Home

Lincoln Electric IM511-D Portable Generator User Manual

1. oe lue dui Gall d Jg Mall oe Quad us Turn power off before servicing Desconectar el cable de alimentaci n de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entretien e Strom vor Wartungsarheiten abschalten Netzstrom v llig ffnen Maschine anhalten e N o opere com as tampas removidas Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e 4X7TTLA 9 UACEUD PRE EFBRAL FE DF I gt TK EU e Hs HD ER 44 phd NM ele Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e SER HGTBI BUSUB RE SERB emago Yel Gals D dall lin Jio Y e Aale Al dl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO it ie BR Chinese LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR
2. TROUBLESHOOTING ENGINE TROUBLE CAUSE WHAT TO DO A Engine will not crank or is hard to 1 Battery will not hold a charge 1 Replace with known good one crank Faulty battery 2 No or insufficient charging current 2 Check connection of lead from B Engine will not start or shuts down C Engine does not develop full power D Battery does not stay charged Loose battery cable connection s Lead 216A from solenoid to start switch broken Spark plugs fouled Low oil pressure Out of fuel Fault in fuel system 216 lead from start switch to P C board broke Onan engine Oil pressure switch faulty Generator terminal block connection faulty Faulty Board Onan engine Fuel filter clogged 2 Air filter clogged Faulty battery 2 Faulty charging system Loose or broken lead in charging circuit 24 voltage regulator on engine to charging ammeter and battery lead 208 and 209 Check and tighten connection at battery at starter at engine foot or at frame Repair Replace spark plugs Check oil level and add oil as req d Add fuel to tank Repair Repair Replace Repair Check leads 208 224A 224B 212 Replace Replace 2 Replace Replace with a new battery 2 Refer to Engine Operators Manual for charging system service Refer to wiring diagram and check related leads
3. 608 YOLOVINOO GION310S YALYVIS HOLIMS 39085399 110 in imd al NOLLO3NNOO 312018 7IVNIWH3L 3NION3 WvHOVIG OV 4 OV NOLLVNIAY T 183UV3N 9NIH 9118 AILISOd SONIH 418 YOLVNHALTV T33HMA 14 aiwenon NONI INON NOILINOI 122 91315 80108 4s I S310H N33A 138 8 107 19 008 BER H 340100 dra 115 EY PAu TA STWNINGSL 0980100 Haat 88 V Jug HAMO18 MHS NORD 3TOV1d303H TIONIS OND EN 10 SI SIUL 310 WOH4 SIN3NOdWOO 1NOH4J 38 2919 STOSWAS 1VOIHL9373 SALON 1ON3HdWY HOLOVLNOD 6 1 asooo 89 408 allto y L o inoo vano fox g 089 916 Ox amp os D 09 40 j o3 Ole Ones 777 NOLINE 1915 15 NOILISOd ANNE NI NMOHS ES V60c EN 802 NOILISOd SAM NI NMOHS NOLLO3NNOO 5190718 3NION3 803 33s KH avez H GION310S anad H NOILISOd SLOW NI NMOHS 99 54 OLMS 31038 104 yo AWISOSHY SYOLIOWdVO AN 0001 KO LV HOLIMS 10OH1NOO
4. TWNINH3LONITHM WOSN3S 1N3uuno 63914 SHO103NNOO INIT NI a lOHINOO 310 3H H V OKI x WOLOVINOO vr oo 263 0 v viel OV 300919313 104110 HOLIMS ALHVT10d 3004193713 15 SNUNL 09901 20072 NOISH3A WSO 6 H39NVH 30 RANGER 9 LN 25 ACROSS THE ARC CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK ean kill MOVING PARTS injure Do not operate with panels open e Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment 14 PIN 6 PIN AMPHENOL AMPHENOL OPTIONAL K444 1 REMOTE CONTROL G LN 25 WIRE FEEDER TO WORK ELECTRODE WORK CLIP LEAD TO WORK hm ELECTRODE CABLE N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION N D WELDING TERMINALS SWITCH MUST BE PLACED IN ALWAYS ON POSITION TO WORK 12 16 93 M
5. Liners Electronic Low Idle Ignition 2200 RPM Ranger 9 20 HP 38 1 cu in Kohler Command 3600 RPM 624 cc 9 Gal 34 L CH20S Fuel Lubricating Oil 2 0 Qts 1 9 L OPTIONAL FEATURES A B C D E F K768 2 Two Wheel Undercarriage For in plant and yard towing For highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc Two 4 80 x 12 four ply tubeless tires Bed plate mounting Has stand for tow bar and grips for hand pulling Overall width 43 06 1 09 m K886 1 Canvas Cover To protect the Ranger 9 when not in use Made from attractive red canvas material that is flame retardant mildew resistant and water repellent K894 1 Spark Arrester Kit Includes a heavy gauge steel approved spark arrester and clamp for easy mounting to muffler exhaust pipe K896 1 GFCI Receptacle Kit Includes two UL approved 115 Volt ground fault circuit interrupter duplex type receptacles with covers and installation instructions Replaces the two factory installed 115 Volt duplex receptacles Each recepta cle of each GFCI duplex is rated at 15 Amps but the maximum total current from each GFCI duplex is limited to 20 amps K930 1 TIG Module Provides high frequency and shielding gas control for AC and DC GTAW TIG welding applications Compact case is designed for easy carrying complete with handle High frequency bypass is built
6. g Set the IDLER switch to the HIGH idle position Connection of the LN 742 to the Ranger 9 a Shut off the welder b Connect per the instructions on the appropriate connection diagram in rear of this manual c Set the output control toggle switch to CONTROL AT WELDER when not using remote control When the LN 742 has a K589 1 remote control attached set output control to REMOTE d Set POLARITY switch to either WIRE FEED DC or WIRE FEED DC e Set RANGE switch to either HIGH MED or LOW as required by the process f Set the WELDING TERMINAL control switch to REMOTELY CONTROLLED position g Set IDLER switch to the AUTO position 14 Connection of the Magnum Spool Gun and SG Control Module to the Ranger 9 a Shut off the Welder b Connect per the instructions on the appropriate connection diagram in the rear of this manual c Set the output control toggle switch to CONTROL AT WELDER when not using remote control d Set the POLARITY switch to WIRE FEED e Set the RANGE switch to either HIGH MED or LOW as required by the process f Set the WELDING TERMINALS Control switch to the REMOTELY CONTROLLED position 9 Set the IDLER switch to the HIGH idle position Remote Output Control The Ranger 9 has a 6 pin and a 14 pin Amphenol connector These connectors are located above the output studs The 6 pin
7. ALIAVO 8722 ALIAVO 310N Qv31 SZ b ALIAVO 88 7 LH ALAYO 21 avi CA ONILVOOT e ALIAVO 802 NOLLO3NNOO 490718 TWNIANYAL 3NION3 WVHOVIQ Ov d OV uo1vin93d BOVLIOA NOLLVNIAV T 80104 1S3UV3N 9NIH 918 3AI1ISOd SONIY HOIVNU3LTV NOILINOI 7109 NOITINOI 5 008 uvau SIN3NOdWOO LNOHA 3575 TIW S310H N33M138 aNnou9 i gs SWNIWU3L 0340109 uas W I 0860100 LEDUS 3191193939 3IONIS 05 6 1 42913 H3d STOSWAS 1VOlIH103 3 SALON i 8 0 9 d ar 0 3 lt HOLOVINOO zr oO i EE ale 9914 20 0 3 i TOHLNOO 310W3H i23 HOM Td SST 2804 va 9 1 gt HOLOvINOO d Sth VIET O MN Ob avez 212 0744 GION310S WSL
8. SRM OBO X A OHBRBEE lt K MA CUCRITEOSSXSUEIL HS TFS ET EE A RIM 3 0 YANE HAY Set SHSM HECH oe ENEE Saal d aui y Jud al ply Gail Ca L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
9. ema NN NNOHS 65 109 XVW 1 AVLSOSHY GE 000 1 NOILISOd NI NMOHS HOLIMS 1081NOO WNINYAL SNIGTSM 3LIWWY ENV 94 D ein AR YOLOWSY 019 SHOLIINNOD NI eve Kan HOSN3S 1 i 3101 OLM OHO KEN urona L 30001938 8 6 60 3809 NOISH3A VSO NYNO 6 H39NVH 29 epoo 1ueuudinbe BAIN 10 9 si sjeued y jo euo uo y paysed s epoo 10 siu Aq 104 e1enooe eq jou y 688011 N86 06 6 1804918 ANO ALAYO 122 SY3EWNN ALIAVO 310N HACTAM ONILVOOT eit LLZ YOLWINDSY
10. 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 Also see item 1 b 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 stand
