Lincoln Electric RANGER IM819-B, 000 Operator's Manual

RANGER™10,000

R

For Machines with Code Number 11041, 11095, 11151, 11253

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.

IM819-B

September, 2006

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

C US

Copyright © 2005 Lincoln Global Inc.

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.

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.

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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

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.

vapors

to

3.j. Also see Items 6.c. and 8.

5.d. 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.e. 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.f. Also see item 1.b.

AUG 06

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

vv

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Machine Grounding.......................................................................................................A-2

Spark Arrester ...............................................................................................................A-2

Towing, Vehicle Mounting .............................................................................................A-2

Pre-Operation Engine Service..............................................................................................A-3

Fuel, Oil.........................................................................................................................A-3

Battery Connections......................................................................................................A-3

Welding Cable Connections..........................................................................................A-4

Angle of Operation ........................................................................................................A-4

Lifting, Additional Safety Precautions............................................................................A-4

High Altitude Operation .................................................................................................A-4

Muffler Relocation .........................................................................................................A-4

Location and Ventilation................................................................................................A-5

Stacking ........................................................................................................................A-5

Connection of Wire Feeders .........................................................................................A-5

Connection of Tig Module .............................................................................................A-5

Additional Safety Precautions,Welding Operation Output.............................................A-5

Auxiliary Power Receptacles, and Plugs .............................................................................A-6

Motor Starting and Extension Cord Length Table ................................................................A-6

Electrical Device Used with the Ranger 10,000 ...................................................................A-7

Auxiliary Power While Welding, Standby Power Connections ............................................A-8

Premises Wiring ...................................................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Controls Function and Operation .............................................................................B-1

Polarity, Range and Control Switch......................................................................................B-2

Start in/Shutdown Instructions.....................................................................................................B-3

Starting the Engine........................................................................................................B-3

Safety Precautions ........................................................................................................B-3

Stopping the Engine......................................................................................................B-3

Break-In Period .............................................................................................................B-3

Welding Process ..................................................................................................................B-4

Stick (Constant Current) Welding..................................................................................B-4

TIG (Constant Current) Welding ..................................................................................B-4

Wire Feed Welding Processes (Constant Voltage)......................................................B-4

Arc Gouging ..................................................................................................................B-4

Summary of Welding Processes ...................................................................................B-5

________________________________________________________________________________

Accessories.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Recommended Equipment....................................................................................C-2

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Engine Maintenance ..........................................................................D-1,D2

Engine Adjustments...............................................................................................D-3

Slip Rings ..............................................................................................................D-3

Battery Maintenance .......................................................................................D-3

Engine Maintenance Parts..............................................................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Wiring Diagrams & Dimension Print..............................................................Section F

Wiring and Connection Diagrams ...........................................................F-1 Thru F-4

Dimension Print......................................................................................................F-5

________________________________________________________________________

Parts List..................................................................................................................P481

________________________________________________________________________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1)

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Operating

Speed (RPM)

Displacement

cu. in.

(cu.cm.)

Starting

System

Capacities

A-1

(K1419-4)

Kohler

CH20S

(K2160-3)

Honda

GX620KI

(K2468-1)

ROBIN/SUBARU

EH64

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic

Ignition

RATED OUTPUT @ 104°F (40°C)- WELDER

20 HP @

3600 RPM

Kohler

High Idle 3700

20 HP@

3600 RPM

Honda

20.5 HP@
3600 RPM

ROBIN/SUBARU

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

Full Load 3500

Low Idle 2200

Welding Output

38(624)

Kohler

37.5 (614)

Honda

39.9 (653)

ROBIN/SUBARU

12VDC
Battery

Electric Start

Group 58

Battery
(435 cold
Cranking

Amps)

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

Fuel:

9 Gal (34 L)

Lubricating Oil

1.9 Qts. (1.8L)

Fuel:

12 Gal (45.4 L)

Lubricating Oil

1.6 Qts. (1.6L)

RATED OUTPUT @ 104°F (40°C)- GENERATOR

Auxiliary Power

9,000 Watts Continuous, 60 Hz AC

10,000 Watts Peak, 60 Hz AC

120/240 Volts

1

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-4
770 mm 485 mm 1067 mm 505 lbs. (229kg) K2160-3

528 lbs. (240kg) K2468-1

1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.
When welding available auxiliary power will be reduced.

RANGER 10,000

A-2

INSTALLATION

A-2

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.

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

MACHINE GROUNDING

When this welder is mounted on a truck or trailer, it’s
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect­ed between the machine grounding stud and the
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”, as well as the arti­cle on grounding in the latest 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 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.

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.).

WARNING

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.

Do not ground the machine to a pipe that carries
explosive or combustible material.

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

RANGER 10,000

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

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

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincoln’s K957-1. If the user adapts a non-Lincoln
trailer, 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. Design capacity of trailer 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.

(1)

is

A-3

3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.

4. Typical conditions of use, i.e., travel speed; rough-

ness of surface on which the trailer will be operated;
environmental conditions.

INSTALLATION

A-3

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.

WARNING

5. Conformance with federal, state and local laws

(1) Consult applicable federal, state and local laws regarding specific

requirements for use on public highways.

VEHICLE MOUNTING

(1)

WARNING

Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.

• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.

• Distribute, balance and secure loads so vehicle
is stable under conditions of use.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufacture’s instructions.

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

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance
instructions supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away
from tank.

• Do not leave unattended while
fueling.

• Wipe up spilled fuel and allow

GASOLINE

can cause fire
or explosion.

fumes to clear before starting
engine.

