Lincoln Electric SVM120-A User Manual
SVM120-A
March 1999
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.
SERVICE MANUAL
For use with machine code numbers 9815 and 9816
RANGER 10-LX
TM
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
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
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
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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FOR ENGINE
powered equipment.
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.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
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX
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
Design Features and Advantages...............................................................................................B-3
Welding Capability ......................................................................................................................B-3
Page
Limitations .................................................................................................................................B-3
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-10
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual.................................................................................................................................P-217
RANGER 10-LX
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
Engine Coolant.....................................................................................................................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 10-LX
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 10-LX
INPUT - DIESEL ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
KUBOTA 3 cyl., 3600 RPM 52.17 cu. in. Electric Fuel: 10 gal. (38 l)
DH850B-88 liquid-cooled Full load (855 cc)
diesel Oil: 3.9 qt. (3.7 l)
23 HP @ 3750 RPM
3600 RPM High idle
Cooling system:
2150 RPM 5.4 qts. (5.1 l)
Low idle
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 250 AC Constant Current 25
100% Duty Cycle 250 DC Constant Current 25
100% Duty Cycle 250 DC Constant Voltage 30
OUTPUT - WELDER AND GENERATOR
Auxiliary Power for
Welding Ranges Max. Open Circuit Voltage Auxiliary Power
45- 250 Amps 80 Volts RMS 10000 Continuous Watts 42V, 60 Hz, 8 Amps
@ 3700 RPM 87 Amps @ 115 V
43.5 Amps @ 230 V 115V, 60 Hz, 8 Amps
(1)
Wire Feeders
PHYSICAL DIMENSIONS
Height Width Depth Weight
37.4 in. 24.8 in. 60.5 in. 1100 lb.
949 mm 629 mm 1529 mm 499 kg
(1)
Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity.
When welding, available auxiliary power will be reduced.
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RANGER 10-LX
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.
ENGINE EXHAUST can kill.
LOCATION AND VENTILATION
Whenever you use the RANGER 10-LX, be sure that
clean cooling air can flow through the machine’ s diesel
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 10-LX 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 10-LX 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.
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.
• 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.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate
oil to all the parts. See the Maintenance section
of this manual for details on changing oil.
3. If you are storing the machine for more than 30
days, drain the coolant from the radiator. Open the
cock at the bottom of the radiator and remove the
pressure cap so that the coolant drains completely. Attach a note that says “NO WATER” on the
radiator.
4. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
5. If the engine is not used for a long period of time,
every two to three months fill the radiator and run
the engine for about five minutes to keep it free
from rust.
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RANGER 10-LX
A-4 A-4
INSTALLATION
STACKING
RANGER 10-LX 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 diesel 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 20 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 10-LX weighs 1100 lbs/499 kg. A lift bail
is mounted to the machine frame and should always
be used when lifting the machine.
OIL
The RANGER 10-LX is shipped with the
engine filled with SAE 10W-30 oil (API class
CC/DO). CHECK THE OIL LEVEL BEFORE YOU
START 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.
FUEL
Fill the fuel tank with clean, diesel fuel only.
The RANGER 10-LX has a 10 gallon (38 litre)
fuel tank with a top fill and fuel gauge
mounted on the control panel. See the
Operation and Maintenance sections of this manual
for more details about fuel.
ENGINE COOLANT
HIGH ALTITUDE OPERATION
It may be necessary to derate welder output at higher
altitudes. Derate the welder output 0.4% for every 100
ft (30 m) above 500 ft (150 m). Some engine adjustment may be required. Contact a Kubota Service
Representative.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the RANGER 10-LX.
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.
WARNING
HOT COOLANT can burn
skin.
• Do not remove cap if radiator is hot.
The welder is shipped with the engine and radiator
filled with a 50% mixture of ethylene glycol and water.
The recovery bottle should be partially filled. See the
Maintenance section and the engine Operator’s
Manual for more information on coolant.
BATTERY CONNECTIONS
–+
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 10-LX is shipped with the
negative battery cable disconnected.
