Lincoln Electric IM753 User Manual [en, de, es, fr]
RANGER 9
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Multi-Process Gasoline Engine Driven Welder and Power Generator
For use with machines having Code Numbers:
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.
10909, 10939
™
IM753-A
January, 2003
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2003 Lincoln Global Inc.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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
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.
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.
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.
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.
5.e. Also see item 1.b.
vapors
Mar ‘95
to
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.
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 non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. 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.
vv
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:
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
Page
Installation.......................................................................................................................Section A
Technical Specifications ................................................................................................A-1,A-2
Installation Instructions.........................................................................................................A-3
Undercarraiges..............................................................................................................A-3
Safety Precautions ........................................................................................................A-3
Spark Arrester ...............................................................................................................A-3
Machine Grounding.......................................................................................................A-3
Welding Output Cables .................................................................................................A-4
Additional Safety Precautions .......................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections......................................................................................................A-4
Exhaust Deflector..........................................................................................................A-4
High Altitude Operation .................................................................................................A-5
Electrical Connections..........................................................................................................A-6
Remote Outpit Control ..................................................................................................A-6
Welding Cable Connections..........................................................................................A-6
Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment ........................................A-7
Standby Power Connections ................................................................................................A-8
Premises Wiring ...................................................................................................................A-9
vi
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
General Description..............................................................................................................B-1
Recommended Applications.................................................................................................B-2
Auxiliary Power.....................................................................................................................B-2
Welder Operation ................................................................................................................B-2
Fuel Consumption .........................................................................................................B-3
Welder Controls Functions and Operations ........................................................................B-3
Idler Switch ...................................................................................................................B-4
Welding ........................................................................................................................B-4
Auxiliary Power .............................................................................................................B-4
Starting / Shutdown Instructions...........................................................................................B-4
Onan Engine .................................................................................................................B-4
Kohler Engine................................................................................................................B-4
Stoping the Engine........................................................................................................B-4
Break-In Period .............................................................................................................B-4
Welding Processes...............................................................................................................B-5
AC / DC Stick (Constant Current) Welding ...................................................................B-5
AC / DC TIG (Constant Current) Welding .....................................................................B-5
Wire Feed (Constant Voltage) Welding.........................................................................B-5
Summary of Welding Processes ..................................................................................B-6
________________________________________________________________________________
Accessories.....................................................................................................Section C
General Options / Accessories..............................................................................C-1
TIG Welding Options / Accessories.......................................................................C-1
vii
TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Engine Adjustments...............................................................................................D-1
Overspeed Is Hazardous.......................................................................................D-1
Routine Maintenance.............................................................................................D-1
Oil....................................................................................................................D-1
Engine Oil Change .........................................................................................D-1
Engine Oil Refill Capacities.............................................................................D-2
Oil Filter Change .............................................................................................D-2
Slip Rings........................................................................................................D-2
Air Cleaner ......................................................................................................D-2
Battery Charging .............................................................................................D-3
Battery.............................................................................................................D-3
Hardware ........................................................................................................D-3
Engine Maintenance Parts..............................................................................D-3
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-5
________________________________________________________________________
Wiring Diagrams, Dimension Print ................................................................Section F
________________________________________________________________________
Parts List..................................................................................................................P230
________________________________________________________________________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 9 (K1420-3,K1421-3)
INPUT - GASOLINE ENGINE
A-1
Make/Model Description Horsepower Operating Displacement
@ 3600 RPM SPEED Bore x Stroke in.(mm) System
Ranger 9 2 Cylinder
Onan P220 4 Cycle 3700RPM ( 653 cc in ) Cold Cranking Lubricating Oil :
{OHV} Air cooled Amps, Toggle 1.6 Qts. (1.5L)
Gasoline Start Switch,
Engine
Aluminum Alloy 3500RPM Manual Choke
Block with Cast
Ranger 9 Iron Liners & Fuel: 9 gal (34L)
Kohler Electronic
Command Ignition 2200RPM ( 624 cc in) 2.0 Qts. (1.9L)
CH20S
20.5 HP High Idle 39.9 cu in 12V Battery Fuel:
Full Load Charging Ammeter
20 HP Low Idle 38.1 cu in
cu. in.(cu. cm)
Starting Capacities
9 gal.
