Lincoln Electric SVM 110-A User Manual
RETURN TO MAIN INDEX
SVM 110-A
For use with machine code numbers 9975 and 9976
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
TM
RANGER 9
January, 1996
View Safety Info View Safety Info View Safety Info View Safety Info
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World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SERVICE MANUAL
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American W elding 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 weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
vapors
to
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5.e. Also see item 1.b.
Mar ‘95
iii iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
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.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
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.
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Mar ‘95
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état 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” CSAStandard
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
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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
v v
RETURNTOMAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Installation Section Table of Contents........................................................................................A-1
Technical Specifications.............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation.............................................................................................................A-3
Pre-operation Engine Service.....................................................................................................A-4
Electrical Output Connections....................................................................................................A-5
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-2
General Description....................................................................................................................B-2
Recommended Applications......................................................................................................B-3
Operational Features and Controls............................................................................................B-3
Design Features and Advantages...............................................................................................B-3
Welding Capability......................................................................................................................B-4
Limitations.................................................................................................................................B-4
Controls and Settings.................................................................................................................B-4
Engine Operation........................................................................................................................B-7
Welding Operation....................................................................................................................B-10
Summary of Welding Processes...............................................................................................B-13
Auxiliary Power.........................................................................................................................B-14
Accessories...........................................................................................................................Section C
Maintenance.........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance............................................................................................D-2
Major Component Locations......................................................................................................D-9
Theory of Operation.............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual................................................................................................................................P-230
RANGER 9 RANGER 9
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications .............................................................................................................A-2
Safety Precautions ......................................................................................................................A-3
Location and Ventilation.............................................................................................................A-3
Storing .................................................................................................................................A-3
Stacking................................................................................................................................A-4
Tilting .................................................................................................................................A-4
Lifting .................................................................................................................................A-4
High Altitude Operation........................................................................................................A-4
Pre-operation Engine Service.....................................................................................................A-4
Oil ........................................................................................................................................A-4
Fuel.......................................................................................................................................A-4
Battery Connections.............................................................................................................A-4
Muffler Relocation ................................................................................................................A-5
Spark Arrester ......................................................................................................................A-5
Electrical Output Connections....................................................................................................A-5
Welding Cable Connections.................................................................................................A-6
Cable Size and Length............................................................................................A-6
Cable Installation.....................................................................................................A-6
Machine Grounding..............................................................................................................A-6
Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment .......................................A-7
Circuit Breakers ....................................................................................................................A-7
Premises Wiring....................................................................................................................A-7
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RANGER 9 RANGER 9
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 9
INPUT - GASOLINE ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
Onan 2 cyl., 3500 RPM 47.7 cu. in. Electric Fuel: 9 gal. (34 l)
®
P218
Duty Cycle Amps Volts at Rated Amperes
4 cycle Full load (782 cc)
air-cooled Manual Oil: 1.8 qt. (1.7 l)
gasoline 3700 RPM choke
18 HP @ High idle
3600 RPM
2200 RPM
Low idle
RATED OUTPUT - WELDER
100% Duty Cycle 250 AC Constant Current 25
100% Duty Cycle 250 DC Constant Current 25
100% Duty Cycle 250 DC Constant Voltage 25
OUTPUT - WELDER AND GENERATOR
Auxiliary Power for
Welding Ranges Max. Open Circuit Voltage Auxiliary Power Wire Feeders
40 - 250 Amps 80 Volts RMS 9000 Continuous Watts 42V, 60 Hz, 8 Amps
@ 3700 RPM 80 Amps @ 115 V
40 Amps @ 230 V 115V, 60 Hz, 8 Amps
PHYSICAL DIMENSIONS
Height Width Depth Weight
With Onan Engine:
30.3 in. 19.2 in. 42.3 in. 562 lb.
770 mm 485 mm 1074 mm 255 kg
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RANGER 9 RANGER 9
A-3 A-3
INSTALLATION
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the work
and ground.
• Always wear dry insulating
gloves.
LOCATION AND VENTILATION
Whenever you use the RANGER 9, be sure that clean
cooling air can flow through the machine’s gasoline
engine and the machine case. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.
The RANGER 9 may be used outdoors. Do not set the
machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause
improper operation and corrosion of parts.
Always operate the RANGER 9 with the case roof on
and all machine components completely assembled.
This will protect you from the dangers of moving parts,
hot metal surfaces, and live electrical devices.
WARNING
Damage to the fuel tank may cause fire or explosion.
Do not drill holes in the RANGER 9 base or weld to the
RANGER 9 base.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the outside.
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate this equipment
with any of its doors open or
guards off.
• Stop the engine before servicing
it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
STORING
1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from construction activities, moving vehicles, and other
hazards.
2. If you will be storing the machine for over 30 days,
you should drain the fuel to protect fuel system
and carburetor parts from gum deposits. Empty
all fuel from the tank and run the engine until it
stops from lack of fuel. If you prefer, you can treat
the gasoline with a stabilizer to prevent deterioration rather than drain the system. Follow the stabilizer manufacturer’s instructions. Add the correct amount of stabilizer for the size of the
RANGER 9 fuel tank. Fill the tank with clean, fresh
gasoline. Run the engine for two to three minutes
to circulate the stabilizer through the carburetor.
3. While the engine is still warm, drain the oil and refill
with fresh 10W30 oil. Change the oil filter.
4. Remove the spark plugs and add one to two tablespoons of engine oil or rust inhibitor into each
cylinder. Replace the spark plugs but do not connect the plug leads. Crank the engine two or three
times to distribute the oil.
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RANGER 9 RANGER 9
5. Clean any dirt and debris from the cylinder and
cylinder head fins and other exterior surfaces.