Before you operate the machine, make
• Keep sparks and flame away from the fuel tank.
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RANGER 10-LX
A-5 A-5
INSTALLATION
FIGURE A.1 - RANGER 10-LX OUTPUT CONNECTIONS
2
1. 115/230 VOLT, 50 AMP RECEPTACLE
2. 115 VOLT, 20 AMP RECEPTACLES (2)
1
5
3. WELD OUTPUT TERMINALS (2)
4. GROUND STUD (LOCATION)
5. CIRCUIT BREAKERS (CSA machines only)
4
3
MUFFLER RELOCATION
WARNING
Shut off the machine and allow the muffler to cool
before touching the muffler.
The RANGER 10-LX is shipped with the exhaust
directed toward the rear. It can be changed to the right
side by loosening the clamp that holds the exhaust
deflector in place and rotating the deflector to the
desired direction.
SPARK ARRESTER
Diesel 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.
Standard mufflers and deflectors (like the ones included with the RANGER 10-LX) 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 (K903-1) is available for your RANGER 10-LX. 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 115 and 230 volt
receptacles, weld output terminals, circuit breakers
and ground stud.
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RANGER 10-LX
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 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
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
CABLE INSTALLATION
Install the welding cables to your RANGER 10-LX as
follows. See Figure A.1 for the location of parts.
1. The diesel engine must be OFF to install welding
cables.
2. Remove the flanged nuts from the output termi-
nals.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identified on the case front.
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the Acces-
sories section of this manual for more information.
MACHINE GROUNDING
Because the RANGER 10-LX creates
its own power from its diesel-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.
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.
• 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.
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WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
CAUTION
RANGER 10-LX
A-7 A-7
INSTALLATION
When the RANGER 10-LX 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 10-LX 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 10-LX features three
auxiliary power receptacles: See Figure A.1.
• Two 20 amp, 125 volt duplex (double outlet) recep-
tacles.
• One 50 amp 115/230 volt simplex (single outlet)
receptacle.
Through these receptacles the machine can supply up
to 10,000 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 10-LX 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 43 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 10-LX
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 10-LX could overheat and/or
cause damage to the equipment being used.
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CAUTION
2. Take the necessary steps to assure that the load is
limited to the capacity of the RANGER 10-LX by
installing a 45 amp 230 volt double pole circuit
breaker. Maximum rated load for the 230 volt auxiliary is 43 amperes. Loading above 43 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. 6, 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 10-LX case front.
RANGER 10-LX
A-8 A-8
INSTALLATION
FIGURE A.2 - CONNECTION OF RANGER 10-LX 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
50 AMP, 115/230 VOLT
RECEPTACLE
RECEPTACLE
LOCATED ON
FRONT OF MACHINE
45 AMP
40 AMP
230 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
GND
PREMISES
SYSTEM
GROUND
EARTH
GROUND
PER THE U.S.
NATIONAL
ELECTRICAL
CODE
N
NOTE: No. 8 COPPER CONDUCTOR CABLE
NOTE: No. 6 COPPER 4 CONDUCTOR CABLE.
SEE NATIONAL ELECTRIC CODE FOR
SEE NATIONAL ELECTRIC CODE FOR
ALTERNATE WIRE SIZE RECOMMENDATIONS.
ALTERNATE WIRE SIZE RECOMMENDA TIONS .
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
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RANGER 10-LX
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
Design Features and Advantages...............................................................................................B-3
Welding Capability ......................................................................................................................B-3
Limitations .................................................................................................................................B-3
Controls and Settings ................................................................................................................B-4
Welder/Generator Controls ..................................................................................................B-4
Diesel Engine Controls.........................................................................................................B-6
Engine Operation........................................................................................................................B-7
Before Starting the Engine ..................................................................................................B-7
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 and Machine Settings ..........................................................B-13
Auxiliary Power.........................................................................................................................B-14
General Information............................................................................................................B-14
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RANGER 10-LX
B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your RANGER 10-LX.