• Do not overfill tank, fuel expan­sion may cause overflow.

GASOLINE FUEL ONLY

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

• Damage to the fuel tank may cause
fire or explosion. Do not
in the RANGER 10,000 base or weld
to the RANGER 10,000 base.

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

OIL

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Kohler CH20S - 2.0 Quarts (1.9 Liters)

Honda GX620KI-1.9 Quarts (1.8 Liters)
Robin/Subaru

The Ranger 10,000 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.

EH6-1.6 Quarts (1.6 Liters)

drill holes

CAUTION

BATTERY CONNECTIONS

Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.

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

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.

NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat­tery with the correct polarity.

RANGER 10,000

A-4

WELDING OUTPUT CABLES

INSTALLATION

ADDITIONAL SAFETY PRECAUTIONS

A-4

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

225 Amps

100% Duty Cycle

0-100 Ft.

100-200 Ft.

200-250 Ft.

1 AWG

1 AWG

1/0 AWG

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 at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.

LIFTING

The RANGER 10,000 weighs approximately 575 lbs.
with a full tank of gasoline. A lift bail is mounted to the
machine and should always be used when lifting the
machine.

WARNING

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable

when lifting.

• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail­er or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

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

HIGH ALTITUDE OPERATION

If the RANGER 10,000 will be consistently operated at
altitudes above 5000 ft, 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.

give increased power which

CAUTION

Do not operate a RANGER 10,000 with a high alti­tude jet installed at altitudes below 5000 ft. This
will result in the engine running too lean and
result in higher engine operating temperatures
which can shorten engine life.

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

Contact your local Kohler, Honda or Robin/Subaru
Authorized Dealer for high altitude jet kits that are
available from the engine manufacturer.

Muffler Relocation

WARNING

• Shut off welder and allow muffler to cool before

touching muffler.

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

The RANGER 10,000 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 10,000 without the cover in place will
result in a higher noise level and no increase in
machine output.)

RANGER 10,000

A-5

INSTALLATION

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 welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.

STACKING

RANGER 10,000 machines cannot be stacked.

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off welder before making any electrical
connections.

-----------------------------------------------------------------------­WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER

The LN-15 has an internal contactor and the electrode
is not energized until the gun trigger is closed. When
the gun trigger is closed the wire will begin to feed and
the welding process is started.

A-5

d. Position the “RANGE” switch to the “WIRE FEED”

position.

e. Attach the single lead from the LN-25 control box

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

lead - it carries no welding current.
f. Place the engine switch in the “AUTO” position.
g. Adjust wire feed speed at the LN-25 and adjust

the welding voltage with the output “CONTROL”

at the welder.
NOTE: The welding electrode is energized at all
times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.

CONNECTION OF K930-2 TIG MODULE TO THE
RANGER 10,000.

The 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. However, if the
RANGER 10,000 is used with any other high frequen­cy equipment, the bypass capacitor must be installed,
order kit T12246.

a. Shut the welder off.
b.

Connect the electrode cable from the LN-15 to
the

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

c. Set the Polarity switch to the desired polarity, either

DC (-) or DC (+).

d. Attach the single lead from the front of the LN-15

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

e. Set the “RANGE” switch to the “WIRE FEED-CV”

position

f. Place the Engine switch in the “High Idle” position.
g. Adjust the wire feed speed at the LN-15 and adjust

the welding voltage with the output “CONTROL” at
the welder.

Note: LN-15 Control Cable model will not work with

the RANGER 10,000.

CONNECTION OF THE LN-25 TO THE

10,000

a. Shut the welder off.
b.

Connect the electrode cable from the LN-25 to
the

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

c. Position the welder “Polarity” switch to the desired

polarity, either DC (-) or DC (+).

Output “CONTROL” must be set above 3.

RANGER

INSTRUCTIONS

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air flow.

Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Owner’s Manual.

WELDER OPERATION

WELDER OUTPUT

• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.

• Duty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty Cycle
for the RANGER 10,000 is 100%.

RANGER 10,000

Constant Current 225 Amps AC @ 25 Volts

210 Amps DC @ 25 Volts

Constant Voltage 200 Amps DC @ 20 Volts

RANGER 10,000

A-6

INSTALLATION

A-6

AUXILIARY POWER

The RANGER 10,000 can provide up to 9,000 watts of
120/240 volts AC, single phase 60Hz power for con­tinuous use, and up to 10,000 watts of 120/240 volts
AC, single phase 60Hz power peak use. The front of
the machine includes three receptacles for connecting
the AC power plugs; one 50 amp 120/240 volt NEMA
14-50R receptacle and two 20 amp 120 volt NEMA 5­20R receptacles. Output voltage is within +/-10% at all
loads up to rated capacity.

CAUTION

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 receptacles for auxil­iary power.

120/240 VOLT DUAL VOLTAGE RECEPTACLE

The 120/240 volt receptacle can supply up to 38 amps
of 240 volt power to a two wire circuit, up to 38 amps
of 120 volts power from each side of a three wire cir­cuit (up to 76 amps total). Do not connect the 120 volt
circuits in parallel. Current sensing for the automatic
idle feature is only in one leg of the three wire circuit
as shown in the following column.

GND

120 V

240 V

120 V*

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

120 V DUPLEX RECEPTACLES

The 120V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.

The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle.

MOTOR STARTING

Most 1.5 hp AC single phase 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

1.5 hp motor is approximately 20 amperes (10

amperes for 240 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stated
is not exceeded. This may necessitate 240V operation
only.