11. state and local laws 1 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways PRE OPERATION SERVICE A CAUTION READ the engine operating and maintenance instruc tions supplied with this machine A WARNING GASOLINE fuel can cause fire or explosion 4 e Stop engine while fueling Do not smoke when fueling Do not overfill tank Keep sparks and flame away from tank Wipe up spilled fuel and allow fumes to clear before starting engine H Oil 7 The Ranger 9 is shipped with the engine crankcase filled with SAE 10W 30 oil Check the oil level before starting the engine It if is not up to the full mark the dipstick add oil as required Make certain that the oil filter cap is tightened securely Refer to the engine Operators Manual for specific oil recommendations LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Onan P218 1 8 Quarts 1 7 Liters Kohler CH20S 2 0 Quarts 1 9 Liters Fuel Fill the fuel tank with clean fresh lead free gasoline The capacity is approximately 9 gallons 34 liters Observe the fuel gauge while filling to prevent overfill ing 12 Battery Connection This welder is shipped with the negative battery cable disconnected Make sure that the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal before attempting to operat
12. 521 MAINTENANCE Safety Precautions A WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or AR vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off e Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Engine Adjustments A WARNING OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at spee
13. DC 25 volts Constant 250 amps DC 25 volts Voltage Maximum Open Circuit Voltage at 3700 RPM is 80 volts Duty Cycle 100 for both welding and auxiliary power Ranger 9 Approximate Fuel Consumption ONAN P218 KOHLER PERFORMER CH20S Low Idle No Load A gallons hour 4 gallons hour 2200 RPM 1 5 liters hour 1 5 liters hour 1 0 gallons hour 3 9 liters hour 8 gallons hour 3 1 liters hour High Idle No Load 3700 RPM 1 5 gallons hour 5 7 liters hour 1 6 gallons hour 6 2 liters hour AC CC Weld Output 250 Amps 25 Volts 1 7 gallons hour 6 5 liters hour 1 8 gallons hour 7 0 liters hour 1 7 gallons hour 1 6 gallons hour 6 5 liters hour 6 2 liters hour Auxiliary Power 1 8 gallons hour 1 7 gallons hour 9000 kVA 7 0 liters hour 6 5 liters hour DC CC Weld Output 250 Amps 25 Volts DC CV Weld Output 250 Amps 25 Volts 15 Welder Controls Function and Operation Explanation of Symbols that Appear on this Equipment Low Idle High Idle ENGINE ON OFF Switch When placed in the ON position this switch energizes the engine ignition circuit When placed in the OFF position the ignition circuit is de energized to shut down the engine ENGINE START Push Button Switch Energizes engine starter motor POLARITY Switch Three STICK TIG constant d polarity settings DC DC and Two wir
14. FREQ KIT WHILE REMOTELY CONTROLLING THE OUTPUT CURRENT OF A LINCOLN POWER SOURCE THE POWER SOURCE MUST BE EQUIPPED WITH A ennemi Bei 6 PIN REMOTE CONTROL AMPHENOL CONNECTOR SEE THE HI FREQ KIT AND POWER SOURCE INSTRUC TION MANUAL FOR INFORMATION ON PROPER SWITCH AND CONTROL SETTINGS K799 HI FREQ KIT SEE INSTRUCTIONS INCLUDED WITH HI FREQ KIT FOR CONNECTION INFORMATION 820909 34 RANGER 9 AND 10LX 691 10 K488 K487 SPOOL GUN CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK can kill MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment 115 RECEPTACLE K488 SG CONTROL MODULE RANGER K487 25 SPOOL GUN K691 10 RECEPTACLE COUP 6 PIN REMOTE RECEPTACLE INPUT CABLE TO WORK ELECTRODE ELECTRODE CABLE TO WORK TO CONTROL MODULE CAUTION BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE LINCOLN CONTACT CLOSURE POSITION BEFORE ATTEMPTING TO OPERATE CONTROL MODULE INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND OR POWER SOURCE ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN
15. connector is intended to be used with the optional K857 Remote Output Control or in the case of TIG welding applications with the Foot or Hand Amptrol The 14 pin connector is used to connect a wire feeder control cable If the wire feeder has a built in power source output control do not connect a remote output control to the 6 pin connector When remote output control is used the output control toggle switch is to be set at CONTROL REMOTE High Frequency Generator for TIG welding applications The K930 1 TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW TIG welding See IM528 supplied with the TIG Module for installation instructions Note The TIG Module does not require the use of a high frequency bypass capacitor If any other high frequency accessory is used with the Ranger 9 a bypass capacitor Order Kit T12246 must be installed in the Ranger 9 OPERATING INSTRUCTIONS Additional Safety Precautions Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read carefully the Safety Precautions page in the Instruction Manual before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual Welder Operation Welder Output RANGER9 9 Constant 250 amps ee 25 volts Current 250 amps
16. gun trigger Ranger 9 LN 7 contactor closes Welding starts immediately 18 Auxiliary Power The Ranger 9 can provide up to 9 000 watts of 115 230 volts AC single phase 60HZ power for contin uous use The front of the machine includes three receptacles for connecting AC power plugs The K1420 1 has one 50 amp 115 230 volt NEMA 14 receptacle and two 20 amp 115 volt NEMA 5 20R receptacles The K1420 2 CSA machine has one 50 amp 115 230 volt NEMA 14 50R receptacle and two 15 amp 115 volt NEMA 5 15R receptacles Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the desired operating mode Set the CONTROL to 10 Voltage is now correct at the receptalces for auxiliary power 115 230 Volt Dual Voltage Receptacle The 115 230 volt receptacle can supply up to 40 amps of 230 volt power to a two wire circuit up to 40 amps of 115 volt power from each side of a three wire circuit up to 80 amps total Do not connect the 115 volt circuits in parallel Current sensing for the automatic idle feature is only in the leg of the three wire circuit as shown below Current Sensing for Automatic Idle Receptacle viewed from front of machine 115V Duplex Receptacles The 115V auxiliary power receptacles should only be used with three wire grounding type plugs or approved double insulated tools with two wire plugs Maximum Current D
17. have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 LINCOLN 5 CYLINDER may explode DO ae Es 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 Always keep cylinders in an upright position se
18. in The K939 1 Docking Kit is available for mounting the TIG Module on top of the Ranger 9 The K936 1 control cable is required K933 1 Four Wheel Undercarriage Allows movement of the Ranger 9 by hand without lifting Easily assembles to the Ranger 9 It includes two rugged hard molded wheels and two durable pneumatic tires The spring loaded handle provides convenient comfortable steering The k934 1 Bracket is available for mounting a gas cylinder on the under carriage G H J K L M K934 1 Bracket for Mounting a Gas Cylinder to a K933 1 Undercarriage Easily mounts on the back of the K933 1 Four Wheel Undercarriage to carry a welding gas cylinder K889 2 Two Wheel Undercarriage For moving by hand Two 4 00 x 8 industrial tires Overall width 29 74m K857 Remote Control Consists of a control box with 25 7 5 m of four conductor cable Permits remote adjustment of output voltage K893 1 Caster for Two Wheel Undercarriage Mounts to the front of the K889 2 Two Wheel Undercarriage to allow easy movement on smooth surfaces Includes a 6 diameter hard rubber wheel with a convenient toe on toe off locking brake K702 Accessory Kit Accessory Set includes 35 ft 2 AWG electrode cable 30 ft 2 AWG work cable headshield with number 12 filter work clamp and Cooltong 300 electrode holder Cables are rated at 250 Amps 40 duty cycle K802 R Power Plug Kit Provides four 115 Volt plugs