6. Store in a clean, dry area.
A-4 A-4
INSTALLATION
STACKING
RANGER 9 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The gasoline engine is designed to run in a level position for best performance. It can operate at an angle,
but this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level at the
FULL mark as it would be in its normal level condition.
Also, fuel capacity will be a little less at an angle.
LIFTING
The RANGER 9 weighs 562 lbs/255 kg. A lift bail is
mounted to the generator stator frame and should
always be used when lifting the machine.
HIGH ALTITUDE OPERATION
WARNING
• Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
The RANGER 9 is shipped with the engine
filled with SAE 10W-30 oil. CHECK THE
OIL LEVEL BEFORE YOU ST ART THE ENGINE. This
is an added precaution. When full, the oil level should
be up to but not over the FULL mark on the dipstick.
If it is not full, add enough oil to fill it to the full mark.
For more oil fill and service information, see the
MAINTENANCE section of this manual.
If you operate the RANGER 9 at altitudes above 5000
feet, you should install a carburetor jet designed for
high altitude operation. This will result in better fuel
economy, cleaner exhaust, and longer spark plug life.
It won’t give increased power. Power is decreased at
higher altitudes. Contact the engine manufacturer to
obtain these high altitude jet kits (Onan kit part number 146-0458).
CAUTION
Do not operate a RANGER 9 with a high altitude jet
installed at altitudes below 5000 feet. The engine will
run too lean and operate at higher engine temperatures, which can shorten engine life.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the gasoline engine in the Operation and Maintenance sections of this manual before you operate the RANGER
9.
FUEL
Fill the fuel tank with clean, fresh, regular
grade lead-free gasoline. DO NOT MIX
OIL WITH THE GASOLINE.
The RANGER 9 has a 9 gallon (34.1 litre),
bottom mounted fuel tank with a top fill and fuel
gauge. See the Operation and Maintenance sections of this manual for more details about fuel.
BATTERY CONNECTIONS
–+
you operate the machine, make sure the Engine
Switch is in the STOP position and attach the disconnected cable securely to the battery terminal. If the
battery is discharged and won’t start the engine, see
the battery charging instructions in the Maintenance
section.
The RANGER 9 is shipped with the negative battery cable disconnected. Before
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RANGER 9 RANGER 9
A-5 A-5
INSTALLATION
FIGURE A.1 - RANGER 9 OUTPUT CONNECTIONS
2
6
5
7
4
3
2
90
70
50
LINCOLN
ELECTRIC
125
175
225 AC
210 DC
1
RANGE
16 to 25
WARNING
8
9
1
10 max
RANGER 9
43
DC+
DC-
AC
5
1. OUTPUT RANGE SELECTOR
2. FINE OUTPUT CONTROL
3. CONTROL AT WELDER/REMOTE CONTROL SWITCH
CHOKE
7
AUTO
START
RUN
IDLER
STOP
HIGH
4. WELDING TERMINALS SWITCH
5. POLARITY SWITCH
6. 115/230 VOLT, 50 AMP RECEPTACLE
7. 115 VOLT, 20 AMP RECEPTACLES (2)
8. WELD OUTPUT TERMINALS (2)
9. GROUND STUD
6
9
MUFFLER RELOCATION
Shut off the machine and allow the muffler to cool
before touching the muffler.
The RANGER 9 is shipped with the exhaust coming
out on the left side. It can be changed to the right side
by removing two screws that hold the exhaust port
cover in place and installing the cover on the opposite
side.
NOTE: Operating the RANGER 9 without the cover in
SPARK ARRESTER
Gasoline engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
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8
WARNING
place will not increase the machine output and
will result in a higher noise level.
Standard mufflers and deflectors (like the ones included with the RANGER 9) do not act as spark arresters.
When local laws require it, a spark arrester must be
installed on the machine and properly maintained. An
optional spark arrester kit (K894-1) is available for your
RANGER 9. See the Accessories section of this manual for more information.
CAUTION
An incorrect spark arrester may lead to damage to the
engine or reduce performance.
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the output range
selector, fine output control, polarity switch, control at
welder/remote control switch, welding terminals
always on/remotely controlled switch 115 and 230 volt
receptacles, weld output terminals, and ground stud.
RANGER 9 RANGER 9
A-6 A-6
INSTALLATION
WELDING CABLE CONNECTIONS
CABLE SIZE AND LENGTH
Be sure to use welding cables that are large enough.
The correct size and length becomes especially important when you are welding at a distance from the
welder.
TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Cable Size for 250 Amp Cable Size for 250 Amp
Cable Length 40% Duty Cycle 100% Duty Cycle
0-50 feet (0-15 meters) 2 AWG 1 AWG
50-100 feet (15-39 meters) 2 AWG 1 AWG
100-150 feet (30-46 meters) 1 AWG 1 AWG
150-200 feet (46-61 meters) 1 AWG 1 AWG
200-250 feet (61-76 meters) 1/0 AWG 1/0 AWG
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
CABLE INSTALLATION
Install the welding cables to your RANGER 9 as follows. See Figure A.1 for the location of parts.
1. The gasoline engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identified on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
(the “work”) is properly connected to the work
clamp and cable.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output termi-
nal connection. Keep the cables isolated and separate from one another.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the Acces-
sories section of this manual for more information.
For more information on welding, see WELDING
OPERATION and SUMMARY OF WELDING PROCESSES in the Operations section of this manual.