RANGER 10,000 Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

15
20
15
20
38

Voltage

Volts

120
120
240
240
240

Current

(Amps)

Load

(Watts)

1800
2400
3600
4800
9000

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

30

60

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

Maximum Allowable Cord Length in ft. (m) for Conductor Size

40
30
75
60

(12)

(9)
(23)
(18)

75

50
150
100

50

(23)
(15)
(46)
(30)
(15)

125

88
225
175

90

(38)
(27)
(69)
(53)
(27)

175
138
350
275
150

(53)
(42)

(107)

(84)
(46)

RANGER 10,000

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

A-7

ELECTRICAL DEVICE USE WITH THE RANGER 10,000.

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capac-

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain

INSTALLATION

TABLE lll

itative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe
operation. DO NOT RUN

THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.

maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

A-7

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required,
and liabilities still exist. DO

NOT USE THESE DEVICES
WITH A RANGER 10,000

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect­ed to the RANGER 10,000.

RANGER 10,000

A-8

INSTALLATION

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time).
Also, the “Output Control” is set at “10” for maximum
auxiliary power.

TABLE I

SIMULTANEOUS WELDING AND POWER

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Factor) @ 120V

Max. Stick or Wire

Feed Setting None 0 0

145 Stick Setting 3450 32 16

90 Stick Setting 6000 50

NO WELDING 9000 76

*-or- @ 240V

** 25

** 38

A-8

1. Install a double pole, double throw switch 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.

2. Take necessary steps to assure load is limited to
the capacity of the RANGER 10,000 by installing a
38 amp 240V double pole circuit breaker.
Maximum rated load for the 240V auxiliary is 38
amperes. Loading above 38 amperes 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 120/240V plug (NEMA type 14-50)
to the Double Pole Circuit Breaker using No. 8,
4 conductor cable of the desired length. (The
50 amp 120/240V plug is available in the
optional plug kit.)

* Each duplex receptacle is limited to 20 amps.
**Not to exceed 40A per 120VAC branch circuit when

splitting the 240 VAC output.

STANDBY POWER CONNECTIONS

The RANGER 10,000 is suitable for temporary, stand­by, or emergency power using the engine manufactur­er’s recommended maintenance schedule.

The RANGER 10,000 can be permanently installed as
a standby power unit for 240V-3 wire, single phase 38
ampere service.

WARNING

(Connections must be made by a licensed electri­cian who can determine how the 120/240V 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 connection diagram shown in Figure 1.)

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

4. Plug this cable into the 50 amp 120/240V
receptacle on the RANGER 10,000 case front.

RANGER 10,000

A-9

240 Volt

60 Hz.
3-Wire

Service

INSTALLATION

Figure 1

CONNECTION OF RANGER 10,000 TO PREMISES WIRING

240 VOLT

POWER

COMPANY

METER

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

120 VOLT

120 VOLT

GROUNDED CONDUCTOR

NEUTRAL
BUS

A-9

N

LOAD

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

240 VOLT

40 AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

GND

WARNING

DISCONNECT AND

GROUND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

OVERCURRENT

PROTECTION

PREMISES

SERVICE

Connection of RANGER 10,000 to premises wiring
must be done by a licensed electrician and must
comply with the National Electrical Code and all
other applicable electrical codes.

RANGER 10,000

B-1

OPERATION

SAFETY PRECAUTIONS

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.

• Always operate the welder with the hinged door

closed and the side panels in place.

B-1

WELDER CONTROLS - FUNCTION AND
OPERATION

ENGINE SWITCH

The engine switch is used to Start the Engine, Select
High Idle or Auto Idle while the engine is running, and
stop the Engine.

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

When held in the “START” position, the engine
starter motor is energized.

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

• Read carefully the Safety Precautions page

before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.

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

GENERAL DESCRIPTION

The Ranger™10,000 is a twin-cylinder, gasoline dri­ven, multiprocess arc welder and AC power genera­tor. It is built in a heavy gauge steel case for durability
on the job site.

When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:

• Welding

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

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

• 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.

RANGER 10,000

B-2

OPERATION

“ RANGE” SWITCH

The “Range” switch is used to select one of three
amperage ranges with generous overlap for Stick/TIG
welding, or one Wire Feed welding range.

Process Range Setting Current Range

STICK/TIG
(constant current)
(3 range settings)

WIRE FEED

(constant voltage)

(one range setting)

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

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

“ CONTROL” DIAL

90 Max.

145 Max.

210DC/225AC Max.

15 to 25V

CAUTION

40 to 90 Amps

70 to 145 Amps

120 to 210 (DC) 225(AC)

Up to 200 Amps

B-2

Low Idle - No Load

2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
225 Amps @ 25 Volts
DC CC Weld Output
210 Amps @ 25 Volts
DC CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power
9000 Watts

Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and weld­ing voltage control with the Range switch set in the
wire feed mode.

POLARITY SWITCH

Provides three selectable welding polarities:
AC, DC+ & DC-

CAUTION

Never change the Polarity switch setting while
welding. This will damage the switch.