19. in place and installing the cover on the opposite side Operating the Ranger 9 without the cover in place will result in a higher noise level and no increase in machine output 13 Connection of Lincoln Electric Wire Feeders A WARNING Shut off welder before making any electrical connections Connection of K428 or K446 LN 25 with K624 1 42 volt Remote Output Control Module to the Ranger 9 Requires K626 xx Control Cable Provides cold electrode until gun trigger is pressed and also provides voltage control at the feeder The K446 LN 25 includes a gas solenoid See the appropriate connection diagram in rear of this manual a Shut off the welder b Connect the electrode cable from the LN 25 to the ELECTRODE stud of the welder Connect the work cable to the TO WORK stud of the welder c Connect the control cable from the LN 25 to the 14 pin amphenol on the Ranger 9 d Attach the single lead from the front of the LN 25 to the work using the spring clip on the end of the lead This is a control lead to supply the current to the wire feeder motor it does not carry welding current e Set the POLARITY switch to either WIRE FEED DC or WIRE FEED DC as required by the electrode being used f Set the RANGE switch to either HIGH MED or LOW as required by the process g Set WELDING TERMINALS Control switch to the REMOTELY CONTROLLED position h Set the IDLER switc
20. remote voltage and wire speed control or K857 Remote Voltage Control Kit connects to the Ranger 9 for voltage control at the feeder LN 7 K521 or LN 7 GMA K440 requires K584 xx Input Cable Assembly Provides cold electrode until gun trigger is pressed K440 LN 7 GMA included gas solenoid K8567 Remote Voltage Control Kit is required for voltage control at the feeder Ranger 9 must be operated at HIGH idle Magnum Gun is required for gas shielded welding Innershield Gun is required for gas less welding INSTALLATION INSTRUCTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 9 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing N Keep away from moving parts See additional warning information at front of this operator s manual Machine Grounding Because this portable engine driven welder or generator creates its own power it is not necessary
21. to connect it s frame to an earth ground unless the machine is connected to premises wiring your home shop etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must a be grounded to the frame of the welder using a grounded type plug or b be double insulated When this welder is mounted on a truck or trailer it s frame must be securely connected to the metal frame of the vehicle Where this engine driven welder is connected to premises wiring such as that in your home or shop frame must be connected to the system earth ground See further connection instructions in the section entitled Standby Power Connections in this manual as well as the article on grounding in the latest U S National Electrical Code and the local code 11 In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder Spark Arrester Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they
22. welder output contactor With the switch in the ALWAYS ONT position the output contactor is closed at LOW and HIGH idle With the switch in the REMOTELY CONTROLLED position the contactor is open at LOW idle and HIGH idle until a control cable is attached to the welder amphenol connector from a wire feeder Under this condition contactor closes when the wire feeder trigger is depressed and opens when the trigger is released IDLER Switch The idler switch has two positions HIGH and AUTO When in HIGH continuously at high idle position the engine will run When in AUTO idle position the idler operates as follows a Welding Low idle and in the WELDING TERMINALS ALWAYS ON mode Stick Welding only When the electrode touches work the welding arc is initiated and the engine accelerates to full speed Low idle and in the WELDING TERMINALS REMOTELY CONTROLLED mode Wire Welding Only Pressing the gun trigger closes the Ranger 9 output contactor and causes the engine to accelerate to full speed After the gun trigger is released and or welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds 16 b Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will ac
23. 0 OUTPUT AMPS DC WIRE FEED CV OUTPUT OUTPUT VOLTS DC 100 150 200 250 300 350 400 OUTPUT AMPS 0 50 SPECIFICATIONS Machine Product Ordering Description Rated DC Output Auxiliary Power for AC Power Dimensions Name Information Amps Volts Duty Cycle Wire Feeders amp Weight Ranger 9 K1420 1 9 000 Watts i Green 250 Amp AC Constant Current 42V 60 Hz 8 Amps 30 3 x 19 2 x 42 3 in NOM AC DC 250A 25V 10096 7 770 x 488 x 1075 mm CSA Meets Multi Process 115V 60 Hz 8 Amps Arc Welder DC Constant Current 80 Amps Canadian 1009 115V 598 lbs 272 kg Standards 250A 25V 100 wit DC Constant Voltage 40 Amps 9 000 Watts AC 250A 25V 100 230V Auxiliary Ranger 9 K1421 1 Power Max OCV 3700 RPM 30 3 x 19 2 x 42 3 in Kohler CSA Meets SC Canadian 770 x 488 x 1075 mm Standards 591 Ibs 269 kg Based on a 10 min period When welding available AC auxiliary power will be reduced 115V will operate either 60Hz or 50 60Hz power tools lights etc Engine Product Description Horsepower Operating Displacement Capacities Name Speeds Ranger 9 2 Cylinder Full Load 47 7 cu in 12V Battery 430 Fuel Onan P218 4 Oycle 18 HP 3500 RPM 782 cc Cold Cranking 9 Gal 34 L Air Cooled 3600 RPM Amps Toggle Start Gasoline Engine High Idle Switch Charging Lubricating Oil Aluminum Alloy 3700 RPM Ammeter Manual 1 8 Qts 1 7 L Block with Cast Iron Choke
24. 17090 RANGER 9 K867 K775 LN 7 CONNECTION DIAGRAM WARNING e 1 MOVING PARTS can injure e Do not operate with panels open Keep guards in place e Disconnect NEGATIVE BATTERY LEAD away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment LN 7 WIRE FEEDER 32 14 PIN 2 2 AMPHENOL 4 TO WORK ELECTRODE 21 867 UNIVERSAL 291 OR K404 ADAPTER PLUG x GND INPUT CABLE GREEN ELECTRODE CABLE 75 TO WIRE FEED UNIT 76 Q TO WORK 77 K775 OPTIONAL CAUTION N E REMOTE CONTROL ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE Aal LINKAGE WiL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY B DAMAGED THE ENGINE GOVERNOR SETTI NG IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIEICATIONS LISTED Ne THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION N D INSULATE EACH UNUSED LEAD INDIVID
25. DERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRc5cuc 9 fsPBHEICTABSESUCFEU in ER e zc EUR Ea fE SH7IAE S XACE E AAS AH FAAA H4 Assis
26. GINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N C INSULATE EACH UNUSED LEAD INDIVIDUALLY N D SPLICE LEADS AND INSULATE PLACE IDLER SWITCH IN HIGH IDLE POSITION 12 16 93 M17094 RANGER 9 LN 742 CONNECTION DIAGRAM ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 742 INPUT 14 PIN CABLE PLUG AMPHENOL M K592 CONTROL CABLE TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT CAUTION TO WORK ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING T