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 10-LX is a diesel-engine driven, multiprocess AC and DC arc welder and AC power generator for commercial and residential applications. As a
generator it can supply up to 10,000 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 10-LX can
also perform AC/DC TIG welding and DC semiautomatic wire feed welding.
The RANGER 10-LX is powered by the Kubota
DH850B-88 water-cooled, three-cylinder diesel
engine.
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RANGER 10-LX
B-3 B-3
OPERATION
RECOMMENDED APPLICATIONS
WELDER
The RANGER 10-LX 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 10-LX 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.
DESIGN FEATURES AND
ADVANTAGES
• 10,000 watts of auxiliary power
• Enhanced constant voltage capability with low (9-19
volts), medium low (10-24 volts), medium high (1529 volts) and high (22-40 volts) range settings for
greater control of wire feed applications.
• Built-in contactor with front panel selection of
“cold” or “hot” welding terminals.
• Constant current AC/DC Stick welding (SMAW)
process capability with output range from 45-250
amps (AC) or 45-250 amps (DC).
• Constant voltage DC Semiautomatic Wire Feed
Welding with output range from 45-250 amps.
• Constant current AC/DC TIG Welding with output
across the entire range of settings.
• Top-mounted 10 gallon (38.0 litre) fuel tank with
convenient top fil.
• Front-panel mounted fuel gauge.
• Quiet engine muffler and insonorized case for
extremely quiet operation.
• 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 circuit breakers.
WELDING CAPABILITY
The RANGER 10-LX is rated 250 amps, 25 volts constant current AC or 250 amps, 25 volts constant current DC (250 amps 30 volts constant voltage DC) at
100% duty cycle on a ten-minute basis.
The current is continuously variable from 45 to 250
amps AC or 45 to 250 amps DC. The RANGER 10-LX
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.)
• 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 10 kVA auxiliary power
receptacle.
• Double duplex 20 amp, 125 volt auxiliary power
receptacles.
• Electric starting.
• Battery Charging Ammeter.
• Engine Hour Meter for determining periodic maintenance.
• 23 HP Kubota DH850B-88 diesel engine.
• Durable, heavy-gauge steel case.
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LIMITATIONS
• The RANGER 10-LX is not recommended for any
processes besides those that are normally performed using stick welding (SMAW), TIG welding
(GTAW), MIG (GMAW) welding and Innershield
(FCAW) welding. Specific limitations on using the
RANGER 10-LX for these processes are described
in the Welding Operation section of this manual.
• The RANGER 10-LX 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 per-
missible simultaneous welding and auxiliary power
loads.
RANGER 10-LX
®
B-4 B-4
OPERATION
CONTROLS AND SETTINGS
All generator/welder controls are located on the
Output Control Panel of the machine case front.
Diesel engine glow plug, idler control, and start/stop
FIGURE B.1 – OUTPUT PANEL CONTROLS
1
2
7
8
controls are also on the case front. See Figur e B.1 and
the explanations that follow.
14
3
4
5
6
1. OUTPUT RANGE SELECTOR
2. FINE OUTPUT CONTROL
3. POLARITY SWITCH
4. CONTROL AT WELDER/REMOTE CONTROL SWITCH
5. WIRE FEEDER NO CONTROL CABLE/WIRE FEEDER
WITH CONTROL CABLE 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 (LOCATION)
12. 14 PIN AMPHENOL
13. 6 PIN AMPHENOL
14. VOLTMETER
11
12
9
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1. OUTPUT RANGE SELECTOR: Selects continu-
ous current output for constant current stick or
TIG applications (blue settings) and constant voltage wire feed applications (white 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 adjust-
ment 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 (white) polarity setting. The color setting of the polarity switch
must match the color setting of the OUTPUT
RANGE SELECTOR. Never change the polarity
13
10
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. WIRE FEEDER NO CONTROL CABLE/WIRE
FEEDER WITH CONTROL CABLE SWITCH:
Allows control of the RANGER 10-LX output contactor. In the “NO CONTROL CABLE” position, the
switch closes the output contactor, and welding
begins when an arc is struck between the electrode
and the workpiece. In the “WITH CONTROL
CABLE” 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 10-LX
B-5 B-5
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, 230/115 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 10-LX. (Includes
contactor closure circuit, remote control circuit,
wire feeder 115/42 volt power source.)