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

RANGER 10,000 APPROXIMATE FUEL CONSUMPTION

KOHLER

20 H.P. CH20S

.4 Gallons/Hour

(1.5 Liters/Hour)

.7 Gallons/Hour

(2.8 Liters/Hour)

1.2 Gallons/Hour
(4.6 Liters/Hour)

1.3 Gallons/Hour
(4.9 Liters/Hour)

1.2 Gallons/Hour
(4.5 Liters/Hour)

1.4 Gallons/Hour)
(5.3 Liters/Hour)

HONDA

20 H.P. GX620KI

.3 Gallons/Hour

(1.3 Liters/Hour)

.7 Gallons/Hour

(2.8 Liters/Hour)

1.3 Gallons/Hour
(5 Liters/Hour)

1.5 Gallons/Hour

(5.9 Liters/Hour)

1.2 Gallons/Hour

(4.5 Liters/Hour)

1.7 Gallons/Hour)
(6.5 Liters/Hour)

ROBIN / SUBARU

1.6 Gallons/Hour)

20.5 H.P. EH64

.6 Gallons/Hour

(2.3 Liters/Hour)

.8 Gallons/Hour

(3.0 Liters/Hour)

1.5 Gallons/Hour
(5.8 Liters/Hour)

1.6 Gallons/Hour
(6.1 Liters/Hour)

1.2 Gallons/Hour
(4.5 Liters/Hour)

(6.1 Liters/Hour)

RANGER 10,000

B-3

OPERATION

B-3

STARTING/SHUTDOWN INSTRUCTIONS

STARTING THE ENGINE

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 before
starting for the first time.

Remove all loads connected to the AC power recepta­cles. Use the choke control as follows:

KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.

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

10,000 because the fuel tank is mounted below the

engine.

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:

HONDA ENGINE - IF the engine is cold, pull the
choke control out. Do Not use the choke if the engine
is warm or hot.

Turn the engine switch to the “start” position and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
and turn the switch to the Auto Idle( / )
position. Do not turn the switch to the “start” position
while the engine is running because this will cause
damage to the ring gear and/or starter motor

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.

RANGER 10,000

KOHLER HONDA ROBIN / SUBARU

CH20S GX620KI EH64

5 HRS. First Month 25 HRS.

or 20 HRS.

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

B-4

OPERATION

WELDING PROCESS

For any electrodes the procedures should be kept
within the rating of the machine. For electrode infor-

mation see the appropriate Lincoln publication.

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. The “RANGE”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The “OUTPUT” Control provides fine adjust­ment of the welding current within the select range.
For maximum output within a selected range set the
“OUTPUT” Control at 10. For minimum output within a
selected range set the “OUTPUT” Control at 5. (“OUT­PUT” Control settings below 5 may reduce arc stabili­ty) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUT­PUT” Control near the maximum to achieve the
desired welding current.

RANGE SETTING TYPICAL CURRENT RANGE

ELECTRODE SIZE

90 MAX.

3/32

40 TO 90 AMPS

B-4

SETTINGS FOR 1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps

The K930-[ ] TIG Module should be used with the Ranger
10,000 on high idle to maintain satisfactory operation. It
can be used in the AUTO position but the delay going to
low idle after welding is ceased will be increased if the
AFTER FLOW CONTROL is set above 10 seconds.

NOTE: For AC TIG Welding, the maximum TIG welding
output currents on each range setting will be approxi­mately 50% higher than those marked on the nameplate.
This is due to the special nature of the AC TIG welding
arc. Do not AC TIG weld on the 225AC range setting.
The output current may exceed the rating of the Ranger
10,000.

WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)

The Innershield® electrode recommended for use with
the RANGER 10,000 is NR
sizes and welding ranges that can be used with the
RANGER 10,000 are shown in the following table:

-211-MP. The electrode

®

145 MAX.

210(DC)/225(AC)

MAX.

1/8

5/32

70 TO 145 AMPS

120 TO 210(DC),

225(AC) AMPS

The RANGER 10,000 can be used with a broad range
of AC and DC stick electrodes. See “Welding Tips 1”
included with the RANGER 10,000 for electrodes with­in the rating of this unit and recommended welding
currents of each.

TIG (CONSTANT CURRENT) WELDING

The K930-[ ] TIG Module installed on a Ranger 10,000
provides high frequency and shielding gas control for
AC and DC GTAW (TIG) welding processes. Output
control is from the Ranger 10,000. The output control
on the TIG Module is not functional. After flow time is
adjustable from 0 to 55 seconds.

When using the Ranger 10,000 for AC TIG welding of
aluminum, the following settings and electrodes are
recommended:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/16 90 40 - 80 Amps

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A

The RANGER 10,000 is recommended for limited “MIG”
welding (GMAW - gas metal arc welding). The recom­mended electrodes are .030” and .035” L-50 and L-56.
They must be used with a blended shielding gas such as
C25 (75% Argon - 25% CO

). The welding ranges that

2

can be used with the RANGER 10,000 are shown in the
following table:

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.030 75 - 300 50A to 130A
.035 100 - 250 90A to 175A

ARC GOUGING

The Ranger 10,000 can be used for limited arc gouging.

Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:

ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)

1/8 30 - 60 Amps
5/32 90 - 150 Amps
3/16 150 - 250 Amps

RANGER 10,000

B-5

SUMMARY OF WELDING PROCESSES

CONTROL ELECTRODE

CABLE IDLE WHEN NOT TO START

PROCESS USED MODE WELDING WELDING

STICK No AUTO Hot Touch electrode to work.

WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding

TIG, TIG MODULE WITH Yes High Cold Press Arc Start Switch
WITH CONTACTOR KIT contactor closes,
CONTROL CABLE, & ARC welding starts immediately.
START SWITCH

OPERATION

Welding starts immediately
and engine goes to high
idle.

starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”

B-5

WIRE FEED, LN-15 No High Cold Press gun trigger.
ACROSS the ARC LN-15 contactor closes,
(has internal contactor) Welding starts immediately

Note: Output Control must
be set above “3”.