27. HE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION N D PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 12 16 93 M17100 33 RANGER 9 LN 25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM WARNING e Mite es ma 3 rli Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 25 INPUT 14 PIN CABLE PLUG AMPHENOL K626 XX INPUT CABLE ASSEMBLY TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT CAUTION TO WORK ANY INCREASE OF THE HIGH IDLE ENG
28. INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N C IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION N D PLACE IDLER SWITCH IN HIGH IDLE POSITION CRM23615 M17902 35 MAR 95 S1410H ONILNNOW UU ch 0006 T 08 8 NI TIO ALIAVHO 40 HAIN30 8 30 b 6 LNIHd NOISNANIQ Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese it ie BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v t
29. INE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION N D PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 12 16 93 M17214 K915 1 AMPTROL ADAPTER FOR K799 HI FREQ KITS TURN THE ENGINE OR POWER SWITCH POWER SOURCE OF THE WELDING POWER SOURCE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRIC SHOCK PLUGS TO WELDING POWER SOURCE can kill Po Po Po K963 HAND Katsa AMPTROL AMPTROL i ADAPTER 6 SOCKET BYPASS RECEPTACLE CAPACITOR KIT K870 FOOT AMPTROL ELECTRODE LEAD HI FREQ WORK SENSE LEAD INPUT POWER THIS ADAPTER ALLOWS AMPTROL TO OPERATE K799 HI
30. ONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTI NG IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET DESIRED POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION N C INSULATE EACH UNUSED LEAD INDIVIDUALLY 2 0 TO N D FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT USE ISOLATION TO WIRE RELAY TO CLOSE LEADS 2 amp 4 K867 T 4 0 FEEDER 4 N E REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW 12 16 93 M17093 _ 32 RANGER 9 K867 LN 8 CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill ma MOVING 5 can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing 4 Only qualified personnel should install use Do not touch electrically live parts or service this equipment SPARE o 82 LN 8 81 NC WIRE 42 5 FEEDER 41 o O 31 32 f 14 PIN AMPHENOL 4 TO WORK ELECTRODE K196 INPUT CABLE K867 UNIVERSAL ADAPTER PLUG ELECTRODE CABLE 75 A TO WIRE FEED UNIT 76 B TO WORK 77 7 CAUTION WE ANY INCREASE OF THE HIGH IDLE EN
31. RANGER 9 Multi Process Gasoline Engine Driven Welder and Power Generator For use with machines having Code Number 10378 10379 10539 10540 and 10550 RETURN TO MAIN MENU 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT most importantly think before you act and be careful This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and availability of optional Date of Purchase features may have Serial Number changed Code Number Model Where Purchased E OPERATOR S MANUAL II ee 22 97 9 2000 Lincoln Global nc World s Leader in Welding and Cutting Products e 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 i SAFETY i WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 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 engine exhaust from this product contains c
32. TE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION N D PLACE IDLER SWITCH IN HIGH IDLE POSITION 12 16 93 M17092 RANGER 9 TO K867 ADAPTER CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open e Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment 81 o 82 gt NOT USED ON RANGER POWER SOURCES SPARE o K867 UNIVERSAL 2 O CONNECT TOGETHER FOR ADAPTER PLUG 9 WELDING OUTPUT 2 42 VAC 42 o s one 115 VAC 32 GND o POWER SOURCE FRAME CONNECTION 14 PIN ND WORK ELECTRODE 21 WIRE FEEDER VOLTMETER CONNECTION ELECTRODE CABLE CONNECTS TO WORK TERMINAL OF POWER SOURCE TO WIRE FEED UNIT 77 0 10 K 76 o gt REMOTE OUTPUT CONTROL TO WORK 75 o MIN Q CAUTION _ ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE ec LINKAGE WILL CAUSE AN INCREASE IN THE AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER C
33. UALLY N E SPLICE LEADS AND INSULATE N F PLACE IDLER SWITCH IN HIGH IDLE POSITION 12 16 93 M17091 281 RANGER 9 LN 7 CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill FH MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 7 INPUT 14 PIN CABLE PLUG AMPHENOL cL OPTIONAL K857 REMOTE CONTROL AMPHENOL Te K584 XX INPUT CABLE ASSEMBLY 6PIN ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA
34. a boite de fusibles Garder tous les couvercles et dispositifs de s ret leurplace Mar 93 J A for selecting a QUALITY product by Lincoln Electric We want you ank You to take pride in operating this Lincoln Electric Company product see as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the inf
35. aissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut le total de la tension a vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se soudage Utiliser des lunettes avec crans lateraux dan
36. aker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known 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 4 2 Never coil the electrode lead around your body 2 4 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 95 LINCOLN 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
37. ards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 3 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Al
38. are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations the K894 1 arrester must be installed and properly maintained A CAUTION Use of an incorrect arrester may lead to engine damage or performance loss Undercarriages The recommended undercarriage for use with this equipment for in plant and yard towing by a vehicle V is Lincoln s K768 2 If the user adapts a non Lincoln undercarriage he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways 1 Design capacity of undercarriage vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework Proper placement of the equipment on the undercarriage to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use travel speed rough ness of surface on which the trailer will be operated environmental conditions like maintenance 5 Conformance with federal
39. atch starting when engine goes to high idle F Contactor does not pull in when using a wire feeder with a control cable plugged into amphenol G Contactor does not drop out CAUSE WHAT TO DO 1 Welding terminal switch in wrong position Faulty wiring in contactor circuit Faulty remote switch S6 Faulty contactor Faulty Board PCB1 WELDING TERMINALS switch in wrong position Faulty wiring in contactor circuit Faulty amphenol or bypass P C Board PCB2 Faulty contactor Faulty P C Board PCB1 Faulty control cable from wire feeder or amphenol Faulty wire feeder Faulty wiring Faulty amphenol or bypass P C Board PCB2 Faulty contactor Faulty P C Board PCB1 27 Place switch S6 in Always On position Check for broken leads 224C 232A and 224 Check switch and leads 247 and 250 Replace contactor with known good one Replace Board with known good one Place switch S6 in REMOTELY CONTROLLED position Check for broken leads 224 224 232A Refer to wiring diagram and check related leads 2 and 4 Replace contactor with known good one Replace P C Board with known good one Replace Repair or replace Check that lead 232 is not grounded Look for shorts to ground Repair or replace Replace with known good one Replace with known good
40. celerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle Starting Shutdown Instructions Starting the Engine A WARNING A Do not touch electrically live parts of electrode with skin or wet clothing Ke DE Keep flammable material away Insulate yourself from work and ground Wear eye ear and body protection Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone E X Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owners Manual Remove all loads connected to the AC power recepta cles To start the engine set the Idler Control switch in the Automatic 3 14 position Use the choke control as follows Onan Engine If the engine is cold pull the choke control out Do not use the choke if the engine is warm or hot Kohler Engine Always pull the choke control out when starting the engine cold warm or hot Place the Engine switch in the ON position Push the START button and crank the engine until it starts Release the button as soon as the engine starts Do not push the START button while the engine is running because this will cause damage to the ring gear and or starter motor After the engine has started slowly return the choke control to the full in position choke open After running a
41. control cable Faulty wire feeder Faulty P C Board Wire feeder circuit breaker open or faulty Broken 31 32 or 42 lead at amphenol No 115V or 42V output from stator Faulty wiring in control cable Faulty wire feeder 26 Refer to wiring diagram and check related leads 7 amp 9 200 201 and 219 Lift brushes and check rotor continuity between slip rings Should be approx 7 3Q Disconnect lead 7 at D2 and check for continuity between leads 7 and 9 Replace with known good one Refer to wiring diagram and check related leads and contactor Replace Board with known good one Place switch in Output Control at Welder Check and replace switch if faulty Check and replace potentiometer if faulty Check for broken leads 75 76 and 77 from Board and 75A 76D and 77D from potentiometer to remote switch Replace Board with known good one Place switch in Remote position Repair Repair Repair Replace wire feeder with known good one Replace P C Board with known good one Reset or replace Repair Check continuity on 31 32 and 42 at stator Check buildup If O K stator may be faulty Replace Repair or replace cable Replace Board with known good one OUTPUT SYSTEM TROUBLE E Contactor does not pull in when scr
42. cted to the auxiliary power receptacles Output Selector Setting Welding Output Permissible Power Watts Unity Power Standby Power Connections The Ranger 9 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The Ranger 9 can be permanently installed as a standby power unit for 230 volt 3 wire 40 ampere service Connections must be made by a licensed electrician who can determine how the 115 230 volt power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications refer also to the Premises Wiring diagram shown IMPORTANT When the Ranger 9 is connected to a 230 volt 3 wire line the unit should be operated with the idler switch in the HIGH idle position to avoid load sensing problems If the machine is set for automatic idle the 230 volt circuit will sense loads and cause the engine to accelerate to high idle However since only one line of the circuit senses current 115 volt power drawn from only one line to neutral may result in the engine not going to high idle 1 Install the double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service overcurrent protection Permissible Permissible Aux
43. curely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parr
44. ds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop Routine Maintenance 1 At the end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated 2 OIL Maintenance schedule for changing the oil and oil filter after break in Kohler Onan CH20S P218 Oil Filter 200 hr 100 hr The above schedule is for normal operating condi tions More frequent oil changes are required with dusty high temperature and other severe operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information CAUTION Engine life will be reduced if the oil and oil filter are not changed according to the manufacturer s recommendation 3 Air Cleaner With normal operating conditions the maintenance schedule for cleaning and re oiling the foam pre filter is every 25 hours and replace ment of the air cleaner filter every 100 hours More frequent servicing is required with dusty operating conditions Refer to maintenance section of the Engine Owner s Manual for more information 4 Refer to the maintenance section of the Engine Owner s Manual for the maintenance schedule for spark plug servicing cooling system servicing and fuel filter replacement CAUTION Make certain
45. e arc will be initiated and the engine will accelerate to full Some recommended solid wires for MIG welding are speed To stop welding release the gun trigger and 030 0 8mm 035 0 9mm and 045 1 1mm L 50 pull the gun away from the work With the IDLER and L 56 Request Lincoln publication GS 100 for SWITCH in the AUTO position the engine will go additional information back to low idle in approximately 12 seconds when no auxiliary power is drawn NOTE The LN 7 and the LN 8 must be operated in the HIGH idle position SUMMARY OF WELDING PROCESS CONTROL OUTPUT WELDING ELECTRODE CABLE CONTROL TERMINALS WHEN NOT PROCESS USED SWITCH SWITCH WELDING TO START WELDING Touch electrode to work STICK CC AT ALWAYS HOT Welding starts immediately WELDER ON and engine goes to high idle TIG CC Press Amptrol Welding K930 1 K936 1 REMOTE REMOTE COLD starts immediately WITH AMPTROL WIRE FEED CV Press gun trigger Ranger 9 LN 25 WITH 42V REMOTE REMOTE COLD contactor closes Welding REMOTE CON starts immediately and engine TROL KIT goes to high idle WIRE FEED CV Press gun trigger LN 25 LN 25 WITH AT ALWAYS COLD contactor closes Welding INTERNAL WELDER ON starts immediately and engine CONTACTOR goes to high idle WIRE FEED CV Press gun trigger Ranger 9 LN 742 REMOTE REMOTE COLD contactor closes Welding starts immediately and engine goes to high idle WIRE FEED CV REMOTE REMOTE COLD Press
46. e feed constant voltage settings DC and DC NOTE The setting of this switch must match the color band setting of the Range Switch both switches must be set for the same welding process A CAUTION Never change the POLARITY switch setting while welding This will damage the switch 45 90 120 160 200 250 gt RANGE Switch STICK TIG constant current range settings WIRE FEED constant voltage range settings LOW MED HIGH CAUTION Never change the RANGE switch setting while welding This will damage the switch CONTROL Provides a fine welding current adjustment within the Range Switch settings in the STICK TIG mode and welding voltage control with the Range switch set in the WIRE FEED mode CONTROL AT WELDER REMOTE CONTROL Switch The toggle switch on the control panel labeled CONTROL AT WELDER and REMOTE CONTROL gives the operator the option of controlling the output at the welder control panel or at a remote station Remote connections are made at the 6 pin or 14 pin amphenol connector For remote control the toggle switch is set in the REMOTE CONTROL position For control at the welder control panel the toggle switch is set in the CONTROL AT WELDER position WELDING TERMINALS Switch The toggle switch labeled WELDING TERMINALS ALWAYS ON WELDING TERMINALS REMOTELY CONTROLLED is used to control the operation of the