(34L)
Lubricating Oil :
RATED DC OUTPUT - WELDER
Welding Output Volts at Rated Amps * Duty Cycle Max. OCV @ 3700 RPM
AC Constant Current 25 Volts at 250 Amps
DC Constant Current 25 Volts at 250 Amps 100% 80 Volts
DC Constant Voltage 25 Volts at 250 Amps
MACHINE OUTPUT - GENERATOR
Description Auxiliary Power for wire feeders AC Power * *
250 Amp AC/DC Multi-Process 42V, 60 Hz, 8 Amps 9,000 Watts 60 Hz. DC
Arc Welder with 40 Amps @ 115V
9,000 Watts AC Auxiliary Power 115V, 60 Hz, 8 Amps 40 Amps @ 230V
40 Amps @ Duplex Outlet
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT
Ranger 9 Onan 30.3 in ( 770 mm ) 19.2 in ( 488 mm ) 42.3 in ( 1075 mm ) 598 lbs ( 272 kg
{P220 OHV}
Ranger 9 ( Kohler 591 lbs ( 269 kg )
Command CH20S )
* Based on a 10 min. period.
* * When welding, available AC auxiliary power will be reduced.
115V will operate either 60 Hz or 50/60 Hz power tools, lights, etc.
RANGER 9
A-2
SPECIFICATIONS
80
70
60
50
40
30
INSTALLATION
AC STICK / TIG (CC) OUTPUT
250
A 225 OUTPUT RANGE
45
B 50 OUTPUT RANGE
A-2
20
OUTPUT VOLTS AC (RMS)
10
0
80
70
60
50
40
30
20
OUTPUT VOLTS DC (RMS)
10
0
B
A
0
0 50 100 150 200 250 300 350
0 50 100 150 200 250 300 350 400 450
0
50 100 150 200
OUTPUT AMPS
DC STICK / TIG (CC) OUTPUT
250
A 210 OUTPUT RANGE
45
B 50 OUTPUT RANGE
B
50 100 150
A
200 250 300
OUTPUT AMPS
250
350
55
50
45
40
35
30
25
HIGH
20
15
OUTPUT VOLTS DC
10
MED
LOW
5
0
0 50 100 150 200 250 300 350 400
OUTPUT AMPS
RANGER 9
A-3
INSTALLATION
INSTALLATION INSTRUCTIONS
SAFETY PRECAUTIONS
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.
A-3
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”, as well
as the article on grounding in the latest U.S. National
Electrical Code and the local code.
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 spark arrester must be
installed and properly maintained.
CAUTION
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
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:
• Be grounded to the frame of the welder using a
grounded type plug, or
• 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.
RANGER 9
UNDERCARRIAGES
The recommended trailer for use with this equipment
for in plant and yard towing by a vehicle (1) 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:
• Design capacity of undercarriage vs. weight of
Lincoln equipment and likely additional attachments
• Proper support of, and attached to, the base of the
welding equipment so there will be no undue stress
to the frame work.
• 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.
A-4
• Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated;
environmental conditions; like maintenance.
• Conformance with federal, state and local laws.(1)
(1)
Consult applicable federal, state and local laws
regarding specific requirements for use on public
highways.
INSTALLATION
PRE-OPERATION SERVICE
CAUTION
READ the engine operating and maintenance
instructions supplied with this machine.
WARNING
GASOLINE
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
fuel can cause fire or explosion.
• Stop engine while fueling.
• Do not smoke when fueling.
• Do not overfill tank.
• Keep sparks and flame away from
fuel tank.
-
A-4
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. Loose connections will result in overheating of
the output studs.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
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
250 Amps
40% Duty Cycle
0-50 Ft.(15.2M)
50-100 Ft.(15.2-30.5M)
2 AWG
2 AWG
250 Amps
100% Duty Cycle
1 AWG
1 AWG
Oil
The Ranger 9 is shipped with the engine crankcase
filled with SAE 10W-30 oil. Check the oil level before
starting the engine. If it is not up to the full mark on the
dip stick, add oil as required. Make certain that the oil
filler cap is tightened securely. Refer to the engine
Owner’s Manual for specific oil recommendations.
LUBRICATION SYSTEM CAPACITY
(INCLUDING FILTER)
Onan P220 - 1.65 Quarts (1.6 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 fuel gauge while filling to prevent overfilling.
BATTERY CONNECTIONS
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 battery charging instructions in the
Battery section.
100-150 Ft.(30.5-45.7M)
150-200 Ft.(45.7-61.0M)
200-250 Ft.(61.0-76.0M)
2 AWG
1 AWG
1/0 AWG
1 AWG
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 Not
the Ranger 9 base.