RANGER 10,000

C-1

ACCESSORIES

OPTIONAL EQUIPMENT (Field Installed)

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS - For road, off-road and in-plant

and yard towing. (For highway use, consult applicable
federal, state and local laws regarding requirements
for brakes, lights, fenders, etc.)
Order K957-1 Trailer

K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack

K889-2 & -3 Two-Wheel Undercarriage - For moving
by hand. Overall Width 29 in (.74m) Both have pneu­matic tires. Puncture proof tires included with K889-3.

K1631-1 Puncture Proof Wheel Kit - For converting
K889-2 or K933-1 to puncture proof pneumatic tires.

K893-1 Caster for Undercarriage - Mounts to the
front of the K889-2 or 3 to allow easy movement on
smooth surfaces. Includes 6” diameter hard rubber
wheel and convenient toe-on, toe-off locking brake.

C-1

K802-R Power Plug Kit- provides four 120V plugs

rated at 15 amps each and one dual voltage, Full
KVA plug rated at 120/240V, 50 amps.

K802-N Power Plug Kit - Provides four 120V plugs
rated at 20 amps each and one dual voltage, full KVA
plug rated at 120/240V, 50 amps.

K894-1 Spark Arrester Kit - Includes a heavy gauge
steel, approved spark arrester and clamp for easy
mounting to muffler exhaust pipe.

K1690-1 GFCI RECEPTACLE KIT -

approved120V ground fault circuit interrupter duplex type
receptacle with cover and installation instructions.
Replaces the factory installed 120V duplex receptacle.
Each receptacle of the GFCI Duplex is rated at 20 Amps,
the maximum total current from the GFCI Duplex is limit­ed to the 20 Amps. Two kits are required.

K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
(which accepts 4-prong plugs) and converts it to a
NEMA 6-50R receptacle, (which accepts 3-prong
plugs.)

Includes one UL

K933-1 Four Wheel Undercarriage - For Hand
Moving. Rear pneumatic tires, front molded wheels.

K934-1 Cylinder Brackets - For use with K933-1.
For transporting one welding gas cylinder.

K1737-1 FOUR WHEEL ALL-TERRAIN UNDER­CARRIAGE - For moving by hand at construction

sites. Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY) - For mov­ing by hand on a smooth surface. One or two gas
cylinders can be mounted on the rear of the undercar­riage with the installation of K1745-1 Cylinder
Holder(s). Heavy duty puncture resistant pneumatic
tires and front caster.

K1745-1 GAS CYLINDER HOLDER

Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.

K1788-1 ROLL CAGE - Gives added damage protec­tion.
Attaches to K1737-1, K1770-1, and K957-1.

K886-1 Canvas Cover -To protect the RANGER
10,000 when not in use. Made from attractive red can­vas material which is flame retardant, mildew resis­tant, and water repellent.

T12153-9 Full-KVA Power Plug - One dual voltage
plug rated at 120/240V, 50 amps.

K930-2 TIG Module - Provides high frequency and
shielding gas control.for AC and DC GTAW (TIG)
welding applications. Its compact case is designed foe
easy carrying, complete with a handle. High frequency
bypass is built in requires K938-1 Contactor Kit, K936­4 Control Cable, and K814 Arc Start Switch.

K938-1 Contactor Kit - For use with TIG Module,
Provides a “cold” electrode until the triggering device
(Arc Start Switch) is pressed.

K936-4 Control Cable - Connects TIG Module to
Ranger 10,000.

K814 Arc Start Switch - Attaches to the TIG torch for
convenient finger control.

K937-45 Control Cable Extension - Allows TIG
Module to be operated at distances up to 200ft. from
the power source. Available in 45ft. (13.7m).

K844-1 Water Valve Kit - For use with water cooled
TIG torch, Installs inside of TIG Module.

K939-1 Docking Kit - For Mounting the K930-2 TIG
Module on top of the Ranger 10,000.

RANGER 10,000

C-2

ACCESSORIES

RECOMMENDED EQUIPMENT

STICK

K704 Accessory Kit - For Stick Welding. Includes 35 ft

(10.7m).

• 2/0 AWG electrode cable, 30 ft. (9.1m)

• 2/0 AWG work cable with lugs, headshield, filter plate, work

clamp, and electrode holder. 400 amp capacity.

K875 Accessory Kit - For stick welding. Includes 20 Ft. (6.1m).
#6 electrode cable with lug, 15 Ft. (4.6m) #6 work cable with
lugs, headshield, filter plate, work clamp, and electrode holder
and sample pack of mild steel electrode. 150 amp capacity.

WIRE FEED

K449 LN-25 - Includes internal contactor for across

the arc operation (no control cable). Provides “cold”
electrode until gun trigger is pressed. Includes gas
solenoid.

C-2

K1870-1 LN-15 Across the Arc

Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.

K126-2 Magnum 350 Innershield Gun (for LN-25, LN-

15).

K1802-1 Magnum 300 MIG Gun (for LN-25, includes

Connector Kit).

K470-2 Magnum 300 MIG Gun (for LN-15, requires

K466-10 Magnum Gun Connector Kit).

K1500-1 Gun Receiver Bushing (for LN-15, K126-2)

Note: See Wire Feeder IM Manual for appropriate

Drive Roll & Guide Tube Kits.

TIG WELDING

K1783-9- PTA-26V TIG Torch.
KP509- Magnum Parts Kit and Argon gas.
K930-2- TIG Module.

Required TIG Equipment:

K938-1 Connector Kit
K936-4 Control Cable
K814 Arc Start Switch

Optional TIG Equipment:

K939-1 Docking Kit
K937-45 Control Cable Extension
K844-1 Water Valve Kit

PLASMA CUTTING:

K1580-1- Pro-Cut 55 (Requires full KVA Adapter

K1816-1).

RANGER 10,000

D-1

MAINTENANCE

D-1

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

throughout this operator’s manual and
the Engine manual as well.

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

Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.

Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, cloth­ing, and tools away from gears, fans, and all other
moving parts when starting, operating, or repairing the
equipment.

Routine Maintenance

• 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.

RANGER 10,000

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.

• OIL - Maintenance schedule for changing the oil and

oil filter after break-in :

KOHLER HONDA

CH20S GX620KI EH64

6 Months

Oil 100 HRS. 100 HRS. 100 HRS.

1 Year or

Oil Filter 200 HRS. 200 HRS. 200 HRS.

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.

NOTE

: Engine life will be reduced if the oil and oil

filter are not changed according to the manufacturer’s
recommendation.

ENGINE OIL CHANGE

Drain the oil while the engine is warm to assure rapid
and complete draining.

• Remove the oil filler cap and dipstick. Remove the

yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable contain­er.

• Close the drain valve by pushing in and twisting

clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the

recommended oil. Tighten the oil filler cap securely.

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

•1.6 US qt. (1.3 IMP qt., 1.5 liter)-Honda GX620KI

•1.5 US qt. (1.2 IMP qt., 1.4 liter)-Robin / Subaru

With oil filter replacement:

• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

•1.9 US qt. (1.6 Imp qt. , 1.8 liter)-Honda GX620KI

•1.6 US qt. (1.4 IMP qt., 1.6 liter)-Robin / Subaru

ROBIN / SUBARU

D-2

MAINTENANCE

D-2

Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil con­tainer to be sure it includes the letters SG or SH.

SAE 10W-30 is recommended for general, all-tempera­ture use, -5 F to 104 F (-20 C to 40 C).

See Engine Owner’s Manual for more specific informa­tion on oil viscosity recommendations.

Wash your hands with soap and water after handling
used oil.

Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.

Do not throw it in the trash, pour it on the ground or
down a drain.

OIL FILTER CHANGE

1. Drain the engine oil.

AIR CLEANER AND OTHER MAINTENANCE

• Air Cleaner - With normal operating conditions, the

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 the maintenance
section of the Engine Owner’s Manual for more
information.

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

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

• 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.

2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.

3. Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.

4. Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil fil­ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.

5. Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.

6. Start the engine and check for oil filter leaks.

7. Stop the engine, and check the oil level. If neces­sary, add oil to the upper limit mark on the dipstick.

RANGER 10,000

D-3

MAINTENANCE

D-3

ENGINE ADJUSTMENTS

OVERSPEED IS HAZARDOUS

WARNING

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.

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary.If brushes are
to be replaced, clean slip rings with a fine emery
paper.

CAUTION

Do not attempt to polish slip rings while engine is
running.

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

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
last.

• CONNECTING A BATTERY CHARGER - Remove bat­tery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When rein­stalling, connect negative cable last. Keep well venti­lated.

• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.

BATTERY

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 in damage to the internal charger
components. When reconnecting the cables,
connect the positive cable first and the negative
cable last.

HARDWARE

Both English and Metric fasteners are used in this
welder.

KOHLER C20S HONDA GX620KI ROBIN / SUBARU EH64

KOHLER 1205001 HONDA ROBIN / SUBARU

Oil Filter FRAM PH3614* 15410-ZJ4-999A 248-65801-00, FRAM PH4967

Air Filter KOHLER 4708303 HONDA ROBIN / SUBARU
Element FRAM CA79 17210-ZJ1-841 263-32610-A1

Air Filter KOHLER 2408302 HONDA N/A
Pre-Cleaner 17218-ZJ1-840

Fuel Filter KOHLER 2505002 HONDA ROBIN / SUBARU

FRAM G1 16910-ZE8-015 011-00600-20

Spark Plugs CHAMPION RC12YC CHAMPION -J16CR-U ROBIN / SUBARU
(Resistor (.030” GAP) NGK-ZGR5A X65-01407-30

Type) 030in, (76 mm) Gap NGK-BPR4EY

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

ENGINE MAINTENANCE PARTS

RANGER 10,000

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 10,000

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

No welder or output power.

Engine will not idle down to low
speed.

1. Open in miscellaneous leads.

2. Open lead in flashing or field
circuit.

3. Faulty rotor.

4. Faulty Potentiometer (R1).

5. Faulty stator Field winding.

6. Faulty Field rectifier (D2).

7. Faulty P.C. Board.

1. Idler switch on High Idle.

2. Insufficient voltage present
between terminals #213 and
#5E. (Voltage should be 12V
DC).

3. External load on welder or
auxiliary power.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Engine will not go to high idle when
attempting to weld.

4. Faulty wiring in solenoid circuit.

5. Faulty idler solenoid.

6. Faulty P.C. Board.

1. Poor work lead connection to
work.

2. No voltage signal from the
current sensor.

3. No open circuit voltage on
output studs.

4. Faulty P.C. Board.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 10,000

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-3

RECOMMENDED

COURSE OF ACTION

Engine will not go to high idle when
using auxiliary power.

Engine will not crank or is hard to
crank.

Engine shuts down.