13. 6 PIN AMPHENOL: For attaching optional remote
control equipment to the RANGER 10-LX.
(Includes contactor closure circuit & remote control circuit.)
14. VOLTMETER – Displays actual voltage at the out-
put terminals when welding in CV-mode.
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RANGER 10-LX
B-6 B-6
OPERATION
FIGURE B.2 – ENGINE CONTROLS
8
1. ENGINE GLOW PLUG PUSHBUTTON
2. IDLER CONTROL SWITCH
3. START PUSHBUTTON
4. ENGINE HOUR METER
5. BATTERY CHARGER LIGHT
6. OIL PRESSURE LIGHT
7. WATER TEMPERATURE LIGHT
8. FUEL LEVEL GAUGE
9. ENGINE ON-OFF SWITCH
DIESEL ENGINE CONTROLS
See Figure B.2 for the location of the following features:
1. GLOW PLUG PUSHBUTTON: Acti-
vates glow plugs to preheat engine for
starting.
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; Wire Feeder switch in
“NO CONTROL CABLE” position:
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.
Wire Welding; Wire Feeder switch in “WITH CONTROL CABLE” position: The engine accelerates to
high speed when the electrode touches the workpiece. 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.
4
2
1
9
3
7
6
5
3. START PUSHBUTTON: When the
pushbutton is held, the starter motor
cranks over the engine – release the
button once the engine starts.
NOTE: If you press the START pushbutton 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 LIGHT: Is off when battery charging
system is functioning normally. If light turns on
while the engine is running, the fan belt may be
broken or the alternator or the voltage regulator
may be defective.
WARNING
MOVING PARTS can injure.
• Have qualified personnel do maintenanace and troubleshooting work.
• If possible, turn the engine off and
disconnect the battery before working inside the machine.
• Remove guards only when necessary to perform
maintenance, and replace them when the maintenance requiring their removal is complete.
• If fan guards are missing from a machine, obtain
replacements from a Lincoln Distributor. (See Parts
List.)
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RANGER 10-LX
B-7 B-7
OPERATION
6. OIL PRESSURE LIGHT: Remains off
with proper oil pressure. If light turns
on, the engine protection system will
stop the engine. The light will go on
when the “Engine” switch is switched to the “ON”
position with engine not running. It will go off after
one minute if the engine is not started.
7. WATER TEMPERATURE LIGHT:
Remains off under normal operating
temperatures. If light turns on, the
engine protection system will stop the
engine. The light will remain on when the engine is
over temperature and the “Engine” switch is in the
“ON” position (engine not running).
WARNING
HOT COOLANT can burn skin.
• Do not remove cap if radiator is hot.
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. 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.
Check and fill the engine fuel tank:
WARNING
DIESEL fuel can cause fire or
explosion.
• Stop engine when fueling.
• Do not smoke when fueling.
8. FUEL LEVEL GAUGE: Displays the level of diesel
fuel in the 10-gallon fuel tank.
9. ENGINE ON-OFF SWITCH: Energizes the fuel
solenoid in the ON position. In the STOP position,
stops fuel flow to the injection pump and stops the
engine.
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.
The maximum allowable high idle speed for the
RANGER 10-LX 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 Kubota instruction manual that is shipped with
your RANGER 10-LX.
Refer to Pre-Operation Engine Service in the
Installation section of this manual.
• Remove cap slowly to release pressure.
• Do not overfill tank.
• Wipe up spilled fuel and allow fumes to clear before
starting engine.
• Keep sparks and flame away from 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: DO NOT allow the RANGER 10-LX to run out
of fuel. If it does, you will have to bleed the injection
system.
NOTE: USE DIESEL FUEL ONLY.
NOTE: Purchase diesel fuel in quantities that will be
used within 30 days, to assure freshness.