MACHINE GROUNDING
Because the RANGER 9 creates its
own power from its gasoline-engine
driven generator, you do not need to
connect the machine frame to an
earth ground. However, for best protection against electrical shock, connect a heavy
gauge wire (#8 AWG or larger) from the ground stud
located on the bottom of the output panel (see Figure
A.1) to a suitable earth ground such as a metal pipe
driven into the ground.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
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RANGER 9 RANGER 9
A-7 A-7
INSTALLATION
When the RANGER 9 is mounted on a
truck or a trailer, the machine generator
ground stud MUST be securely connected to the metal frame of the vehicle. See
Figure A.1. The ground stud is marked
with the ground symbol.
If the RANGER 9 is connected to premises wiring such
as a home or shop, it must be properly connected to
the system earth ground. See the PREMISES WIRING
section of this manual for details.
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
The control panel of the RANGER 9 features two auxiliary power receptacles: See Figure A.1.
• Two 20 amp, 115 volt duplex (double outlet) receptacles.
• One 50 amp 115/230 volt simplex (single outlet)
receptacle.
Through these receptacles the machine can supply up
to 9,000 rated continuous watts of single-phase, 60 Hz
AC power. The machine output voltages fall within ±
10% of the rated voltage.
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an
Underwriter’ s Laboratories (UL) appr oved double insulation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the Accessories section of this manual for details.
If you need ground fault protection for hand-held
equipment, refer to the Accessories section of this
manual for the K896-1 GFCI Receptacle kit.
PREMISES WIRING
The RANGER 9 is suitable for temporary, standby, or
emergency power using the engine manufacturer’s
recommended maintenance schedule. With its threewire grounded neutral generator, it can be permanently installed as a standby power unit for 230 volt, threewire, single phase 40 ampere service.
WARNING
Only a licensed, certified, trained electrician should
install the machine to a premises or residential electrical system. Be certain that:
• The installation complies with the National Electrical
Code and all other applicable electrical codes.
• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and local
laws require the premises to be isolated before the
generator is linked to the premises. Check your
state and local requirements.
• A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit
breaker is connected between the generator power
and the utility meter.
The following information and the connection diagram,
Figure A.2, can be used as a guide by the electrician
for most applications to premises wiring.
1. Install a double pole, double throw switch between
the power company meter and the premises disconnect. The switch rating must be the same as
or greater than the premises disconnect and
service overcurrent protection.
CIRCUIT BREAKERS
Canadian Standards Association
(CSA) versions of the RANGER 9 are
equipped with 50 amp circuit breakers
on the 115/230 V receptacle and 15
amp circuit breakers on the 115 V receptacles for
overload protection. Under high heat a breaker may
tend to trip at lower loads than it would normally.
Never bypass the circuit breakers. Without overload
protection, the RANGER 9 could overheat and/or
cause damage to the equipment being used.
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RANGER 9 RANGER 9
CAUTION
2. Take the necessary steps to assure that the load is
limited to the capacity of the RANGER 9 by
installing a 40 amp 230 volt double pole circuit
breaker. Maximum rated load for the 230 volt auxiliary is 40 amperes. Loading above 40 amperes
will reduce output voltage below the allowable
– 10% of rated voltage. This may damage appliances or other motor-driven equipment.
3. Install a 50 amp 115/230 volt plug (NEMA type 14-
50) to a double pole circuit breaker using No. 8, 4
conductor cable of the desired length. (The 50
amp 115/230 volt plug is available in the optional
power plug kit. See the Accessories section for
details.)
4. Plug this cable into the 50 amp 115/230 volt
receptacle on the RANGER 9 case front.
A-8 A-8
INSTALLATION
FIGURE A.2 - CONNECTION OF RANGER 9 TO PREMISES WIRING
230 VOLT
230 V olt
60 Hz.
3-Wire
Service
POWER
COMP ANY
METER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
115 VOLT
115 VOLT
GROUNDED CONDUCTOR
NEUTRAL
BUS
LOAD
50 AMP, 115/230
VOLT PLUG
NEMA TYPE 14-50
230 VOLTS
50 AMP, 115/230 VOLT
RECEPTACLE
40 AMP
230 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
GND
PREMISES
DISCONNECT AND
GROUND
N
NOTE: No. 8 COPPER CONDUCTOR CABLE
SEE NATIONAL ELECTRIC CODE FOR
ALTERNATE WIRE SIZE RECOMMENDATIONS .
SERVICE
OVERCURRENT
PROTECTION
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RANGER 9 RANGER 9
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-2
General Description....................................................................................................................B-2
Recommended Applications ......................................................................................................B-3
Welder .................................................................................................................................B-3
Generator .............................................................................................................................B-3
Operational Features and Controls ............................................................................................B-3
Design Features and Advantages...............................................................................................B-3
Welding Capability ......................................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings ................................................................................................................B-4
Welder/Generator Controls ..................................................................................................B-5
Gasoline Engine Controls.....................................................................................................B-7
Engine Operation........................................................................................................................B-7
Before Starting the Engine ..................................................................................................B-8
Starting the Engine ..............................................................................................................B-8
Stopping the Engine ............................................................................................................B-8
Break-in Period ....................................................................................................................B-8
Welding Operation....................................................................................................................B-10
General Information............................................................................................................B-10
AC/DC Constant Current Stick Welding ......................................................................B-10
AC/DC TIG (Constant Current) Welding.......................................................................B-11
DC Wire Feed Welding.................................................................................................B-12
Summary of Welding Processes...............................................................................................B-13
Auxiliary Power.........................................................................................................................B-14
General Information............................................................................................................B-14
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RANGER 9 RANGER 9
B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your RANGER 9.
SAFETY INSTRUCTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and
ground.
WARNING
ARC RAYS can burn.
• Wear eye, ear, and body protection.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with
any of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
Only qualified personnel should install, use, or service this equipment.
GENERAL DESCRIPTION
The RANGER 9 is a gasoline-engine driven, multiprocess arc welder and AC power generator for commercial and residential applications. As a generator it
can supply up to 9,000 continuous watts of 115/230
volt, 60 Hz, single-phase AC power to operate AC
power tools, battery chargers, and lighting; it can also
be used to provide standby power. As a welder it provides 250 amps of AC current for welding with AC
stick electrodes or 250 amps of DC current for DC
stick welding. The RANGER 9 can also perform
AC/DC TIG welding and DC semiautomatic wire feed
welding.
The RANGER 9 is powered by the Onan P218
Performer®air-cooled, twin-cylinder engine.
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RANGER 9 RANGER 9
B-3 B-3
OPERATION
RECOMMENDED APPLICATIONS
WELDER
The RANGER 9 provides excellent constant current
AC/DC welding output for stick (SMAW) welding and
for TIG welding, and it offers constant voltage output
for DC semiautomatic wire feed welding. For more
details on using the machine as a welder, see WELDING OPERATION in the Operation section of this
manual.
GENERATOR
The RANGER 9 gives AC generator output for medium
use demands. For more details on operating the generator, see AUXILIARY POWER in the Operation section of this manual.
OPERATIONAL FEATURES AND
CONTROLS
The RANGER 9 was designed for simplicity. Therefore, it has very few operating controls. Three switches are used for welding operations:
• A nine-position output range selector switch selects
current output for constant current stick or TIG
applications and constant voltage wire feed applications.
• A fine output control switch for fine adjustment of
current or voltage within the selected output range
• A three-position polarity switch for selecting DC+,
DC- or AC welding output.
• A two-position toggle switch for selecting between
CONTROL AT WELDER or REMOTE CONTROL
(Remote control connections are made at either the
6 pin or the 14 pin amphenol connector.
• A two-position toggle switch for selecting between
control of the output contactor by the RANGER 9
(WELDING TERMINALS ALWAYS ON) or control of
the output contactor by a cable from a wire feeder
gun (WELDING TERMINALS REMOTELY CONTROLLED).
The gasoline engine control is a three-position toggle
switch for START, RUN, and STOP and a two-position
“IDLER” switch that selects engine speed for welding
or auxiliary power applications. See ENGINE OPERATION in the Operation section of this manual for
details about starting, running, stopping, and breaking
in the gasoline engine.
DESIGN FEATURES AND
ADVANTAGES
• 9,000 watts of auxiliary power
• Enhanced constant voltage capability with low (1221 volts), medium (15-27 volts), and high (18-35
volts) range settings for greater control of wire feed
applications.
• Built-in contactor with front panel selection of
“cold” or “hot” welding terminals: Cold (WELDING
TERMINALS REMOTELY CONTROLLED) – Closing
wire feeder trigger switch or amptrol causes contactor to close and engine to accelerate to high idle.
Hot (WELDING TERMINALS ALWAYS ON) – The
contactor is closed and welding begins when electrode touches work; engine automatically goes to
high idle.
• Constant current AC/DC Stick welding (SMAW)
process capability with output range from 40-250
amps (AC) or 40-250 amps (DC).
• Constant voltage DC Semiautomatic Wire Feed
Welding with output range from 40-250 amps.
• Constant current AC/DC TIG Welding with output
across the entire range of settings.
• Polarity switch for selecting DC+, DC-, or AC welding output.
• Separate ground stud for safe connection of case to
earth ground.
• Single 50 amp, 230 volt, full 9 kVA auxiliary power
receptacle.
• Double duplex 20 amp, 115 volt auxiliary power
receptacles.
• Electric starting.
• Battery Charging Ammeter.
• Engine Hour Meter for determining periodic maintenance.
• Top-of-the-line 18 HP Onan P218 Performer
engine.
• Durable, heavy-gauge steel case.
• Built-in feet for easy mounting to truck bed or trailer.
• Bottom-mounted 10 gallon (38.0 litre) fuel tank with
convenient top fill and fuel gauge.
®
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RANGER 9 RANGER 9
B-4 B-4
OPERATION
• Quiet engine muffler with reversible exhaust feature
for right or left side.
• All copper alternator windings and high quality insulation for dependable long life.
• Automatic engine shutdown protection for low oil
pressure.
• Automatic engine idler goes to low idle 10 to 14
seconds after welding for greater fuel economy;
includes high idle switch.
• Standard Remote Control Receptacle provides
interface for Lincoln remote control accessories.
Both 6 pin and 14 pin amphenols are provided for
ease in hooking up wire feeders.
• Canadian Standard Association (CSA) approved
models available; include integrated generator output overload protection through two 50 amp circuit
breakers.
WELDING CAPABILITY
The RANGER 9 is rated 250 amps, 25 volts constant
current AC or 250 amps, 25 volts constant current DC
(250 amps 25 volts constant voltage DC) at 100% duty
cycle on a ten-minute basis.
LIMITATIONS
• The RANGER 9 is not recommended for any
processes besides those that are normally performed using stick welding (SMAW), TIG welding,
MIG (GMAW) welding and Innershield®(FCAW)
welding. Specific limitations on using the
RANGER 9 for these processes are described in the
WELDING OPERATION section of this manual.
• The RANGER 9 is not recommended for pipe thawing.
• During welding, generator power is limited and output voltages can drop. Therefore, DO NOT OPERATE ANY SENSITIVE ELECTRICAL EQUIPMENT
WHILE YOU ARE WELDING. See Table B.4 for permissible simultaneous welding and auxiliary power
loads.