------------------------------------------------------------------------
drill holes in the Ranger 9 base or weld to
RANGER 9
A-5
INSTALLATION
A-5
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
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 at the normal (FULL) oil capacity in the
crankcase in a level condition.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 10
gallons.
HIGH ALTITUDE OPERATION
If the Ranger 9 will be consistently operated at altitudes above 5000ft.(1524m), 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
power which is decreased at higher altitudes. Engine
horsepower is reduced by 3.5% per 1000ft.(304.8m)
for altitudes above 377ft.(114.9m).
give increased
CAUTION
Do not operate a Ranger 9 with a high altitude jet
installed at altitudes below 5000ft.(1529m). This
will result in the engine running too lean and
result in higher engine operating temperatures
which can shorten engine life.
-----------------------------------------------------------------------
High altitude jet kits are available from the engine
manufacturer. Contact your local Onan, or Kohler
Authorized Dealer.
Muffler Relocation
WARNING
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
WARNING
Shut off welder before making any electrical
connections.
-----------------------------------------------------------------------
Connection of the LN-7 or LN-8 to the
Ranger 9.
•
Shut off the welder.
• Connect the LN-7 or LN-8 per the instructions on
the the appropriate connection diagram in the rear
of this manual.
• 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.
• Set “POLARITY” switch to either WIRE FEED DC+
or WIRE FEED DC-.
* Set the “RANGE” switch to either HIGH, MED or
LOW as required by the process.
• Set the ‘WELDING TERMINALS” Control switch to
the ‘REMOTELY CONTROLLED” position.
• Set the ‘IDLER” switch to the “HIGH”idle position.
Connection of the LN-742 to the Ranger 9.
• Shut off the welder.
• Connect per the instructions on the appropriate con
nection diagram in the rear of this manual.
Shut off welder and allow muffler to cool before
touching muffler.
The Ranger 9 is shipped with the exhaust coming
out on the left side. 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.)
---------------------------------------------------
RANGER 9
• 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”.
• Set “POLARITY” switch to either WIRE FEED DC+
or WIRE FEED DC-.
• Set the ‘RANGE’”switch to either HIGH, MED or
LOW as required by the process.
• Set the ‘WELDING TERMINALS” Control switch to
the ‘REMOTELY CONTROLLED” position.
• Set the ‘IDLER” switch to the “AUTO” idle position.
A-6
INSTALLATION
A-6
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.
• Shut the welder off.
•
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.
• Connect the control cable from the LN-25 to the
14 pin amphenol on the Ranger 9.
• Attach the single lead from the front of the LN-25 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.
• Set the “POLARITY” switch to either WIRE FEED
DC+ or WIRE FEED DC- as required by the electrode being used.
• Set the “WELDING TERMINAL” Control switch to
the “ALWAYS ON” position.
• Set the “IDLER” switch to the “AUTO” position.
Connection of the Magnum Spool Gun
and SG Control Module to the Ranger 9
• Shut off the welder.
• Connect per the instructions on the appropriate connection diagram in the rear of this manual.
• Set the output control toggle switch to ‘CONTROL
AT WELDER” when not using remote control.
• Set “POLARITY” switch to either WIRE FEED DC+.
* Set the ‘RANGE” switch to either HIGH, MED or
LOW as required by the process.
• Set the ‘WELDING TERMINALS” Control switch to
the ‘REMOTELY CONTROLLED” position.
• Set the ‘IDLER” switch to the ‘HIGH” idle position.
Connection of Spool Gun to LN-25 with
contactor, soleniod K449 .
• Set the “RANGE” switch to either HIGH,MED or
LOW as required by the process.
• Set the “WELDING TERMINALS” Control switch to
the “REMOTELY CONTROLLED” position.
• Place the idler switch in the “AUTO” position.
Connection of the K449 LN-25 to the
Ranger 9.
• Shut off the welder.
• 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.
• 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 feed motor; it does not carry welding current.
• Set the “POLARITY” switch to either WIRE FEED
DC+ or WIRE FEED DC - as required by the
electrode being used.
• Set the “RANGE” switch to either HIGH, MED or
LOW as required by the process.
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 installations instructions.
Note: The TIG Module does not require the use of a
high frequency bypass capacitor. If any other high frequency accessary is used with the Ranger 9, a
bypass capacitor (Order Kit T12246) must be installed
in the Ranger 9.
REMOTE OUTPUT CONTROL
The Ranger 9 has a 6-pin and a 14-pin 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 builtin 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”.
RANGER 9
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