Lincoln Electric IM511-D User Manual
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
TM
9
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
Copyright © 2000 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
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
i
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
ii
SAFETY
ii
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
to
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
iv
SAFETY
iv
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
vv
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
80
70
60
50
40
30
20
10
0
0 50 100 150 200 250 300
350
OUTPUT AMPS
B
B
A
A
250 OUTPUT RANGE
45 OUTPUT RANGE
DC STICK / TIG (CC) OUTPUT
OUTPUT VOLTS DC
80
70
60
50
40
30
20
10
0
0 50 100 150
200 250 300 350 400 450
OUTPUT AMPS
A
A
B
B
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)
in
mm)
in
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.
------------------------------------------------------------------------
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.
-----------------------------------------------------------------------
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:
(
)
1
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)
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