CONTROLS AND SETTINGS
All generator/welder controls are located on the
Output Control Panel of the machine case front.
Gasoline engine choke control, idler control, and
start/stop controls are also on the case front. See
Figure B.1 and the explanations that follow.
The current is continuously variable from 40 to 250
amps AC or 40 to 250 amps DC. The RANGER 9 can
weld with all 3/32 and most 1/8 inch and 1/16 diameter Lincoln AC stick electrodes. Wire feed processes
using wire diameters from .030 to .068 inch are possible, depending on the specific process and wire feeder. (See LIMITATIONS.)
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RANGER 9 RANGER 9
B-5 B-5
OPERATION
FIGURE B.1 – OUTPUT PANEL CONTROLS
1
7
8
11
RANGE
16 to 25
WARNING
50
LINCOLN
70
ELECTRIC
2
6
5
7
4
2
1
10 max
225 AC
210 DC
RANGER 9
8
9
3
90
125
175
54 6
DC+
DC-
AC
3
1. OUTPUT RANGE SELECTOR
2. FINE OUTPUT CONTROL
CHOKE
AUTO
START
RUN
IDLER
STOP
HIGH
3. POLARITY SWITCH
4. CONTROL AT WELDER/REMOTE CONTROL SWITCH
5. WELDING TERMINALS ALWAYS ON/
WELDING TERMINALS REMOTELY CONTROLLED SWITCH
6 WIRE FEEDER POWER CIRCUIT BREAKER
7. 115 VOLT, 20 AMP RECEPTACLES (2)
8. 115/230 VOLT, 50 AMP RECEPTACLE
9. WELD OUTPUT TERMINAL (TO WORK)
10. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER)
11. GROUND STUD
12. 14 PIN AMPHENOL
13. 6 PIN AMPHENOL
9
1012 13
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1. OUTPUT RANGE SELECTOR: Selects continuous
current output for constant current stick or TIG
applications (blue settings) and constant voltage
wire feed applications (red settings). The amperages on the dial correspond to the maximum
amperages for each corresponding range setting.
Never change the range switch setting while
welding since this could damage the switch.
2. FINE OUTPUT CONTROL: Allows fine adjustment
of current or voltage within the selected output
range.
3. POLARITY SWITCH: Selects DC+, DC- or AC
welding output. Color codings aid in the proper
selection of stick (blue) or wire feed (red) polarity
setting. The color setting of the polarity switch
must match the color setting of the OUTPUT
RANGE SELECTOR. Never change the polarity
switch setting while welding since this could
damage the switch.
4. CONTROL AT WELDER/REMOTE CONTROL
SWITCH: Allows the operator to control welding
output at the welding control panel or at a remote
station. Remote connections are made at the 6 pin
or 14 pin amphenol connector.
5. WELDING TERMINALS ALWAYS ON/WELDING
TERMINALS REMOTELY CONTROLLED SWITCH:
Allows control of the RANGER 9 output contactor.
In the ALWAYS ON position, the switch closes the
output contactor, and welding begins when an arc
is struck between the electrode and the workpiece.
In the REMOTELY CONTROLLED position, the
switch places control of the contactor at the wire
feeder. The contactor closes when the wire feeder
gun trigger or amptrol switch closes and opens
when it is released.
6. WIRE FEEDER POWER CIRUIT BREAKER: Opens
the wire feeder circuit and disables the feeder if a
fault is detected in the circuit.
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RANGER 9 RANGER 9
B-6 B-6
OPERATION
7. 20 AMP, 115 VOLT DUPLEX RECEPTACLES:
Connection point for supplying 115 volt power to
operate one or two electrical devices.
8. 50 AMP, 230 VOLT RECEPTACLE: Connection
point for supplying 230 volt power to operate one
electrical device.
9. WELD OUTPUT TERMINAL (TO WORK) WITH
FLANGE NUT: Provides the connection point for
the work cable.
10. WELD OUTPUT TERMINAL (TO ELECTRODE
HOLDER) WITH FLANGE NUT: Provides the connection point for the electrode holder.
11. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
12. 14 PIN AMPHENOL: For attaching wire feeder
control cables to the RANGER 9.
13. 6 PIN AMPHENOL: For attaching optional remote
control equipment to the RANGER 9.
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RANGER 9 RANGER 9
B-7 B-7
OPERATION
FIGURE B.2 – GASOLINE ENGINE CONTROLS
6
5
7
RANGE
4
3
2
90
125
70
50
16 to 25
175
225 AC
210 DC
8
DC+
9
1
10 max
DC-
AC
1. ENGINE CHOKE CONTROL
2. IDLER CONTROL SWITCH
WARNING
3. START/STOP SWITCH
4. ENGINE HOUR METER
5. BATTERY CHARGING SYSTEM METER
GASOLINE ENGINE CONTROLS
See Figure B.2 for the location of the following features:
1. ENGINE CHOKE CONTROL: Provides
a richer air/fuel mixture for cold engine
starting conditions. See the topic
ENGINE OPERATION, below, for details
on setting the choke.
2. IDLER CONTROL SWITCH: Adjusts
the running speed of the engine. The
switch has two positions, HIGH and
AUTO. In HIGH, the engine runs continuously at high idle. In AUTO, the
idler control works as follows:
Stick Welding, “WELDING TERMINALS ALWAYS
ON” mode: The engine accelerates to high speed
when the electrode touches the work and strikes a
welding arc. The engine returns to low idle approximately 10-14 seconds after welding stops, as
long as no auxiliary power is being drawn.
LINCOLN
ELECTRIC
RANGER 9
1
5
CHOKE
AUTO
START
RUN
IDLER
STOP
HIGH
2
3
3. START/STOP SWITCH: Has three positions,
START, RUN, and STOP. When the switch is held
in the START position, the starter motor cranks
over the engine – release the switch once the
engine starts. The STOP position stops the
engine.
NOTE: If you place the switch in the START position when the engine is running, you may damage
the ring gear or starter motor.
4. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to perform
required maintenance.
5. BATTERY CHARGING SYSTEM METER: Shows
whether the charging circuit is performing its job of
charging the battery when the engine is running.
The meter will register discharge during starting,
but then the needle should return to a position
slightly toward positive during running. The needle
will hold position when the engine stops.
4
Wire Welding, “WELDING TERMINALS ALWAYS
ON” mode: The engine accelerates to high speed
when the wire feeder gun trigger or amptrol is
closed. The engine returns to low idle approximately 10-14 seconds after the gun trigger is
released and the welding stops, provided that no
auxiliary power is being drawn.
Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacles for
lights or tools. The engine returns to low idle
approximately 10-14 seconds after demand for
auxiliary power stops.
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RANGER 9 RANGER 9
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.
The maximum allowable high idle speed for the
RANGER 9 is 3750 RPM, no load. Do NOT adjust the
governor screw on the engine. Severe personal injury
and damage to the machine can result if it is operated
at speeds above the maximum rated speed.
Read and understand all safety instructions included in
the Onan instruction manual that is shipped with your
RANGER 9.
B-8 B-8
OPERATION
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
1. Be sure the machine is on a level
surface.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick. On the Onan engine, the oil
fill cap and dipstick are a unit. See Figure D.1 in
the Maintenance section of this manual.
3. Add oil (if necessary) to bring the level up to the
full mark. Do not overfill.
Replace the dipstick and tighten it securely.
Check and fill the engine fuel tank:
1. Remove the fuel tank cap.
2. Fill the tank approximately 4 inches
(100 mm) from the top of the filler neck to allow for
fuel expansion (observe the fuel gauge). DO NOT
FILL THE TANK TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: Use only fresh, unleaded gasoline with octane
rating 87 or higher. Gasoline/alcohol blends are
approved for use with your engine as long as the blend
does not exceed 10% ethyl alcohol by volume. Other
gasoline/alcohol blends are not approved, and their
use may damage fuel system and engine parts.
NOTE: Purchase gasoline in quantities that will be
used within 30 days, to assure freshness.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the gasoline engine.
2. Hold the Engine Switch in the START
position. Release the switch when the
engine starts. Slowly return the choke
control to the full “in” position.
The engine will run at high idle for 10-14 seconds,
then go to low idle.
3. Let the engine run at low idle for a few minutes to
warm up before you use the RANGER 9 for welding or auxiliary power.
If the engine will not start, see the Trouble-
shooting section of this manual.
STOPPING THE ENGINE
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes at low idle.
2. Stop the engine by placing the Engine
Switch in the STOP position.
A fuel shutoff valve is not required on the
RANGER 9 because the fuel tank is mounted
below the engine.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
“break-in” period. For the gasoline engine on the
RANGER 9, break-in is about 50 running hours.
Check the oil at least twice a day during break-in.
Change the oil after the first 25 hours of operation.
Change the oil filter at the second oil change. For
more details, see the Maintenance section of this
manual.
For a “cold” engine:
1. Set the Idler Control Switch in
the AUTO position.
Use the Choke Control as follows:
If the engine is cold, pull the choke
control out. If the engine is warm or
hot, DO NOT use the choke control.
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RANGER 9 RANGER 9
CAUTION
During break-in, subject the RANGER 9 to moderate
loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow the
engine to cool several minutes.
B-9 B-9
OPERATION
TABLE B.1
TYPICAL RANGER 9 FUEL CONSUMPTION
ONAN P218 PERFORMER
Low Idle – No Load, 2150 RPM .40 Gallons/hour (1.5 liters/hour)
High Idle – No Load, 3700 RPM .82 Gallons/hour (3.10 liters/hour)
AC CC Weld Output, 250 Amps @ 25 Volts 1.7 Gallons/hour (6.5 liters/hour)
DC CC Weld Output, 250 Amps @ 25 Volts 1.7 Gallons/hour (6.5 liters/hour)
DC CV Weld Output, 250 Amps @ 25 Volts 1.7 Gallons/hour (6.5 liters/hour)
Auxiliary Power, 9000 kVA 1.7 Gallons/hour (6.5 liters/hour)
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RANGER 9 RANGER 9
B-10 B-10
OPERATION
WELDING OPERATION
GENERAL INFORMATION
WARNING
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Do not breathe welding fumes or gases.
• Use ventilation or exhaust to remove
welding fumes from the breathing area.
• Keep flammable material away.
• Wear eye, ear, and body protection.
The RANGER 9 can deliver from 40 to 250 amps of
constant current for AC/DC stick welding or from 40 to
250 amps of constant voltage current for DC semiautomatic wire feed welding. AC/DC TIG welding is possible across the entire range from 40 to to maximum
rated output. Output can be adjusted by setting the
POLARITY SWITCH, the OUTPUT RANGE dial, and
the FINE CONTROL dial on the output control panel to
the settings that are best for your selected welding
process.
To use the RANGER 9 for AC/DC
Constant Current Stick Welding:
1. Remove the flange nuts from output terminals and
place the work and electrode welding cables over
the terminals. See Figure B.3. Replace and tighten the flange nuts securely. Be sure the connections are tight.
2. Select the appropriate electrode. See “Welding
Tips 1” included with your RANGER 9.
3. Attach the work clamp securely to the work you
are welding.
4. Insert the electrode into the electrode holder.
5. Set the IDLER CONTROL to AUTO and start the
gasoline engine. See ENGINE OPERATION in this
section of the manual.
6. Set the OUTPUT RANGE dial to a setting equal to
or slightly higher than the welding current recommended for the electrode being used.
7. Set the POLARITY SWITCH to the desired polarity.
8. Set the FINE OUTPUT CONTROL. Use a setting
that results in the highest output at the lowest setting of the RANGE switch for the application.
9. Strike an arc and begin welding.
After you finish welding:
1. Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode fr om the
electrode holder.
5. If you are finished using the RANGER 9 for welding, disconnect the welding cables from the weld
output terminals. Reattach the flange nuts and
leave them on the terminals.
8
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RANGER 9 RANGER 9
FIGURE B.3 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
6
5
7
4
8
3
RANGE
50
16 to 25
WARNING
LINCOLN
70
ELECTRIC
1
175
225 AC
210 DC
2
90
125
9
AC
10 max
RANGER 9
DC+
DC-
CHOKE
AUTO
START
RUN
IDLER
STOP
HIGH
5
4
6
7
1
1. OUTPUT CONTROL PANEL
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. OUTPUT TERMINALS
6. WORK
7. WORK CLAMP
8. WORK CABLE
2
3
B-11 B-11
OPERATION
To Use the RANGER 9 for AC/DC TIG
(Constant Current) Welding:
1. Connect the K930-1 TIG Module to the RANGER
9. Follow the installation instructions provided
with the kit. Also be sure to follow the special
machine grounding instructions given in the manual.
2. Refer to the instruction manual with the TIG module (IM 528) for operation with a RANGER 9 and
proper machine settings.
3. Set the OUTPUT RANGE dial to the appropriate
setting for the electrode you are using. Refer to
IM -528 with the TIG module or refer to Table B.2
for AC TIG welding.
4. Set the POLARITY SWITCH to the desired polarity.
5. Do not AC TIG weld on the 250 AC range setting.
The output current may exceed the rating of the
RANGER 9.
6. Start the arc and begin welding.
NOTE: When using the RANGER 9 for AC TIG weld-
ing of aluminum, the TIG Module is to be set
for CONTINUOUS HF.
After you finish welding:
1. Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
Tungsten Diameter (inches) Range Switch Settings Appropriate Current Range
1/8 90 or 120 160 - 200 Amps
3/32 45 or 90 45 - 140 Amps
1/16 45 or 90 45 - 100 Amps
Tungsten Diameter (inches) Range Switch Settings Appropriate Current Range
1/8 90, 120, or 180 160 - 250 Amps
3/32 45, 90, or 120 100 - 180 Amps
1/16 45 or 90 60 - 120 Amps
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RANGER 9 RANGER 9
TABLE B.2 - AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS
Settings for Pure Tungsten
Settings for 1% Thoriated Tungsten
B-12 B-12
OPERATION
To Use the RANGER 9 for DC Wire Feed
Welding (Constant Voltage):
1. Connect one of the following: the LN-25, LN-7,
LN-8, or LN-742 Wire Feeder. Follow the installation instructions in the ACCESSORIES section of
this manual.
2. Some recommended Innershield electrodes are:
NR-211MP, NR-311, NR-203 series, as well as
Lincore®33 and 55 hardfacing electrodes.
Diameters from .035 (0.9mm) up to and including
5/64” (2.0mm) can be used. 5/64” (2.0mm) NS3M can be used in limited applications. Cable
length and other conditions can affect the ultimate
results of this application. Request Lincoln publication N-675 for additional information.
Recommended Outershield electrodes are .045,
.052, and 1/16 Outershield 71 and 1/16
Outershield 70. Request Lincoln publication
GS-200 for additional information.
For MIG welding, the recommended electrodes
are .030, .035 and .045 L-50 and L-56. You must
use a blended shielding gas such as C25 (75%
Argon, 25% CO2). Request Lincoln publication
GS-100 for additional information.
4. Set the OUTPUT RANGE dial to either HIGH,
MED, or LOW depending on your wire size and
speed.
5. Set the POLARITY SWITCH to either WIRE FEED
DC+ or WIRE FEED DC- (red), depending on the
electrode.
6. Set the FINE OUTPUT CONTROL to a setting that
gives the most stable arc for the application.
7. Strike an arc and begin welding.
After you finish welding:
1. Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Allow the work to cool completely. The wire gun
and wire are “cold.”
3. Remove the work clamp from the work.
3. Set the IDLER CONTROL to “AUTO” for the LN-25
or LN-742 or “HIGH” for the LN-7 or LN-8 and
start the gasoline engine. See ENGINE OPERATION in this section of the manual.
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RANGER 9 RANGER 9
B-13 B-13
OPERATION
SUMMARY OF WELDING
PROCESSES AND MACHINE
SETTINGS
Table B.3 summarizes the requirements for various
welding processes you can perform with the
RANGER 9.
TABLE B.3 - SUMMARY OF WELDING PROCESSES
Process Control Idle Output Welding Electrode To Start Welding
Cable Mode Control Terminals State When
Used Switch Switch Not Welding
Stick – CC No Auto At Welder Always on Hot Touch electrode to work.
Welding starts immediately and engine goes to
high idle.
TIG - CC Yes Auto Remote Remote Cold Press Amptrol. Welding
K930-1/K936-1 starts immediately.
(With Amptrol)
Wire Feed - CV, Yes Auto Remote Remote Cold Press gun trigger,
LN-25 with 42V RANGER 9 contactor
Remote Control Kit closes. Welding starts
immediately and engine
goes to high idle.
Wire Feed - CV No Auto At Welder Always on Cold Press gun trigger, LN-25
LN-25 with internal contactor closes. Weldcontactor ing starts immediately
and engine goes to high
idle.
Wire Feed - CV Yes Auto Remote Remote Cold Press gun trigger,
LN-742 RANGER 9 contactor
closes. Welding starts
immediately and engine
goes to high idle.
Wire Feed - CV, Yes High Remote Remote Cold Press gun trigger,
LN-7 RANGER 9 contactor
closes. Welding starts
immediately.
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RANGER 9 RANGER 9
B-14 B-14
OPERATION
AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a
±10% voltage and a ±3% frequency variation.
GENERAL INFORMATION
The RANGER 9 generator is rated at 9000 continuous
watts. It provides both 115 volt and 230 volt power.
You can draw up to 80 amps total from the 115 volt
receptacles, but no more than 20 amps (15 amps CSA)
from each receptacle at once. See Tables B.4A and
B.4B. Up to 40 amps can be drawn from the single 230
volt receptacle.
The current rating of any plug used must be at least
equal to the current load being drawn from the receptacle. Do not try to connect the receptacles in parallel.
Electrical loads in watts are calculated by multiplying
the voltage rating of the load by the number of amps it
draws. (This information is given on the load device
nameplate.) For example, a device rated 115 volts, 2
amps will need 230 watts of power (115 x 2 = 230).
You can use Table B.6, GENERATOR POWER APPLICATIONS, to determine the wattage requirements of
some common types of loads you can power with the
RANGER 9. Be sure to read the notes at the bottom
of the table.
Powering Motors
You can start most 1.5 HP, single-phase electric
motors if there is no load on the motor or other load
connected to the RANGER 9. After starting, the motor
may be run at full load. Larger motors (up to 2 HP)
may be started and run as long as you don’t exceed
the current rating of the receptacle. This may mean
that only 230 volt motors of this size may be operated.
Using Auxiliary Power and Welding at the
Same Time
It is possible to weld and use the RANGER 9 for auxiliary power at the same time. However, the size of the
loads you can power is reduced when you weld. See
Table B.5 in this section of the manual for a list of permissible simultaneous welding and load ratings. The
table assumes that power is being drawn from either a
115 volt or the 230 volt receptacle, but not both at the
same time.
NOTE: For simultaneous welding and power, set the
OUTPUT CONTROL at “10” for maximum auxiliary
power. At settings below “10,” only incandescent
loads should be connected to the auxiliary receptacles.
To use the generator as an auxiliary power supply:
1. Start the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Set the IDLER CONTROL to the desired operating
mode, HIGH or AUTO. Set the OUTPUT CONTROL to “10.” See Figure B.1.
3. Plug the load(s) into the appropriate 115 volt or
230 volt power receptacle.
NOTE: The 115 volt auxillary power receptacles
should only be used with three-wire grounded
type plugs or approved double insulated
devices with two-wire plugs.
MAXIMUM CURRENT DRAW FROM 115V DUPLEX
Load From Each Total Each Total
115V/230V Half of from Half of from
Dual Voltage Each 115V Both 115V Each 115V Both 115V
Receptacle Duplex Duplexes Duplex Duplexes
0 20* 78 15 60
2.2 KW 20* 60 15 60
4.5 KW 20* 40 15 40
6.7 KW 20* 20 15 20
9.0 KW 0 0 0 0
*NEMA 5-20P plug required for 20 amp draw.
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RANGER 9 RANGER 9
TABLE B.4A
RECEPTACLES – NO WELDING
K1420-1 K1420-2 (CSA)
TABLE B.4B
MAXIMUM CURRENT DRAW FROM OPTIONAL
115V GFCI DUPLEX RECEPTACLES – NO WELDING
K1420-1* K1420-2**
Load From Each Total Each Total
115V/230V Half of from Half of from
Dual Voltage Each 115V Both 115V Each 115V Both 115V
Receptacle Duplex Duplexes Duplex Duplexes
015401530
2.2 KW 15 40 15 30
4.5 KW 15 40 15 30
6.7 KW 15 20 15 20
9.0 KW 0 0 0 0
*Maximum current draw from each 115V GFCI Duplex is 20 amps.
**Maximum current draw from each 115V GFCI Duplex is 15 amps.
B-15 B-15
OPERATION
TABLE B.5 - SIMULTANEOUS WELDING AND AUXILIARY POWER
Output Selector Welding Permissible Power in Watts Permissible Auxiliary Current
Setting Output (Unity Power Factor) in Amperes
@ 115V @230V
250 250 None — —
200 200 2500 22 11
160 160 3700 32 16
120 120 5000 44 22
90 90 6000 52 26
45 45 7500 65 32.5
CV Low 200 5000 43 21.5
60 7500 65 32.5
CV Medium 250 2750 40 20
80 6500 56 28
CV High 250 1200 10 5
100 6000 52 26
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RANGER 9 RANGER 9
B-16 B-16
OPERATION
TABLE B.6
TYPICAL GENERATOR POWER APPLICATIONS
Suggested Power Applications Running Watts *Start-up Watts
*Air Compressor - 3/4 HP 1,250 3,100 - 5,000
*Airless Sprayer - 1/3 HP 600 1,500 - 2,400
Chain Saw 1,200
Circular Saw 1,200
Coffee Maker 1,000
*Deep Freezer 500 750 - 2,000
*Electric Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 100 or 125 Amp Wire Feeder/Welder 4,000
NOTES:
Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in the
table, multiply RUNNING WATTS by 2.
Multiple loads can be used as long as the total load does not exceed 9,000 watts. Be sure to start the
largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may
require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to
start.
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RANGER 9 RANGER 9
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