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RANGER 10-LX
B-8 B-8
OPERATION
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.
1. Open the engine compartment door and check
that the fuel shutoff valve located above the clear
plastic fuel filter housing is in the open position
(lever in the vertical position). See Figure B.3.
2. Check for proper level of coolant in the plastic
reserve overflow tank. The level should be
between the full and the low marks.
3. Check for proper oil level on the oil dipstick. Close
engine compartment door.
4. Set “IDLER” switch to “AUTO”.
5. Set the “ENGINE” switch to “ON”. Observe that
both the oil pressure light and battery charger light
are on. Check the fuel gauge to make sure that
there is an adequate fuel level (NEVER ALLOW
THE RANGER 10-LX TO RUN OUT OF FUEL).
6. Press the “GLOW PLUG” button for 15
seconds (30 seconds if below 0°C/32°F)
and then press the “START BUTTON”.
7. Release both buttons when the engine
starts.
8. Check that the indicator lights are off. If not,
immediately stop the engine and investigate the
indicated problem.
9. Allow the engine to warm up at low idle speed for
several minutes before applying a load and/or
switching to high idle. Allow a longer warm up
time in cold weather.
NOTE: If the engine fails to start in 60 seconds or
stops running, the “ENGINE” switch must be switched
to “OFF” and then switched back to “ON” before
attempting to restart the engine. This resets the
engine protection circuit.
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 OFF position. This turns off the fuel solenoid.
You can also stop the engine by turning off the fuel
valve located on the fuel filter housing.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
“break-in” period. For the diesel engine on the
RANGER 10-LX, break-in is about 50 running hours.
Check the oil every four hours during break-in.
Change the oil after the first 50 hours of operation,
every 100 hours thereafter. Change the oil filter at the
second oil change. For more details, see the
Maintenance section of this manual.
CAUTION
During break-in, subject the RANGER 10-LX to moderate loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow the
engine to cool several minutes.
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FIGURE B.3 – FUEL SHUTOFF VALVE
RANGER 10-LX
B-9 B-9
OPERATION
TABLE B.1
TYPICAL RANGER 10-LX FUEL CONSUMPTION
KUBOTA DH850-B-88
Low Idle – No Load, 2150 RPM .30 Gallons/hour (1.0 liters/hour)
High Idle – No Load, 3750 RPM .60 Gallons/hour (2.2 liters/hour)
AC CC Weld Output, 250 Amps @ 25 Volts 1.1 Gallons/hour (4.2 liters/hour)
DC CC Weld Output, 250 Amps @ 25 Volts 1.2 Gallons/hour (4.6 liters/hour)
DC CV Weld Output, 250 Amps @ 30 Volts .90 Gallons/hour (3.6 liters/hour)
Auxiliary Power, 10,000 kVA 1.3 Gallons/hour (4.9 liters/hour)
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RANGER 10-LX
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 10-LX can deliver from 45 to 250 amps
of constant current for AC/DC stick welding or from 45
to 250 amps of constant voltage current for DC semiautomatic wire feed welding. AC/DC TIG welding is
possible across the entire range from 45 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 10-LX 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.4. 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 10-LX.
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
diesel 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 diesel 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 10-LX for
welding, disconnect the welding cables from the
weld output terminals. Reattach the flange nuts
and leave them on the terminals.
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FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
1. OUTPUT CONTROL PANEL
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. OUTPUT TERMINALS
6. WORK
7. WORK CLAMP
8. WORK CABLE
RANGER 10-LX
B-11 B-11
OPERATION
To Use the RANGER 10-LX for AC/DC TIG
(Constant Current) Welding:
1. Connect the K930-1 TIG Module to the RANGER
10-LX. 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 10-LX
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 10-LX.
6. Start the arc and begin welding.
NOTE: When using the RANGER 10-LX for AC TIG
welding of aluminum, the TIG Module is to be
set for CONTINUOUS HF.