47. e the machine If the battery is discharged and does not have enough power to start the engine see the Maintenance Battery section of this manual for battery charging instructions Welding Output Cables With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodically and tightened if necessary Listed below are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 250 Amps 100 Duty Cycle 250 Amps 40 Duty Cycle 0 50 Ft 2 AWG 1 AWG 2 AWG 1 AWG 50 100 Ft 100 150 Ft 1 AWG 1 AWG 150 200 Ft 1 AWG 1 AWG 200 250 Ft 1 0 AWG 1 0 AWG Location Ventilation The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid heated air coming out of the back of the welder recirculating back to the cooling air inlets below the exhaust Also locate the welder so that the engine exhaust fumes are properly vented to an outside area WARNING Damage to fuel tank may cause fire or explosion Do NOT drill holes in the Ranger 9 base or weld to the Ranger 9 base Angle of Operation Engines are designed to run in the level condition wh
48. ements mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Beriihren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas electrodos com a pele ou roupa molhada Isole se da e terra RABHICE ELE et EE LATE OMLMPT APSSAPRBS NTUSHIELTFSU e SR TERRE ER ER 945 MIER HIER ecran SSE RE HE PSE uu e axe MSA AMI W o puny ol all Quali eani ag ENT gh la plat Jai UA dan Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guardados SOOM LU THEW ECA ein OSTER eis ap d s s ALD al gl pis Wu AA uie Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HAUSHERMRELTT RRR HRSRSOREMNE ez 119 59 s ESSAI didi s due de Lily putes cl gal A d READ AND UN
49. especially 208 and 209 leads IDLER SYSTEM TROUBLE A Engine will not idle down to low speed B Engine will not go to high idle when attempting to weld Scratch Start 1 When using wire feeder with con trol cable plugged into amphenol connector or using amptrol when trigger is depressed C Engine will not go to high idle when using auxiliary power Idler switch in HIGH idle position 2 External load on welder or auxiliary power Mechanical problem in idler solenoid linkage Idler solenoid position out of adjust ment Faulty wiring in solenoid circuit Contactor circuit 2 or 4 closed or shorted Engine goes to high idle when contactor circuit closes Faulty idler solenoid Low voltage at 224D to ground stud Voltage should be 12 14V DC Faulty P C Board PCB1 Poor work lead connection to work WELDING TERMINALS switch in wrong position No open circuit voltage on output studs Faulty P C Board PCB1 WELDING TERMINALS switch in wrong position Faulty wiring No signal from current sensor Auxiliary power lead less than 100 watts Faulty idler P C Board 25 CAUSE WHAT TO DO Set switch to AUTO position Remove all external loads Repair Adjust solenoid as necessary Check for broken leads 224D 214 Refer to wiring diagram Check related leads and amphenol connecto
50. h to the AUTO position Connection of the K449 LN 25 to the Ranger 9 a Shut off the welder b Connect the electrode cable from the LN 25 to the ELECTRODE stud of the welder Connect the work cable to the TO WORK stud of the welder c Attach the single lead from the front of the LN 25 to work using the spring clip on the end of the lead This is a control lead to supply the current to the wire feeder motor it does not carry welding current d Set the POLARITY switch to either WIRE FEED DC or WIRE FEED DC as required by the electrode being used e Set the RANGE switch to either HIGH MED or LOW as required by the process f Set the WELDING TERMINAL Control switch to the ALWAYS position g Set the IDLER switch to the AUTO position Connection of the LN 7 or LN 8 to the Ranger 9 a Shut off the welder b Connect the LN 7 or LN 8 per the instructions on the appropriate connection diagram in the rear of this manual c Set the output control toggle switch to appropriate position CONTROL REMOTE for LN 8 and LN 7 with K857 attached CONTROL AT WELDER for LN 7 with no remote voltage control d Set POLARITY switch to either WIRE FEED DC or WIRE FEED DC Set the RANGE switch to either HIGH MED or LOW as required by the process the WELDING TERMINALS Control switch to the REMOTELY CONTROLLED position
51. he battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover skin careful when boosting charging or working near battery If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result to damage to the internal charger components When re connecting the cables connect the positive cable first and the negative cable last battery clamp When reinstalling connect the negative cable last Using a booster connect the positive lead to HARDWARE the battery first then connect the negative lead to the ground lead on the base Both English Metric fasteners are used in this welder To prevent ELECTRICAL DAMAGE when Installing a new battery b Using a booster a Engine Maintenance Parts __ ___ ONAN P218 KOHLER CH20S ONAN 122 0645 KOHLER 1205001 FRAM PH3614 FRAM PH3614 Air Filter ONAN 140 2628 01 KOHLER 4708303 Element FRAM CA140PL FRAM CA79 Air Filter ONAN 140 1496 KOHLER 2408302 Pre Cleaner Fuel Filter ONAN 149 2005 KOHLER 2505002 FRAM G1 FRAM G1 Spark Plugs ONAN 167 0263 CHAMPION RC12YC Resistor CHAMPION RS14YC 030 GAP Type 025 GAP Oil capacity increases from 2 0 Qts to 2 1 Qts when using this filter 23
52. hemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines PERFORMED ONLY BY QUALIFIED INDIVIDUALS AN FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 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 overr
53. ich is where the optimum performance is achieved The maximum angle of operation for the engine is 15 degrees from horizontal in any direction If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 10 gallons High Altitude Operation If the Ranger 9 will be consistently operated at altitudes above 5 000 feet a carburetor jet designed for high altitudes should be installed This will result in better fuel economy cleaner exhaust and longer spark plug life It will not give increased power which is decreased at higher altitudes Engine horsepower is reduced by 3 5 per 1000 feet for altitudes above 377 feet High altitude jet kits are available from the engine manufacturer Order Onan kit part number 146 0458 A CAUTION Do not operate a Ranger 9 with a high altitude jet installed at an altitude below 5 000 ft This will result in the engine running too lean and result in higher engine temperatures which can shorten engine life Muffler Relocation A WARNING Shut off welder and allow muffler to cool before touching muffler The Ranger 9 is shipped with the exhaust coming out on the left side of the machine The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover
54. ide the governor or idler by pushing on the throttle control rods while the engine is running M 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 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 pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society PO 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 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 23 ELECTRIC AND RS 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 EMF fields may interfere with some pacemakers and welders having a pacem