1. No voltage signal from the
current sensor.

2. Auxiliary power load less than
100 to 150 watts.

3. Faulty P.C. Board.

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

2. No or insufficient charging
current.

3. Loose battery cable
connection(s).

1. Out of fuel.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Engine does not develop full power.

Engine is hard to start.

2. Low oil level.

1. Fuel filter clogged.

2. Air filter clogged.

1. Spark plugs do not have
specified gap.

2. Spark plugs are fouled.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 10,000

STARTER

CR1

STARTER

SOLENOID

12 VOLT

IDLER

SOLENOID

BATTERY

AC ACB+

SWITCH

REGULATOR

FLYWHEEL ALTERNATOR

B-

HOUR METER

5E

5D

224

ENGINE COMPONENTS

224A

12

3

CONNECTOR PIN NUMBERS:

7

6

12

12

34

J1

N.A.

B

J2

SOLENOID

FUEL

SHUTOFF

OIL

PRESSURE

TERMINAL BLOCK

(SEE CONN.)

209A

209A

224C

210

B

B

GENERATOR LEAD END

(NOTE CAVITY NUMBERS)

LOCATING TAB

TERMINAL BLOCK

CONNECTION

208

208 (CAVITY #2)

211 (CAVITY #3)

224C (CAVITY #4)

13

2

4

211

IGNITION

MODULE

M20226

215

+

ELECTRICAL SYMBOLS PER E1537

STATOR

REACTOR

S1

WORK

ELECTRODE

CHOKE

D1

S2

ROTOR

PCB1

SLIP RING NEAREST LAMINATION

W1

W2

C1

S1

R1

R5

C1

L1

-

+

+

R3

STATOR

REACTOR

+

10

8

1

7

12

6

6

5

3

9

7

200A

219

3

ENGINE

CROSS

SUPPORT

GROUND SCREW

GND-E

GND-E

GND-G

200A

219

224

215

76A

5E

75A

77A

J1

8

10

5D

254

R1

OUTPUT

CONTROL

75A

76A

77A

75A

77A

76A

ON UPPER CASEFRONT

-

209

+

R

R

U

V

W

ENGINE

FOOT

GND-D

GND-C

5F

224A

GND-H

TERMINALS

6

5

5L

120V/240V

5K

GND-D

GND-C

J4

J3

J2

GND-G

5

5L

5K

120V

120V

12

11

11

3A

3A

CB1

40A

40A

CB2

CB3

20A

20A

CB4

3

SILVER COLORED

(WHITE WIRES)

RANGER 10,000 (KOHLER) (CSA) WIRING DIAGRAM FOR 11041

A

CCW

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

210

CB7

25A

R = RED OR PINK

B = BLACK OR GRAY

V = VIOLET

U = BLUE

W = WHITE

LEA

D COLOR CODE:

254

3

12

3

4

261

260

1 TURN

211

213

208C

6A

6

LEADS 3 AND 6:

2 TURNS THRU TOROID IN

OPPOSITE DIRECTIONS

6

6

79

J2

S2 E

GND-I

P5

J5

GROUND SCREW

ON LOWER CASEFRONT

S3

3B

6B

-

+

D2

213A

215A

F-1

DIAGRAMS

F-1

RANGER 10,000

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.

F-2

DIAGRAMS

F-2

A

1

J1

7

PCB1

75A

R1

CCW

LEADS 3 AND 6:

2 TURNS THRU TOROID IN

OPPOSITE DIRECTIONS

261

76A

77A

OUTPUT

CONTROL

260

213A

J2

4

3

12

77A
75A

5E

76A
215
224

219

200A

6

12

8

10

79

77A

75A

76A

+

+

200A

ROTOR

219

SLIP RING NEAREST LAMINATION

M20301

3

6

254

8

10

1 TURN

254

+

-

D1

L1

CHOKE

S2

GROUND SCREW

ON MIDDLE CASEFRONT

209A

211

213

213A

RANGER 10,000 (HONDA) WIRING DIAGRAM FOR CODE 11095

S3

208C

213 210 211

208C

S2 E

S1

WORK

GND-I

5D

5F

HONDA

ENGINE

CB7

25A

XXX

XX

HIGH

AUTO

OFF

C1

R5

R3

R1

ELECTRODE

GND-E

IDLER

COMPONENTS

XXX

X = CLOSED CIRCUIT

START

210

S1

SOLENOID

6

REACTOR

REACTOR

W2

GND-G

+

224A

224

3

7

9

3

5

STATOR

STATOR

C1

6

W1

GND-E

6

GROUND SCREW

ON LOWER CASEFRONT

GND-D

GND-C

215

METER

HOUR

3

5D

5E

211W

B/Y

224A

211B

+

209A

5

120V

J2

GND-D

6A

GND-G

CB1

40A

6

12

ENGINE

FOOT

-

GND-H

209

225A

-

211

B/Y

W

210

STARTER

SOLENOID

OIL

CR1

B/R

PRESSURE

211B

D9

+

B/Y

3B

5L

SWITCH

5K

IGNITION

6B

ENGINE

FUEL

SHUTOFF

MODULE

W/U

CB4

11

J4

120V/240V

CROSS

SUPPORT

SOLENOID

W

W

GY

20A

GND-C

GY

J3

120V

CB3

5K

40A

CB2

11

STARTER

6

5

4

3

2
1

20 AMP

3A

5

5L

20A

3A

TERMINALS

(WHITE WIRES)

SILVER COLORED

MODULE

RECTIFIER/REGULATOR

CHARGE COIL

12

7

3

J1J2

6

12

34

12

CONNECTOR PIN NUMBERS:

B

B/Y = BLACK/YELLOW

W/U = WHITE/BLUE

LEAD COLOR CODE:

B/R = BLACK/RED

B = BLACK OR GRAY

GY = GREY

HONDA ENGINE COMPONENTS

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

RANGER 10,000

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.

F-3

DIAGRAMS

F-3

LEADS 3 AND 6:

CCW

2 TURNS THRU TOROID IN

6

1 TURN

75A76A

R1

213A

77A

OUTPUT

CONTROL

261

260

OPPOSITE DIRECTIONS

3

10

254

L1

CHOKE

8

D1

-

+

S2

GROUND SCREW

ON UPPER

CASEFRONT

213

208C

S3

1

2

7

1

J1

PCB1

J2

4

3

12

254

GND-I

209A

211

4

6

12

8

10

S2 E

C1

R5

S1

R3

R1

WORK E LECTRODE

GROUND SCREW

ON LOWER CASEFRONT

GND-E

GND-D
GND-G

GND-C

5F

5D

213A

CB7

25A

3

210

S1

IDLER

75A
77A

76A

5E

224
215

219

W2

SOLENOID

200A

79

3

6

REACTOR

REACTOR

STATOR

STATOR

C1

215

HOUR

METER

97

3

6

W1

GND-E

5D

5E

+

224

224A

5

12 VOLT

211

208

BATTERY

+

209

209A

224C

TERMINAL BLOCK

6A

6

J2

GND-D

GND-G

J5

(SEE CONN.)

120V

4

3

2

1

208 (CAVITY #2)

224C (CAVITY #4)

+

200A

ROTOR

219

SLIP RING NEAREST LAMINATION

20A

CB4

3B

5K

5L

6B

20A

CB3

11

J4

40A

CB1

12

FOOT

5F

ENGINE

-

P5

R

R

U

V

W

224C

224A

120V/240V

GND-C

ENGINE

GND-H

CR1

SOLENOID

N.A.

210

OIL

J3

5K

CROSS

120V

SUPPORT

REGULATOR

SWITCH

PRESSURE

5

11

5L

CB2

FUEL

B-

AC ACB+

3A

40A

SHUTOFF

SOLENOID

STARTER

MODULE

IGNITION

3

SILVER COLORED TERMINALS

FLYWHEEL ALTERNATOR

ENGINE COMPONENTS

GENERATOR LEAD END

(NOTE CAVITY NUMBERS)

S3 OPERATION

CONNECTOR PIN NUMBERS:

34

2

1

7

12

34

D COLOR CODE:

LEA

211 (CAVITY #3)

OFF

1

2

3

6

12

U = BLUE

B = BLACK OR GRAY

LOCATING TAB

X

X

X

XXX

AUTO

HIGH

J1J2

V = VIOLET

R = RED OR PINK

W = WHITE

X

X

START

TERMINAL BLOCK

X = CLOSED CIRCUIT

C

M20431

CONNECTION

ELECTRICAL SYMBOLS PER E1537

RANGER 10,000 WIRING DIAGRAM - FOR CODE 11151(KOHLER) AND CODE 11253 (ROBIN / SUBARU)

RANGER 10,000

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

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.

F-4

RANGER

10,000

/

LN-15

AND

LN-25

ACROSS

T

H

E

ARC

CONNECTIO

N

DIAGRAM

ELECTRIC SHOCK can kill

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

before servicing.

Do not touch elec

trically live parts.

WARNING

MOVING PARTS can injure

Keep guards in place.

Keep away from moving parts.

Only qualified personnel should install,use

or service this

equipment.

M20266

A.02

TO WORK

ELECTRODE

TO

ENGINE

WELDER

WORK

LN

LN-15 OR

-25

WI

RE

FEEDER

TO

WORK

ELECTRODE

CABLE

WORK CLIP LEAD

N.A. WELDING

CABL

E

MUST

BE

SIZE

D

FO

R

CURRENT

DUTY

CYCLE

OF

APPLICATION.

N.B.

USE

POLARITY

SWIT

CH

TO

SET

FOR

DESIRE

D

ELECTRODE

POLARITY

.

POSITION

TH

E

OUTPUT

SELECTOR

SWITCH

TO

TH

E

WIRE

FEED

(CV)

POSITION.

DIAGRAMS

F-4

N DI

E ARC CONNECT

AND LN-25 ACROSS T

L

/

RANGER 10,000

equipm

or service this

W

A
O

C

D

CU
R

D F

SIZ
B

M
E

C

S

E OU
T

PO

.

P

D EL

D

F

S

CH T

S

PO

USE

PO

(

F

W
E

T

T

RE F

CABL

W

RANGER 10,000

F-5

M20267

A. 0 1

26.59

30.27

9.09 9.09

17.00

21.22

8.80 30.00

42.00

22.15

10.33

CENTER OF GRAVITY WITH OIL IN

ENGINE AND FULL FUEL TANK

9.31

CENTERLINE OF SHAFT

9.59

10.19

OIL FILTER REMOVAL

KOHLER , HONDA AND ROBIN / SUBARU

DIAGRAMS

F-5

A.

KOHLER , HONDA AND ROBIN / SUBARU

RANGER 10,000

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 vête-

ments 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 elec-

trodos 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 guarda-

dos.

● 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 res-

piración.

● 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 aspira-

teur 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 ali-

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

● Débranchez le courant avant l’entre-

tien.

● 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.

• World's Leader in Welding and Cutting Products •

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com