.

3. Check and replace potentiometer

if faulty.

4. Check for broken leads #75, #76, and #77 from P.C. Board and #75A, #76D, and #77D from potentiometer to remote switch.

5. Replace P.C. Board with known good one.

C. Output control or remote not

functioning.

D. Wire feeder does not work when

connected to welder amphenol.

1. Output control switch in wrong position.

2. Leads #75, #76, #77 broken at P.C. Board or S4.

3. Leads #75A, #76A, #77A broken at S4 or amphenol.

4. Remote control leads broken in control cable.

5. Faulty wire feeder.

6. Faulty P.C. Board.

1. Wire feeder circuit breaker open or

faulty.

2. Broken #31, #32, or #42 lead at amphenol.

3. No 115V or 42V output from stator.

4. Faulty wiring in control cable.

5. Faulty wire feeder.

1. Place switch in “Remote” position.

2. Repair.

3. Repair.

4. Repair.

5. Replace wire feeder with known good one.

6. Replace P.C. Board with known good one.

1. Reset or replace.

2. Repair.

3. Check continuity on #31, #32, and #42 at stator. Check buildup. If

O.K. , stator may be faulty. Replace.

4. Repair or replace cable.

5. Replace P.C. Board with known good one.

-26 -

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.

CAUSE

1. Welding terminal switch in wrong position.

2. Faulty wiring in contactor circuit.

3. Faulty remote switch S6.

4. Faulty contactor.

5. Faulty P.C. Board PCB1.

1. “WELDING TERMINALS” switch in wrong position.

2. Faulty wiring in contactor circuit.

3. Faulty amphenol or bypass P.C. Board PCB2.

4. Faulty contactor.

5. Faulty P.C. Board PCB1.

6. Faulty control cable from wire feeder or amphenol.

7. Faulty wire feeder.

WHATTODO

1. Place switch S6 in “Always On” position.

2. Check for broken leads #224C, #232A, and #224.

3. Check switch and leads #247, and #250.

4. Replace contactor with known good one.

5. Replace P.C. Board with known good one.

1. Place switch S6 in “REMOTELY CONTROLLED” position.

2. Check for broken leads #224, #224C & #232A.

3. Refer to wiring diagram and check related leads (#2 and #4).

4. Replace contactor with known good one.

5. Replace P.C. Board with known good one.

6. Replace.

7. Repair or replace.

G. Contactor does not drop out.

1. Faulty wiring.

2. Faulty amphenol or bypass P.C. Board PCB2.

3. Faulty contactor.

4. Faulty P.C. Board PCB1.

1. Check that lead #232 is not grounded.

2. Look for shorts to ground. Repair

or replace.

3. Replace with known good one.

4. Replace with known good one.

-27 -

236

ELECTRODE

WORK

241

GND

(+)

(-)

25W

100

224E

AMMETER

209

AM 1

AUTO

HIGH

212

CAPACITOR

ACAC B+

208

STARTER

REGULATOR

(+)

(-)

200A

219

200

(+)

(-)

ROTOR FIELD

(+)

(-)

(+)

(-)

800 MFD

CV-

CV+

DC+

DC-

212 (CAVITY #1)

208 (CAVITY #3)

(-)

(+)

CR1

209

LOCATING

BOARD

PCB1

CURRENT

SENSOR

75A

AMPHENOL 2

31B

GROUND SCREW

PCB2

BYPASS PC

10K POT

75A

MAX

ENGINE

HOUR METER

115 V

201A

200B

SHOWN IN

POSITION

IDLER

SOLENOID

12V

CONTACTOR

AND

219

3 TURNS

232

254A

235

75A

76A

77A

31A

WHITE

BLACK

GREEN

BLACK

77A

76A

76D

77D

76D

76A

77A

224

200B

224C

219

224E

224D

208A

254A

254

235

242

236

232

216A

224A

224B

240

200B

232A

216

201A

214

201A

216

219

232A

224C

77C

76C

75C

75B

77B

76B

75B

76B

77B

75C

76C

77C

(J)

(A)

(D)

(C)

(H)

(E)

(F)

(G)

(I)

(K)

(B)

(A)

(B)

(C)

(D)

(E)

(F)