55. iliary Current in Auxiliary Current in Amperes 115V Amperes 230V Factor 250 200 160 120 90 45 CV LOW CV MEDIUM CV HIGH MAR 95 20 2 Take necessary steps to assure 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 each leg of the 230 volt auxiliary is 40 amperes Loading above 40 amps will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 3 Install a 50 amp 115 230 volt plug NEMA Type 14 50 to the Double Pole Circuit Breaker using No 8 4 connector cable of the desired length The 50 amp 115 230 volt plug is available in the optional plug kit 4 Plug this cable into the 50 amp 115 230 volt receptacle on the Ranger 9 case front CONNECTION OF RANGER 9 TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR 230 Volt POWER ias 60 2 E 3 Wire COMPANY Service METER NEUTRAL BUS DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE 40 AMP GROUND OVERCURRENT 230 VOLT PROTECTION DOUBLE POLE 50 AMP 115 230 CIRCUIT VOLT PLUG 230 VOLT BREAKER NEMA TYPE 14 50 a 50 AMP 115 230 VOLT N NOTE No 8 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS
56. o ze I Mhen VIE T O lt r lt LION3HdN Y GION3108 NOILISOd 300019313 109 1V1SO3H4 m 9 amis 5 000 L NOILISOd SAVM TV NI NMOHS HOLIMS 10H1NOO HOSN3S IND i wig T E ALI 419373 H SNUNL 62901 9 8460 3802 NVH5VIG 5NIHIM NYNO 6 u39NVH SALON 28 10 SI SIUL 310 Jequunu epoo 1ueuudinbe 10 juouwiyedeg 2011S elqiBelll si sjeued einsojoue y euo uo y episul paysed si epoo sejnomed 104 2utede siy Aq 10 jou y 672011 2
57. onal Safety Precautions nnne rens 15 Welder Operation Pc C 15 Welder Controls Functions and Operation 15 16 Engine Operation EE x C E 16 17 c T 17 18 Auxillary FOR 19 20 Standby Power Information and Connection to Premises Wiring Diagram 20 21 EE E 22 23 General Instructions is 22 Engine cle 22 flip EE 22 Ee 23 AO 23 Le EE 24 27 General Troubleshooting 2 2 24 Electronic Idler Troubleshooting Zug ccccceaenedissedicedesdansadassnsenceaiusd 25 Output System Troubleshooting enne 26 27 NET CASA T DILE 28 30 Connection T 31 35 Dimension EE 36 PS P230 Series GENERAL DESCRIPTION The Ranger 9 is a twin cylinder gasoline engine driven multi process arc welder and AC power generator It is built in a heavy gauge steel case for durability on the job site RECOMMENDED PROCESSES AND EQUIPMENT The Ranger 9 can be used for AC DC Stick welding CC DC Semiautomatic wire feed welding CV AC DC Tig welding CC and also offers a 9 000 Watt AC 115 230 Volt 60 Hertz power generator For AC DC Stick welding the range is 40 250 Amps There is a 100 du
58. one epoo BAIN 104 uewiuedeq 01 eldfBail si JI pased si epoo 10 urejBeip eut Aq Je 10 2 eq jou 872011 sjaued euo uo SUIYORW y episur juo 92u919j91 10 S SIUL 310 SIN3NOdWOO 38 0 TIY 22913 43d SIOSNAS 1VOIH10313 S310H TON3HdNY N33M138 SNL 0340109 bag NOILYNIAYT d HEN NOLLO3NNOO 52018 1 3NION3 NVHOVIQ Ov 8 OV 9 c ALIAVO Graz 913134 80104 a t 102 io 008 01V1N934 ALAYO 212 SY3GWAN ALIAVO ILON 4303M ME Sue 4 1 i amp euuvoot Ze a M HAS go i a ALIAVO a vrac 802 410 4 d HOLVNUSLIV i JINON YILIN no D ONG SINA 602 80 10 M agi 08 0 6 Vi i i 9911 044 i 911H0 lt 3 i TOHLNOO 310 3H HC O4 4 0 0 e gOIOVINOO vw jon
59. ormation must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS rye p ii iv Introductory Information EE General 7 Specifications EESE EEEE EEEE Eeen 7 8 Optional EE 9 Recommended Equipment wvccousccciccterievecedcnereeeanbecestnoncwinnanbeasanndendtdenaendsanedecesedendriecsunenceens 10 Installation 11 12 Machine Grounding 11 Spark EE 11 MI UN M rM 11 12 eil 12 ee 12 32 teer 12 Battery Perge 12 Welding Output E 12 Location Ventilation EE 12 OO TOO TEE 13 14 High Altitude Operation MT 13 Muffler Relocation eege ae 13 Connection of Wire Feeders kA 13 Connection of K428 or K446 with K624 1 Remote Output Module ssssessssreneee 13 Connection of K449 to the Ranger 9 13 Connection of LN 7 or LN 8 to the Ranger 9 14 Connection of the LN 742 to the Ranger 9 14 Connection of the Magnum Spool Gun and SG Control Module to the Ranger 9 14 Remote Output Etgen 14 High Frequency Generator for TIG welding applications 14 Operating Instructions e T ET 15 17 Additi
60. rated at 15 Amps each and one dual voltage full KVA plug rated at 115 230 Volts 50 amps K802 N Power Plug Kit Provides four 115 Volt plugs rated at 20 Amps each and one dual voltage full KVA plug rated at 115 230 Volts 50 Amps Not for use with K1420 2 CSA machine and machines with GFCI receptacles RECOMMENDED EQUIPMENT STICK K702 Accessory Kit which includes Electrode holder and cable Work clamp and cable Headshield K857 Remote Control Kit is optional for remote current control TIG Magnum TIG Torch Magnum Parts Kit and Argon gas K930 1 TIG Module K936 1 Control Cable Optional K939 1 TIG Module Docking Kit K963 Hand Amptrol K870 Foot Amptrol K814 Arc Start Switch 10 WIRE FEED LN 25 K428 or K446 with K624 1 42 Volt Remote Output Control Module Requires K626 xx Control Cable Provides cold electrode until gun trigger is pressed Voltage control is at the feeder K446 LN 25 includes gas solenoid LN 25 K449 Includes internal contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid K444 1 Remote Voltage Control Kit is required for voltage control at the feeder LN 742 K617 1 or K618 1 or LN 742H K617 2 or K618 2 requires K619 xx Input Cable Assembly Provides cold electrode until gun trigger is pressed Includes gas solenoid K589 1 Remote Control Kit connects to the LN 742 to provide
61. raw from 115V Duplex Receptacles No Welding K1420 2 CSA and K1421 1 CSA LOAD FROM 115V 230V DUAL VOLTAGE RECEPTACLE NEMA 5 20P plug required for 20 amp draw Maximum Current Draw from Optional 115V GFCI Duplex Receptacles No Weldin K1420 1 WITH GFCI S K1420 2 and K1421 1 WITH GFCI S LOAD FROM 115V 230V DUAL VOLTAGE RECEPTACLE Maximum current draw from each 115V GFCI Duplex is 20 amps Maximum current draw from each 115V GFCI Duplex is 15 amps Most 1 5 HP motors can be started if there is no load on the motor or other load connected to the machine since the full load current rating of a 1 5HP motor is approximately 20 amperes 10 amperes for 230 volt motors The motor may be run at full load when plugged into only one side of the duplex receptacle Larger motors through 2HP can be run provided the receptacle rating as previously stated is not exceeded This may necessitate 230V operation only It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are permitted by the following table The permissible currents shown assume that current is being drawn from either the 115 volt or 230 volt supply not both at the same time NOTE Voltage and permissible watts decrease as CONTROL is adjusted to settings less than 10 It is recommended that at settings less than 10 only incandescent lighting loads be conne
62. recommended Pure EWP Range Welding S Diameter Switch Settings Current 90 120 100 to 200 amps 45 90 45 to 140 amps 1 16 45 90 45 to 100 amps When AC TIG welding the actual maximum welding current is 40 to 80 amps higher than the current marked on the RANGE SWITCH dial This is a result of a lower effective reactance due to the natural rectifi cation that occurs with the AC TIG welding process Wire Feed Constant Voltage Welding The Ranger 9 can be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc welding 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 NS 3M can be used in limited applications Cable length and other condi tions can affect the ultimate results of this application Request Lincoln publication N 675 for additional infor mation Recommended Outershield electrodes are 045 When using a wire feeder with contactor control the 1 1mm 052 1 3mm and 1 16 1 6mm Outershield electrode will be cold until the gun trigger is pressed 71 and 1 16 1 16mm Outershield 70 Request To start the welding process position the gun and Lincoln publication GS 200 for additional information close the gun trigger The contactor will close th