After you finish welding:
1. Stop the diesel 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.
TABLE B.2 - AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS
Settings for Pure Tungsten
Tungsten Diameter (inches) Range Switch Settings Appropriate Current Range
1/8 65, 90 or 120
3/32 45, 65 or 90 50 - 100 Amps
1/16 45, 65 or 90 45 - 150 Amps
Settings for 1% Thoriated Tungsten
Tungsten Diameter (inches) Range Switch Settings Appropriate Current Range
1/8 90, 120, or 160 160 - 250 Amps
3/32 45, 90, or 120 100 - 180 Amps
1/16 45 or 90 60 - 120 Amps
(1)
The welding current will be approximately 200 amps with the range switch set at 120 and the OUTPUT CONTROL set at 10. Do not use a range setting higher than 120 for AC TIG welding.
(1)
100 - 200 Amps
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RANGER 10-LX
B-12 B-12
OPERATION
To Use the RANGER 10-LX for DC Wire
Feed Welding (Constant Voltage):
1. Connect one of the following: the LN-25, LN-7 or
LN-8 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
(1.1 mm), .052 (1.3 mm), and 1/16 (1.6 mm)
Outershield 71 and 1/16 (1.6 mm) Outershield 70.
Request Lincoln publication GS-200 for additional
information.
For MIG welding, the recommended electrodes
are .030 (0.8 mm), .035 (0.9 mm) and .045
(1.1 mm) 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,
MEDIUM HIGH, MEDIUM LOW, or LOW depending on your wire size and speed.
5. Set the POLARITY SWITCH to either WIRE FEED
DC+ or WIRE FEED DC- (white), 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 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
“HIGH” for the LN-7 or LN-8 and start the diesel
engine. See Engine Operation in this section of
the manual.
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RANGER 10-LX
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 10-LX.
TABLE B.3 - SUMMARY OF WELDING PROCESSES
Process Control Idle Output Wire Electrode To Start Welding
Cable Mode Control Feeder State When
Used Switch Switch Not Welding
Stick – CC No Auto At Welder No Hot Touch electrode to work.
Control Welding starts immedCable ately and engine goes to
high idle.
TIG - CC Yes Auto Remote With Cold Press Amptrol. Welding
K930-1/K936-1 Control starts immediately.
(With Amptrol) Cable
Wire Feed - CV, Yes Auto Remote With Cold Press gun trigger,
LN-25 with 42V Control RANGER 10-LX contactor
Remote Control Kit Cable closes. Welding starts
immediately and engine
goes to high idle.
Wire Feed - CV No Auto At Welder No Cold Press gun trigger, LN-25
LN-25 with internal Control contactor closes. Weldcontactor Cable ing starts immediately
and engine goes to high
idle.
Wire Feed - CV, Yes High Remote With Cold Press gun trigger,
LN-7 or LN-8 Control RANGER 10-LX contactor
Cable closes. Welding starts
immediately.
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RANGER 10-LX
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 10-LX generator is rated at 10,000 continuous watts. It provides both 115 volt and 230 volt
power . You can draw up to 87 amps total, but no more
than 20 amps (15 amps CSA) from each 115V receptacle at once. Up to 43.5 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.5, GENERATOR POWER APPLICATIONS, to determine the wattage requirements of
some common types of loads you can power with the
RANGER 10-LX. 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 10-LX. 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 10-LX for
auxiliary power at the same time. However, the size of
the loads you can power is reduced when you weld.
See Table B.4 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 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.
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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.
RANGER 10-LX
B-15 B-15
OPERATION
TABLE B.4 - 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 3000 26 13
160 160 3500 30 15
120 120 5500 48 24
90 90 6500 56 28
65 65 7500 65 32.5
45 45 8500 74 37
CV Low 200 7000 60 30
40 9500 82 41
CV Medium Low 250 5500 48 24
60 8500 74 37
CV Medium High 250 3500 30 15
80 7000 60 30
CV High 250 1500 13 6.5
100 6000 52 26
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RANGER 10-LX
B-16 B-16
OPERATION
TABLE B.5
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 10,000 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 10-LX
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