GND-C

GND-G

115VAC

CONTACTOR

WORK

REMOTE CONTROL

42VAC

GROUND

REMOTE CONTROL

CONTACTOR

GROUND

GND-B

GND-A

77A

76A

250

50W

242

CB1

SOLENOID

216A

212

250

240

224A&B (CAVITY #4)

232

254

247

REACTOR

STATOR

SHOWN IN

"HIGH'

POSITION

208

31A

224B (CAVITY #2)

232A

200B

GND-G

232A

"ALWAYS ON"

247

208B

201

BETWEEN AMPHENOL HOLES

224C

224E

224

236A

245

7-19-96G

L10248

STARTER

MOTOR

NOTES:

31,000 MFD

CAPACITORS

SLIP

RINGS

WELDER LEAD END

(NOTE CAVITY NUMBERS)

REMOTE SWITCH

(SHOWN IN

REMOTE POSITION)

IN LINE CONNECTORS

(3 PLACES)

ELECTRODE POLARITY

SWITCH

OUTPUT

CONTACTOR

(CHOKE)

OUTPUT

RECTIFIER

IDLER

SWITCH

AMPHENOL 1

125/250V. SINGLE

RECEPTACLE

GROUND SCREW

BLOWER BAFFLE

OUTPUT

RHEOSTAT

OIL PRESSURE

SWITCH

TO SPARK

PLUGS

SLIP RING

NEAREST LAMINATION

FLYWHEEL

ALTERNATOR

ENGINE

FOOT

ENGINE

CROSS

SUPPORT

GND-H

B-

WELDING TERMINAL

CONTROL SWITCH

25 OHM

240

GND-E

242

GREEN

GND-D

GND-C

GND-E

GND-D

GREEN

VOLTAGE

IGNITION

COIL

IGNITION

MODULE

DIAGRAM "A"

ENGINE TERMINAL

BLOCK CONNECTION

SEE DIAGRAM "A" FOR

ENGINE TERMINAL

BLOCK CONNECTION.

IDLER

S2A (CLOSED

WITH S2 IN

C1, C2 OR C3

POSITION)

RANGE

SWITCH

(10AMP)

TAB

COLORED

SILVER

TERMINALS

COLORED

SILVER

TERMINALS

COLORED

SILVER

TERMINALS

RANGER 9 (ONAN) - WIRING DIAGRAM - CODE 10378 & 10539

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS VIEWED FROM REAR.

POSITION

"S3" SHOWN

IN "RUN"

START

BUTTON

-28 -

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

236

ELECTRODE

WORK

241

GND

(+)

(-)

25W

100

224E

AMMETER

209

AM 1

AUTO

HIGH

212

CAPACITOR

ACAC B+

208

STARTER

REGULATOR

(+)

(-)

CV-

CV+

DC+

DC-

212 (CAVITY #1)

208 (CAVITY #3)

CR1

209

LOCATING

BOARD

PCB1

CURRENT

SENSOR

75A

AMPHENOL 2

31B

GROUND SCREW

PCB2

BYPASS PC

10K POT

75A

MAX

ENGINE

HOUR METER

SHOWN IN

POSITION

IDLER

SOLENOID

12V

CONTACTOR

AND

219

3 TURNS

232

254A

235

75A

76A

77A

31A

77A

76A

76D

77D

76D

76A

77A

224

200B

224C

219

224E

224D

208A

254A

254

235

242

236

232

216A

224A

224B

240

200B

232A

216

201A

214

201A

216

219

232A

224C

77C

76C

75C

75B

77B

76B

75B

76B

77B

75C

76C

77C

115VAC

CONTACTOR

WORK

REMOTE CONTROL

42VAC

GROUND

REMOTE CONTROL

CONTACTOR

GROUND

GND-B

GND-A

250

50W

242

CB1

SOLENOID

250

240

224A&B (CAVITY #4)

232

254

247

REACTOR

STATOR

SHOWN IN

"HIGH'

POSITION

208

31A

224B (CAVITY #2)

232A

GND-D

232A

"ALWAYS ON"

247

BETWEEN AMPHENOL HOLES

224C

224E

224

236A

245

7-19-96G

L10249

STARTER

MOTOR

NOTES:

31,000 MFD

CAPACITORS

WELDER LEAD END

(NOTE CAVITY NUMBERS)

REMOTE SWITCH

(SHOWN IN

REMOTE POSITION)

ELECTRODE POLARITY

SWITCH

OUTPUT

CONTACTOR

(CHOKE)

OUTPUT

RECTIFIER

IDLER

SWITCH

AMPHENOL 1

GROUND SCREW

BLOWER BAFFLE

OUTPUT

RHEOSTAT

OIL PRESSURE

SWITCH

TO SPARK

PLUGS

FLYWHEEL

ALTERNATOR

ENGINE

FOOT

ENGINE

CROSS

SUPPORT

GND-H

B-

WELDING TERMINAL

CONTROL SWITCH

25 OHM

240

GND-E

242

GND-E

VOLTAGE

IGNITION

COIL

IGNITION

MODULE

DIAGRAM "A"

ENGINE TERMINAL

BLOCK CONNECTION

SEE DIAGRAM "A" FOR

ENGINE TERMINAL

BLOCK CONNECTION.

IDLER

S2A (CLOSED

WITH S2 IN

C1, C2 OR C3

POSITION)

RANGE

SWITCH

(10AMP)

200A

200

201

(+)

(-)

ROTOR FIELD

(+)

(-)

(+)

(-)

800 MFD

(+)

201

201A

200B

77A

76A

115 V

SILVER

115/230V

15A

CB6

15A

CB4

15A

CB5

CB7

115 V

GREEN

WHITE

BLACK

GND-G

GND-C

GND-D

125/250V. SINGLE

RECEPTACLE

GND-C

GND-G

IN LINE CONNECTORS

(3 PLACES)

SLIP

RINGS

POSITIVE SLIP

RING NEAREST

LAMINATION

50A

CB2

50A

CB3

WHITE

BLACK

33E

TERM.

COLORED

SILVER

COLORED

TERMINALS

SILVER

COLORED

TERMINALS

TAB

RANGER 9 ONAN (CSA VERSION) - WIRING DIAGRAM - CODE 10379 & 10540

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS VIEWED FROM REAR.

216A

212

208B

POSITION

"S3" SHOWN

IN "RUN"

START

BUTTON

-29 -

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

236

ELECTRODE

WORK

241

GND

(+)

(-)

25W

100

224E

AMMETER

209A

AM 1

AUTO

HIGH

221

ACAC B+

208

STARTER

REGULATOR

(+)

(-)

CV-

CV+

DC+

DC-

221 (CAVITY #1)

211 (CAVITY #3)

CR1

209A

LOCATING

BOARD

PCB1

CURRENT

SENSOR

75A

AMPHENOL 2

31B

PCB2

BYPASS PC

10K POT

75A

MAX

ENGINE

HOUR METER

SHOWN IN

POSITION

IDLER

SOLENOID

12V

CONTACTOR

AND

219

3 TURNS

232

254A

235

75A

76A

77A

31A

77A

76A

76D

77D

76D

76A

77A

224

200B

224C

219

224E

224D

208A

254A

254

235

242

236

232

224C

211

240

200B

232A

201A

214

201A

219

232A

224C

77C

76C

75C

75B

77B

76B

75B

76B

77B

75C

76C

77C

115VAC

CONTACTOR

WORK

REMOTE CONTROL

42VAC

GROUND

REMOTE CONTROL

CONTACTOR

GROUND

GND-B

GND-A

250

50W R2

242

CB1

SOLENOID

250

240

232

254

247

REACTOR

STATOR

SHOWN IN

"HIGH'

POSITION

208

31A

208 (CAVITY #2)

232A

GND-D

232A

"ALWAYS ON"

247

224C

224E

224

236A

245

2-20-98N

L10889

STARTER

MOTOR

NOTES:

31,000 MFD

CAPACITORS

WELDER LEAD END

(NOTE CAVITY NUMBERS)

REMOTE SWITCH

(SHOWN IN

REMOTE POSITION)

ELECTRODE POLARITY

SWITCH

OUTPUT

CONTACTOR

(CHOKE)

OUTPUT

RECTIFIER

IDLER

SWITCH

AMPHENOL 1

GROUND SCREW

BLOWER BAFFLE

OUTPUT

RHEOSTAT

OIL PRESSURE

SWITCH

FLYWHEEL

ALTERNATOR

ENGINE

FOOT

ENGINE

CROSS

SUPPORT

GND-H

B-

WELDING TERMINAL

CONTROL SWITCH

25 OHM

240

GND-E

242

GND-E

VOLTAGE

IGNITION

MODULE

DIAGRAM "A"

ENGINE TERMINAL

BLOCK CONNECTION

SEE DIAGRAM "A" FOR

ENGINE TERMINAL

BLOCK CONNECTION.

IDLER

S2A (CLOSED

WITH S2 IN

C1, C2 OR C3

POSITION)

RANGE

SWITCH

(10AMP)

200A

200

201

(+)

(-)

ROTOR FIELD

(+)

(-)

(+)

(-)

800 MFD

(+)

201

201A

200B

77A

76A

115 V

SILVER

115/230V

15A

CB6

15A

CB4

15A

CB5

CB7

115 V

GREEN

WHITE

BLACK

GND-G

GND-C

GND-D

125/250V. SINGLE

RECEPTACLE

GND-C

GND-G

IN LINE CONNECTORS

(3 PLACES)

SLIP

RINGS

POSITIVE SLIP

RING NEAREST

LAMINATION

50A

CB2

50A

CB3

WHITE

BLACK

33E

TERM.

COLORED

SILVER

COLORED

TERMINALS

SILVER

COLORED

TERMINALS

TAB

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS VIEWED FROM REAR.

210

208B

POSITION

"S3" SHOWN

IN "RUN"

START

BUTTON

GROUND SCREW BETWEEN

AMPHENOL HOLES

224C (CAVITY #4)

211

221

210

224C

FUEL

SHUTOFF

SOL.

224A

WHITE

RANGER 9 KOHLER (CSA VERSION) - WIRING DIAGRAM - CODE 10550

-30 -

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

12-16-93

M17090

ELECTRODE CABLE

LN-25

WIRE FEEDER

REMOTE CONTROL

TO WORK

ELECTRODE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

TO WORK

WORK CLIP LEAD

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

TO WORK

6 PIN AMPHENOL

N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.

RANGER 9 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM

14 PIN AMPHENOL

N.D. WELDING TERMINALS SWITCH MUST BE PLACED IN "ALWAYS ON" POSITION.

OPTIONAL K444-1

12-16-93

M17091

SPARE

GND

K867 UNIVERSAL

ADAPTER PLUG

GREEN

TO WORK

ELECTRODE

TO WORK

14 PIN AMPHENOL

CAUTION :

N.D.

N.E.

ELECTRODE CABLE TO WIRE FEED UNIT

LN-7 WIRE FEEDER

K291 OR K404 INPUT CABLE

K775 OPTIONAL REMOTE CONTROL

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.E. SPLICE LEADS AND INSULATE.

N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

RANGER 9 / K867 / K775 / LN-7 CONNECTION DIAGRAM

PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.F. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

– 31 –

12-16-93

M17092

ELECTRODE CABLE

OPTIONAL K857 REMOTE CONTROL

TO WORK

ELECTRODE

6 PIN AMPHENOL

14 PIN AMPHENOL

TO WORK

TO WIRE FEED UNIT

TO LN-7 INPUT CABLE PLUG

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

RANGER 9 / LN-7 CONNECTION DIAGRAM

PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

K584-XX INPUT CABLE ASSEMBLY

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

12-16-93

M17093

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.C.

SPARE

4 41 42 31 32

GND

REMOTE OUTPUT CONTROL

N.D.

10K

MIN.

NOT USED ON RANGER POWER SOURCES

42 VAC

115 VAC

N.E.

POWER SOURCE FRAME CONNECTION

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION

RELAY TO CLOSE LEADS 2 & 4.

K867 UNIVERSAL

ADAPTER PLUG

14 PIN

AMPHENOL

{

TO WORK

ELECTRODE

TO WORK

N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.

CAUTION :

N.B. USE POLARITY SWITCH TO SET DESIRED POLARITY, POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

CONNECT TOGETHER FOR

WELDING OUTPUT

WIRE FEEDER VOLTMETER CONNECTION CONNECTS TO (WORK TERMINAL) OF POWER SOURCE

ELECTRODE CABLE TO WIRE FEED UNIT

TO WIRE FEEDER

TO K867

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

RANGER 9 TO K867 ADAPTER CONNECTION DIAGRAM

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

– 32 –

12-16-93

M17094

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

SPARE

GND

N.C.

K867 UNIVERSAL ADAPTER PLUG

N.D.

N.D. SPLICE LEADS AND INSULATE.

TO WORK

ELECTRODE

TO WORK

CAUTION :

14 PIN

AMPHENOL

K196 INPUT CABLE

LN-8 WIRE FEEDER

ELECTRODE CABLE TO WIRE FEED UNIT

N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM

"REMOTELY CONTROLLED " POSITION.

PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION. PLACE WELDING TERMINALS SWITCH TO

N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

12-16-93

M17100

ELECTRODE CABLE

TO WORK

ELECTRODE

14 PIN AMPHENOL

TO WORK

TO WIRE FEED UNIT

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

K592 CONTROL CABLE

N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

RANGER 9 / LN-742 CONNECTION DIAGRAM

TO LN-742 INPUT CABLE PLUG

PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

– 33 –

12-16-93

M17214

ELECTRODE CABLE

TO WORK

ELECTRODE

14 PIN AMPHENOL

TO WORK

TO WIRE FEED UNIT

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.

RANGER 9 / LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM

K626-XX INPUT CABLE ASSEMBLY

TO LN-25 INPUT CABLE PLUG

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts.

Only qualified personnel should install,use or service this equipment.

4-19-96D

S20909

WARNING

can kill

ELECTRIC SHOCK

POWER SOURCE

6-PIN PLUG

ELECTRODE LEAD WORK SENSE LEAD

BYPASS

CAPACITOR

KIT

HI-FREQ KIT INPUT POWER

5-PIN PLUG

K915-1 AMPTROL ADAPTER

6-SOCKET

RECEPTACLE

K963 HAND

AMPTROL

K870 FOOT

AMPTROL

KIT FOR CONNECTION INFORMATION.

SEE INSTRUCTIONS INCLUDED WITH HI-FREQ

THIS ADAPTER ALLOWS AN AMPTROL TO OPERATE A

OUTPUT CURRENT OF A LINCOLN POWER SOURCE. (THE POWER SOURCE MUST BE EQUIPPED WITH A 6-PIN REMOTE CONTROL AMPHENOL CONNECTOR.) SEE THE HI-FREQ KIT AND POWER SOURCE INSTRUC-

AND CONTROL SETTINGS.

TION MANUAL FOR INFORMATION ON PROPER SWITCH

OF THE WELDING POWER SOURCE "OFF"

TURN THE ENGINE OR POWER SWITCH

BEFORE CONNECTING OR DISCONNECTING

PLUGS TO WELDING POWER SOURCE.

K915-1 AMPTROL ADAPTER FOR K799 HI-FREQ KITS

K799 HI-FREQ KIT WHILE REMOTELY CONTROLLING THE

K799 HI-FREQ KIT

– 34 –

CRM23615

M17902

TO WORK

ELECTRODE

TO WORK

CAUTION :

ELECTRODE CABLE TO CONTROL MODULE

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing.

Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts.

Only qualified personnel should install,use or service this equipment.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

RANGER

14 PIN WIRE FEEDER RECEPTACLE

K488 SG CONTROL MODULE

BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE

CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.

K487-25 SPOOL GUN

K691-10 INPUT CABLE

6 PIN REMOTE RECEPTACLE

115V RECEPTACLE

RANGER 9 AND 10LX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM

N.C. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.

MAR 95

– 35 –

CENTER OF GRAVITY WITH OIL IN

ENGINE AND EMPTY FUEL TANK.

30.008.80

UNDERCARRIAGE MOUNTING HOLES

17.00

9.09

2.75

OF SHAFT

42.00

30.00

9.31 9.29

9.09

26.59

REQUIRED WITH

KOHLER ENGINE)

FOR OIL FILTER

REMOVAL (NOT

12.75~.25

20.51

20.63 ~.25

CENTER OF GRAVITY WITH OIL IN

ENGINE AND EMPTY FUEL TANK.

30.28

DIMENSION PRINT - Ranger 9

– 36 –

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des

vêtements mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e

electrodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem

guardados.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de

respiración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un

aspirateur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de

alimentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant

l’entretien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

– 39 –

• 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

Lincoln Electric IM511 User Manual [en, de, es, fr]

Specifications and Main Features

Frequently Asked Questions

User Manual