63. recommended current for the electrode being used and make a trial weld A fine adjustment of the welding can be made by adjusting the output CONTROL or remote control For the best arc stability always use setting that results in the highest setting of the output or remote control and the lowest setting of the RANGE switch The Ranger 9 can be used with a broad range of AC and DC stick electrodes See Welding Tips 1 included with the Ranger 9 for electrodes within the rating of this unit and recommended welding currents of each See the following table for welding current ranges 17 CURRENT RANGES and DC STICK WELDING 5 to 10 ON CONTROL DIAL RANGE SETTING ACTUAL ON MACHINE CURRENT RANGE 90 25 to 45 AMPS 50 to 90 AMPS 60 to 120 AMPS 80 to 160 AMPS 100 to 200 AMPS 140 to 250 AMPS TIG Constant Current Welding 120 160 200 250 The Ranger 9 can be used in a wide variety of AC and DC Tungsten Inert Gas TIG welding applications for AC TIG welding up to 200 amps and DC TIG welding up to 250 amps The K930 1 TIG Module installed on a Ranger 9 provides high frequency and shielding gas control for AC and DC GTAW TIG welding processes The TIG Module allows full range output control Afterflow time is adjustable from 0 to 55 seconds When using the Ranger 9 for AC TIG welding of aluminum the TIG Module is to be set for CONTINU OUS HF The following settings and electrodes are
64. rs Replace with known good one Check wiring battery and battery charging circuits Replace Board with known good one Make sure work clamp is tightly connected to clean base metal Switch must be in ALWAYS position to scratch start Check leads 247 and 250 for breaks Check Switch S6 for faults Replace P C Board with known good one Switch must be in REMOTELY CONTROLLED position Refer to schematic Check wiring in 2 and 4 circuit Check for broken leads in idler sensing circuit 3 lead Idler may not respond with less than 100 watt load Set idler switch to high idle Replace Board with known good one OUTPUT SYSTEM TROUBLE A No welder or power output B Output control on welder not functioning C Output control or remote not functioning D Wire feeder does not work when connected to welder amphenol 1 Open lead in flashing or field circuit Faulty rotor Faulty stator field Faulty field rectifier D2 Output contactor does not pull in Faulty P C Board Output control switch in wrong position Output control switch defective Output control potentiometer defective Faulty wiring Faulty Board Output control switch in wrong position Leads 75 76 77 broken at PC Board or S4 Leads 75A 76A 77A broken at S4 or amphenol Remote control leads broken in
65. s les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provo quer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 prot ger contre les ch
66. t high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the Ranger 8 because the fuel tank is mounted below the engine Break in Period It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in period approxi mately 50 running hours IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN The engine manufacturers recommendation for the running time until the first oil change is as follows The oil filter is to be changed at the second oil change Refer to the Engine Owner s Manual for more informa tion Welding Processes Stick Constant Current Welding Connect welding cables to the TO WORK and ELECTRODE studs Start the engine Set the POLARITY switch to the desired polarity Set the output CONTROL or remote output control to max 10 and the RANGE switch to the setting that is closest to the
67. that the oil filler cap is securely tightened after checking or adding oil If the cap is not tight oil consumption can increase signifi cantly which may be evidenced by white smoke coming from the exhaust 5 Blow out the machine with low pressure air periodi cally In particularly dirty locations this may be required once per week 6 Output Ranger Selector and Polarity Switches Switch contacts should not be greased To keep contacts clean rotate the switch through its entire range frequently Good practice is to turn the han dle from maximum to minimum setting twice each morning before starting to weld 22 Battery Charging Use correct polarity Negative Ground a b Ww x E To prevent EXPLOSION when 2 Installing a new battery disconnect the negative cable from the old battery first and connect the negative cable to the new battery last Connecting a battery charger remove the battery from the welder by disconnecting the negative cable first then the positive cable and BATTERY ACID can burn eyes and Wear gloves and eye protection and be To prevent BATTERY DISCHARGE if you have an A WARNING ignition switch turn it off when engine is not GASES FROM BATTERY can explode running Keep sparks flame and cigarettes To prevent BATTERY BUCKLING tighten nuts on away battery clamp until snug 1 When replacing jumping or otherwise connecting the battery to t
68. ty cycle on all settings The Output selector covers six ranges with remote output control for fine current adjustment For use with a broad range of AC and DC electrodes including Fleetweld 5P For DC Semi automatic wire feed welding three constant voltage wire feed welding settings are available giving a range of 40 250 Amps at 10096 duty cycle Excellent performance will be obtained aU broad range of Innershield and Outershield electrodes FCAW Excellent arc characteristics are available with MIG GMAW An output contactor is provided for optimum semiautomatic welding AC and DC Tig welding can be done at all constant current output settings The auxiliary power is provided by a 9 000 Watt AC 115 230 Volt 60 Hertz generator It will operate AC power tools It will also power a 1 5 HP motor if started under no load It is capable of lighting ninety 100 Watt incandescent bulbs and can also be used for standby emergency power The Ranger 9 CSA machine K1420 2 has four 15 amp circuit breakers for 115V auxiliary receptacles and two 50 amp circuit breakers for 230V receptacles This machine is CSA approved SPECIFICATIONS AC STICK TIG CC OUTPUT amp 250 OUTPUT RANGE B 45 OUTPUT RANGE OUTPUT VOLTS AC __ 3 0 50 100 150 200 250 300 350 OUTPUT AMPS DC STICK TIG CC OUTPUT 250 OUTPUT RANGE 8 45 OUTPUT RANGE OUTPUT VOLTS DC 0 0 50 100 150 200 250 300 350 400 45
69. utes dans le cas ou on recoit un choc PR CAUTIONS DE S RET POUR Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES SOUDER TRANSFORMATEUR ET donc REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du 1 rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de LINCOLN Relier a la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece a souder doit tre branch a une bonne mise a la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur l
70. ways use enough ventilation especially in confined areas to insure breathing air is safe 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 Mar 95 SAFETY WELDING SPARKS gt 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 Remember that welding sparks and hot 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 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 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 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 though they

Lincoln Electric IM511-D Portable Generator User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents