OPERATOR’S MANUAL For use with machines having Code Number 10378, 10379, 10539, 10540 and 10550 RANGER TM 9 Multi-Process Gasoline Engine Driven Welder and Power Generator IM511-D OCTOBER, 2000 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. And, most importantly, think before you act and be careful. R • 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 • Date of Purchase: Serial Number: Code Number: Model: Where Purchased: Copyright © 2000 Lincoln Global Inc.
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OPERATOR’S MANUAL
For use with machines having Code Number 10378, 10379, 10539, 10540 and 10550
RANGER TM 9Multi-Process Gasoline Engine Driven Welder and Power Generator
IM511-DOCTOBER, 2000
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.
R
• 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 •
Date of Purchase:Serial Number:Code Number:Model:Where Purchased:
Copyright © 2000 Lincoln Global Inc.
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
____________________________________________________1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 andtools away from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
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 & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to causecancer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
iiSAFETYii
ARC RAYS can burn.4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.e. Also see item 1.b. Mar ‘95
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
iiiSAFETYiii
Mar ‘95
WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternatecircuits. This can create fire hazards or overheat liftingchains or cables until they fail.
6.h. Also see item 1.c.
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissent dansce manuel aussi bien que les précautions de sûreté généralessuivantes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines àsouder parce que la tension entre les deux pinces peutêtre le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, seprotéger contre les chutes dans le cas ou on recoit un choc.Ne jamais enrouler le câble-électrode autour de n’importequelle 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 appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres 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 leszones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines delevage, câbles de grue, ou autres circuits. Cela peut provo-quer des risques d’incendie ou d’echauffement des chaines etdes 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gasfortement 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.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Ledispositif de montage ou la piece à souder doit être branchéà une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté àleurplace.
Mar. ‘93
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can be foundon your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information youhave recorded above.
vv
TABLE OF CONTENTS
Safety Precautions ............................................................................................................ii-ivIntroductory Information......................................................................................................vGeneral Description ............................................................................................................7Specifications ....................................................................................................................7-8Optional Features ...............................................................................................................9Recommended Equipment ................................................................................................10Installation Instructions....................................................................................................11-12
Machine Grounding .......................................................................................................11Spark Arrester ...............................................................................................................11Trailers ........................................................................................................................11-12
Pre-Operation Service .......................................................................................................12Oil ..................................................................................................................................12Fuel ...............................................................................................................................12Battery Connection........................................................................................................12Welding Output Cables .................................................................................................12Location/Ventilation .......................................................................................................12
Operation ........................................................................................................................13-14High Altitude Operation .................................................................................................13Muffler Relocation .........................................................................................................13Connection of Wire Feeders .........................................................................................13Connection of K428 or K446 with K624-1 Remote Output Module ..............................13Connection of K449 to the Ranger 9 ............................................................................13Connection of LN-7 or LN-8 to the Ranger 9................................................................14Connection of the LN-742 to the Ranger 9 ...................................................................14Connection of the Magnum Spool Gun and SG Control Module to the Ranger 9........14Remote Output Control .................................................................................................14High Frequency Generator for TIG welding applications .............................................14
Operating Instructions .....................................................................................................15-17Additional Safety Precautions .......................................................................................15Welder Operation ..........................................................................................................15Welder Controls, Functions, and Operation................................................................15-16Engine Operation........................................................................................................16-17Welding Processes .....................................................................................................17-18Auxiliary Power ...........................................................................................................19-20 Standby Power Information and Connection to Premises Wiring Diagram ............... 20-21
Maintenance....................................................................................................................22-23General Instructions ......................................................................................................22Engine Adjustments ......................................................................................................22Slip Rings ......................................................................................................................22Battery ...........................................................................................................................23Hardware.......................................................................................................................23
Troubleshooting ...............................................................................................................24-27General Troubleshooting ...............................................................................................24Electronic Idler Troubleshooting ....................................................................................25Output System Troubleshooting..................................................................................26-27
Wiring Diagram ...............................................................................................................28-30Connection Diagrams......................................................................................................31-35Dimension Print .................................................................................................................36Parts Pages ...............................................................................................................P230 Series
- 7 -
GENERAL DESCRIPTIONThe Ranger™ 9, is a twin cylinder gasoline enginedriven multi-process arc welder and AC powergenerator. It is built in a heavy gauge steel case fordurability on the job site.
RECOMMENDED PROCESSES ANDEQUIPMENTThe 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 WattAC 115/230 Volt, 60 Hertz power generator.
For AC/DC Stick welding, the range is 40-250 Amps.There is a 100% duty cycle on all settings. TheOutput selector covers six ranges with remote outputcontrol for fine current adjustment. For use with abroad range of AC and DC electrodes includingFleetweld® 5P.
For DC Semi-automatic wire feed welding, threeconstant voltage wire feed welding settings areavailable giving a range of 40-250 Amps at 100% dutycycle. Excellent performance will be obtained with abroad range of Innershield® and Outershield®electrodes (FCAW). Excellent arc characteristics areavailable with MIG (GMAW). An output contactor isprovided for optimum semiautomatic welding.
AC and DC Tig welding can be done at all constantcurrent output settings.
The auxiliary power is provided by a 9,000 Watt, AC115/230 Volt, 60 Hertz generator. It will operate ACpower tools. It will also power a 1.5 HP motor (ifstarted under no load). It is capable of lighting ninety100 Watt incandescent bulbs, and can also be usedfor standby emergency power.
The Ranger 9 CSA machine (K1420-2) has four 15amp circuit breakers for 115V auxiliary receptaclesand two 50 amp circuit breakers for 230V receptacles.This machine is CSA approved.
SPECIFICATIONS
AC STICK / TIG (CC) OUTPUT
OU
TP
UT
VO
LT
S A
C
80
70
60
50
40
30
20
10
00 50 100 150 200 250 300 350
OUTPUT AMPS
B
B
A
A 250 OUTPUT RANGE
45 OUTPUT RANGE
DC STICK / TIG (CC) OUTPUT
OU
TP
UT
VO
LT
S D
C
80
70
60
50
40
30
20
10
00 50 100 150 200 250 300 350 400 450
OUTPUT AMPS
A
A
B
B
250 OUTPUT RANGE
45 OUTPUT RANGE
DC WIRE FEED (CV) OUTPUT
OU
TP
UT
VO
LT
S D
C
OUTPUT AMPS0 50 100 150 200 250 300 350 400
LOWMED
HIGH
5550454035
3025201510
50
Ranger 9(Kohler Command
CH20S)
20 HP @ 3600 RPM
38.1 cu in(624 cc)
Fuel:9 Gal (34 L)
Lubricating Oil:2.0 Qts (1.9 L)
ProductName
Description Horsepower OperatingSpeeds
Displacement Ignition Capacities
Machine
Engine
* 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.
- 8 -
SPECIFICATIONS
Product
Name
Ordering
Information
K1420-1
K1420-2
CSA(Meets
Canadian
Standards)
Ranger 9(Onan)
Ranger 9(Kohler)
K1421-1CSA
(MeetsCanadian
Standards)
Rated DC Output *
Amps / Volts / Duty Cycle
AC Constant Current
250A / 25V / 100%
DC Constant Current
250A / 25V / 100%
DC Constant Voltage
250A / 25V / 100%
Max OCV @ 3700 RPM
80V
Auxiliary Power for
Wire Feeders
42V, 60 Hz, 8 Amps
115V, 60 Hz, 8 Amps
AC Power ** Dimensions
& Weight
9,000 Watts
60 Hz. DC
80 Amps @
115V
40 Amps @
230V
30.3 x 19.2 x 42.3 in
(770 x 488 x 1075 mm)
598 lbs (272 kg)
30.3 x 19.2 x 42.3 in
(770 x 488 x 1075 mm)
591 lbs (269 kg)
Description
250 Amp
AC/DC
Multi-Process
Arc Welder
with
9,000 Watts AC
Auxiliary
Power
Ranger 9(Onan P218)
2 Cylinder4 Cycle
Air-CooledGasoline Engine.Aluminum Alloy
Block with Cast IronLiners, Electronic
Ignition
18 HP @ 3600 RPM
Full Load:3500 RPM
High Idle:3700 RPM
Low Idle:2200 RPM
47.7 cu in(782 cc)
12V Battery, 430Cold Cranking
Amps, Toggle StartSwitch, ChargingAmmeter, Manual
Choke
Fuel:9 Gal (34 L)
Lubricating Oil:1.8 Qts (1.7 L)
A) K768-2 Two Wheel Undercarriage
For in-plant and yard towing. (For highway use,consult applicable federal, state, and local lawsregarding 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 gripsfor hand pulling. Overall width 43.06" (1.09 m).
B) K886-1 Canvas Cover
To protect the Ranger 9 when not in use. Made fromattractive red canvas material that is flame retardant,mildew resistant, and water repellent.
C) K894-1 Spark Arrester Kit
Includes a heavy gauge steel, approved sparkarrester and clamp for easy mounting to mufflerexhaust pipe.
D) K896-1 GFCI Receptacle Kit
Includes two UL approved 115 Volt ground fault circuitinterrupter duplex type receptacles with covers andinstallation instructions. Replaces the two factoryinstalled 115 Volt duplex receptacles. Each recepta-cle of each GFCI duplex is rated at 15 Amps but themaximum total current from each GFCI duplex islimited to 20 amps.
E) K930-1 TIG Module
Provides high frequency and shielding gas control forAC and DC GTAW (TIG) welding applications.Compact case is designed for easy carrying,complete with handle. High frequency bypass is builtin. The K939-1 Docking Kit is available for mountingthe TIG Module on top of the Ranger 9. The K936-1control cable is required.
F) K933-1 Four Wheel Undercarriage
Allows movement of the Ranger 9 by hand withoutlifting. Easily assembles to the Ranger 9. It includestwo rugged, hard molded wheels and two durablepneumatic tires. The spring loaded handle providesconvenient, comfortable steering. The k934-1 Bracketis available for mounting a gas cylinder on the under-carriage.
G) K934-1 Bracket for Mounting a Gas Cylinder to aK933-1 Undercarriage
Easily mounts on the back of the K933-1 Four WheelUndercarriage to carry a welding gas cylinder.
H) K889-2 Two Wheel Undercarriage
For moving by hand. Two 4.00" x 8" industrial tires.Overall width 29" (.74m).
I) K857 Remote Control
Consists of a control box with 25' (7.5 m) of fourconductor cable. Permits remote adjustment of outputvoltage.
J) K893-1 Caster for Two Wheel Undercarriage
Mounts to the front of the K889-2 Two-WheelUndercarriage to allow easy movement on smoothsurfaces. Includes a 6" diameter hard rubber wheelwith a convenient toe-on, toe-off locking brake.
K) K702 Accessory Kit
Accessory Set includes 35 ft. 2 AWG electrode cable,30 ft. 2 AWG work cable, headshield with number 12filter, work clamp, and Cooltong® 300 electrodeholder. Cables are rated at 250 Amps, 40% dutycycle.
L) K802-R Power Plug Kit
Provides four 115 Volt plugs rated at 15 Amps eachand one dual voltage, full KVA plug rated at 115/230Volts, 50 amps.
M) K802-N Power Plug KIt
Provides four 115 Volt plugs rated at 20 Amps eachand one dual voltage, full KVA plug rated at 115/230Volts, 50 Amps. (Not for use with K1420-2 CSAmachine and machines with GFCI receptacles.)
OPTIONAL FEATURES
- 9 -
RECOMMENDED EQUIPMENT
STICK
K702 Accessory Kit which includes:
• Electrode holder and cable• Work clamp and cable• Headshield
K857 Remote Control Kit is optional for remotecurrent control.
WIRE FEED
LN-25 (K428 or K446) with K624-1 42 Volt RemoteOutput Control Module - Requires K626-xx ControlCable. Provides "cold" electrode until gun trigger ispressed. Voltage control is at the feeder. K446LN-25 includes gas solenoid.
LN-25 (K449) Includes internal contactor for acrossthe arc operation (no control cable). Provides "cold"electrode until gun trigger is pressed. Includes gassolenoid. K444-1 Remote Voltage Control Kit isrequired for voltage control at the feeder.
LN-742 (K617-1 or K618-1) or LN-742H (K617-2 orK618-2), requires K619-xx Input Cable Assembly.Provides "cold" electrode until gun trigger is pressed.Includes gas solenoid. K589-1 Remote Control Kitconnects to the LN-742 to provide remote voltage andwire speed control or K857 Remote Voltage ControlKit connects to the Ranger 9 for voltage control at thefeeder.
LN-7 (K521) or LN-7 GMA (K440), requires K584-xxInput Cable Assembly. Provides "cold" electrode untilgun trigger is pressed. K440 LN-7 GMA included gassolenoid. K8567 Remote Voltage Control Kit isrequired for voltage control at the feeder. Ranger 9must be operated at "HIGH" idle.
Magnum Gun is required for gas-shielded welding.Innershield Gun is required for gas-less welding.
TIG
Magnum™ TIG TorchMagnum Parts Kit and Argon gasK930-1 TIG ModuleK936-1 Control Cable
Optional:
K939-1 TIG Module Docking KitK963 Hand Amptrol™
K870 Foot AmptrolK814 Arc Start Switch
- 10 -
INSTALLATION INSTRUCTIONS
Machine Grounding
Because this por table engine driven welder orgenerator creates it’s own power, it is not necessaryto connect it’s frame to an earth ground, unless themachine is connected to premises wiring (your home,shop, etc.).
To prevent dangerous electric shock, other equipmentto which this engine driven welder supplies powermust:
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’sframe must be securely connected to the metal frameof the vehicle.
Where this engine driven welder is connected topremises wiring, such as that in your home or shop,it’s frame must be connected to the system earthground. See further connection instructions in thesection entitled Standby Power Connections in thismanual, as well as the article on grounding in thelatest U.S. National Electrical Code and the localcode.
In general, if the machine is to be grounded, it shouldbe connected with a #8 or larger copper wire to asolid earth ground such as a metal water pipe goinginto the ground for at least ten feet and having noinsulated joints, or to the metal framework of abuilding which has been effectively grounded. TheU.S. National Electrical Code lists a number ofalternate means of grounding electrical equipment. Amachine grounding stud marked with the symbolis provided on the front of the welder.
Spark Arrester
Some federal, state or local laws may require thatgasoline engines be equipped with exhaust sparkarresters when they are operated in certain locationswhere unarrested sparks may present a fire hazard.The standard muffler included with this welder doesnot qualify as a spark arrester. When required bylocal regulations, the K894-1 arrester must beinstalled and properly maintained.
-11 -
Undercarriages
The recommended undercarriage for use with thisequipment for in-plant and yard towing by a vehicle (1)
is Lincoln’s K768-2. If the user adapts a non-Lincolnundercarriage, he must assume responsibility that themethod of attachment and usage does not result in asafety hazard nor damage the welding equipment.Some of the factors to be considered are as follows:
(1) Consult applicable federal, state and local lawsregarding specific requirements for use on publichighways.
1. Design capacity of undercarriage vs. weight ofLincoln equipment and likely additionalattachments.
2. Proper support of, and attachment to, the base ofthe welding equipment so there will be no unduestress to the framework.
3. Proper placement of the equipment on theundercarriage to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.
Use of an incorrect arrester may lead to enginedamage or performance loss.-----------------------------------------------------------------------
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------
ELECTRIC SHOCK can kill.• Do not touch electrically live parts or
electrode with skin or wet clothing.• Insulate yourself from work and
ground• Always wear dry insulating gloves.
------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or
guards off.• Stop engine before servicing.• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information atfront of this operator’s manual.
-----------------------------------------------------------
WARNING
CAUTION
4. Typical conditions of use, i.e., travel speed; rough-ness of surface on which the trailer will beoperated; environmental conditions; likemaintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regardingspecific requirements for use on public highways.
PRE-OPERATION SERVICE
READ the engine operating and maintenance instruc-tions supplied with this machine.------------------------------------------------------------------------
The Ranger 9 is shipped with the engine crankcasefilled with SAE 10W-30 oil. Check the oil level beforestarting the engine. It if is not up to the full mark onthe dipstick, add oil as required. Make certain that theoil filter cap is tightened securely. Refer to the engineOperators Manual for specific oil recommendations.
Oil
FuelFill 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.
Battery Connection
This welder is shipped with the negative battery cabledisconnected. Make sure that the Engine Switch is inthe “STOP” position and attach the disconnectedcable securely to the negative battery terminal beforeattempting to operate the machine. If the battery isdischarged and does not have enough power to startthe engine, see the Maintenance-Battery section ofthis manual for battery charging instructions.
Welding Output Cables
With the engine off, connect the electrode and workcables to the studs provided. These connectionsshould be checked periodically and tightened ifnecessary.
Listed below are copper cable sizes recommended forthe rated current and duty cycle. Lengths stipulatedare the distance from the welder to work and back tothe welder again. Cable sizes are increased forgreater lengths primarily for the purpose of minimizingcable voltage drop.
TOTAL COMBINED LENGTH OFELECTRODE AND WORK CABLES
0-50 Ft.
50-100 Ft.
100-150 Ft.
150-200 Ft.
200-250 Ft.
250 Amps40% Duty Cycle
2 AWG
2 AWG
1 AWG
1 AWG
1/0 AWG
250 Amps100% Duty Cycle
1 AWG
1 AWG
1 AWG
1 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 andto avoid heated air coming out of the back of thewelder recirculating back to the cooling air inletsbelow the exhaust. Also, locate the welder so that theengine exhaust fumes are properly vented to anoutside area.
Damage to fuel tank may cause fire or explosion.Do NOT drill holes in the Ranger 9 base or weld tothe Ranger 9 base.------------------------------------------------------------------------
-12 -
CAUTION
GASOLINE fuel can cause fire orexplosion.• 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.
WARNING
WARNING
LUBRICATION SYSTEM CAPACITY(INCLUDING FILTER)
Onan P218 - 1.8 Quarts (1.7 Liters)Kohler CH20S - 2.0 Quarts (1.9 Liters)
-13 -
Angle of Operation
Engines are designed to run in the level conditionwhich is where the optimum performance is achieved.The maximum angle of operation for the engine is 15degrees from horizontal in any direction. If the engineis to be operated at an angle, provisions must bemade for checking and maintaining the oil level at thenormal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effectivefuel capacity will be slightly less than the specified 10gallons.
High Altitude Operation
If the Ranger 9 will be consistently operated ataltitudes above 5,000 feet, a carburetor jet designedfor high altitudes should be installed. This will result inbetter fuel economy, cleaner exhaust, and longerspark plug life. It will not give increased power whichis decreased at higher altitudes. Engine horsepower isreduced by 3.5% per 1000 feet for altitudes above 377feet.High altitude jet kits are available from the enginemanufacturer. Order Onan kit part number 146-0458.
Connection of Lincoln ElectricWire Feeders
Shut off welder before making any electricalconnections.------------------------------------------------------------------------Connection of K428 or K446 LN-25 withK624-1 42 volt Remote Output ControlModule to the Ranger 9.Requires K626-xx Control Cable. Provides “cold” electrodeuntil gun trigger is pressed and also provides voltage control atthe feeder. The K446 LN-25 includes a gas solenoid. See theappropriate 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 thework cable to the “TO WORK” stud of the welder.
c. Connect the control cable from the LN-25 to the14 pin amphenol on the Ranger 9.
d. Attach the single lead from the front of the LN-25to the work using the spring clip on the end of thelead.
This is a control lead to supply the current to the wire feeder motor; it does not carry weldingcurrent.
e. Set the “POLARITY” switch to either WIRE FEEDDC+ or WIRE FEED DC- as required by theelectrode being used.
f. Set the “RANGE” switch to either HIGH, MED orLOW as required by the process.
g. Set the “WELDING TERMINALS” Control switch tothe “REMOTELY CONTROLLED” position.
h. Set the “IDLER” switch to the “AUTO” position.
Connection of the K449 LN-25 to theRanger 9.
a. Shut off the welder.
b. Connect the electrode cable from the LN-25 to the“ELECTRODE” stud of the welder. Connect thework cable to the “TO WORK” stud of the welder.
c. Attach the single lead from the front of the LN-25 towork using the spring clip on the end of the lead.This is a control lead to supply the current to thewire feeder motor; it does not carry welding current.
Do not operate a Ranger 9 with a high altitude jet installedat an altitude below 5,000 ft. This will result in the enginerunning too lean and result in higher engine temperatureswhich can shorten engine life.------------------------------------------------------------------------Muffler Relocation
Shut off welder and allow muffler to cool beforetouching muffler.------------------------------------------------------------------------The Ranger 9 is shipped with the exhaust coming out onthe left side of the machine. The exhaust can be changedto the opposite side by removing the two screws that holdthe exhaust port cover in place and installing the cover onthe opposite side. (Operating the Ranger 9 without thecover in place will result in a higher noise level and noincrease in machine output.)
CAUTION
WARNING
WARNING
d. Set the “POLARITY” switch to either WIRE FEEDDC+ or WIRE FEED DC- as required by theelectrode being used.
e. Set the “RANGE” switch to either HIGH, MED orLOW as required by the process.
f. Set the “WELDING TERMINAL” Control switch to the “ALWAYS ON” position.
g. Set the “IDLER” switch to the “AUTO” position.
Connection of the LN-7 or LN-8 to theRanger 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 thismanual.
c. Set the output control toggle switch to appropriateposition: “CONTROL REMOTE” for LN-8 and LN-7with K857 attached; “CONTROL AT WELDER” forLN-7 with no remote voltage control.
d. Set “POLARITY” switch to either WIRE FEED DC+or WIRE FEED DC-.
e. Set the “RANGE” switch to either HIGH, MED orLOW as required by the process.
f. Set the “WELDING TERMINALS” Control switch tothe “REMOTELY CONTROLLED” position.
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 appropriateconnection diagram in rear of this manual.
c. Set the output control toggle switch to“CONTROL AT WELDER” when not usingremote control. When the LN-742 has a K589-1remote control attached, set output control to“REMOTE”.
d. Set “POLARITY” switch to either WIRE FEEDDC+ or WIRE FEED DC-.
e. Set “RANGE” switch to either HIGH, MED orLOW as required by the process.
f. Set the “WELDING TERMINAL” control switch to“REMOTELY CONTROLLED” position.
g. Set the “IDLER” switch to the “AUTO” position.
-14 -
Connection of the Magnum Spool Gunand SG Control Module to the Ranger 9
a. Shut off the Welder.
b. Connect per the instructions on the appropriateconnection 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 DC+.
e. Set the “RANGE” switch to either HIGH, MED orLOW as required by the process.
f. Set the “WELDING TERMINALS” Control switch tothe “REMOTELY CONTROLLED” position.
g. Set the “IDLER” switch to the “HIGH” idle position.
Remote Output Control
The Ranger 9 has a 6-pin and a 14-pin Amphenolconnector. These connectors are located above theoutput studs. The 6-pin connector is intended to beused with the optional K857 Remote Output Control orin the case of TIG welding applications, with the Footor Hand Amptrol. The 14-pin connector is used toconnect a wire feeder control cable. If the wire feederhas a built-in power source output control, do notconnect a remote output control to the 6-pinconnector. When remote output control is used, theoutput control toggle switch is to be set at “CONTROLREMOTE”.
High Frequency Generator for TIGwelding applications
The K930-1 TIG Module is an accessory that provideshigh frequency and shielding gas control for AC andDC GTAW (TIG) welding. See IM528 supplied withthe TIG Module for installation instructions.
Note: The TIG Module does not require the use of ahigh frequency bypass capacitor. If any other highfrequency accessory is used with the Ranger 9, abypass capacitor (Order Kit T12246) must be installedin the Ranger 9.
Welder Controls - Function and Operation
ENGINE “ON-OFF” Switch
When placed in the “ON” posit ion, this switchenergizes the engine ignition circuit. When placed inthe “OFF” position, the ignition circuit is de-energizedto shut down the engine.
ENGINE “START” Push-Button Switch
Energizes engine starter motor.
“POLARITY” Switch
Three STICK/TIG (constant current) polarity settings:DC+, DC- and AC
Two wire feed (constant voltage) settings:DC+ and DC-
NOTE: The setting of this switch must match thecolor band setting of the Range Switch (both switchesmust be set for the same welding process).
OPERATING INSTRUCTIONS
Additional Safety Precautions
Always operate the welder with the roof and casesides in place as this provides maximum protectionfrom moving parts and assures proper cooling air flow.
Read carefully the Safety Precautions page in theInstruction Manual before operating this machine.Always follow these and any other safety proceduresincluded in this manual and in the Engine InstructionManual.
Welder Operation
Welder Output
• Maximum Open Circuit Voltage at 3700 RPM is 80 volts.
• Duty Cycle: 100% for both welding and auxiliary power.
Constant 250 amps AC @ 25 voltsCurrent 250 amps DC @ 25 volts
Constant 250 amps DC @ 25 voltsVoltage
RANGER 9
ONAN P218PERFORMER
KOHLERCH20S
Low Idle - No Load
2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
250 Amps @ 25 Volts
DC CC Weld Output
250 Amps @ 25 Volts
DC CV Weld Output
250 Amps @ 25 Volts
Auxiliary Power
9000 kVA
.4 gallons/hour
(1.5 liters/hour)
.8 gallons/hour
(3.1 liters/hour)
1.6 gallons/hour
(6.2 liters/hour)
1.8 gallons/hour
(7.0 liters/hour)
1.7 gallons/hour
(6.5 liters/hour)
1.8 gallons/hour
(7.0 liters/hour)
.4 gallons/hour
(1.5 liters/hour)
1.0 gallons/hour
(3.9 liters/hour)
1.5 gallons/hour
(5.7 liters/hour)
1.7 gallons/hour
(6.5 liters/hour)
1.6 gallons/hour
(6.2 liters/hour)
1.7 gallons/hour
(6.5 liters/hour)
Ranger 9 Approximate Fuel Consumption
STICK/TIG (constant current) 6 45,90,120,range settings 160,200,250
WIRE FEED (constant voltage) 3 LOW,MED,HIGHrange settings
CONTROL”“
Provides a fine welding current adjustment within theRange Switch settings in the STICK/TIG mode andwelding voltage control with the Range switch set inthe WIRE FEED mode.
-15 -
ON OFF
Explanation of Symbols that Appear on this Equipment
Low Idle High Idle
Never change the “POLARITY” switch settingwhile welding. This will damage the switch.------------------------------------------------------------------------
Never change the “RANGE” switch setting whilewelding. This will damage the switch.------------------------------------------------------------------------
CAUTION
CAUTION
RANGE” Switch“
Starting/Shutdown InstructionsStarting the Engine
Be sure all Pre-Operation Maintenance has been per-formed. Also, read the Engine Owner’s Manual.
Remove all loads connected to the AC power recepta-cles. To start the engine, set the “Idler Control” switchin the Automatic ( / ) position.
Use the choke control as follows: Onan Engine - If the engine is cold, pull the chokecontrol out. Do not use the choke if the engine is warmor hot.
Kohler Engine - Always pull the choke control outwhen starting the engine; cold, warm or hot. Place the“Engine” switch in the “ON” position.
Push the “START” button and crank the engine until itstarts. Release the button as soon as the enginestarts. Do not push the “START” button while theengine is running because this will cause damage tothe ring gear and/or starter motor. After the enginehas started, slowly return the choke control to the full“in” position (choke open).
After running at high engine speed for 10-14 seconds,the engine will go to low idle.
Allow the engine to warm up by letting it run at low idlefor a few minutes.
“CONTROL AT WELDER /
The toggle switch on the control panel labeled“CONTROL AT WELDER” and “REMOTE CONTROL”gives the operator the option of controlling the outputat the welder control panel or at a remote station.Remote connections are made at the 6-pin or 14-pinamphenol connector.
For remote control, the toggle switch is set in the“REMOTE CONTROL” position.
For control at the welder control panel, the toggleswitch is set in the “CONTROL AT WELDER” position.
“WELDING TERMINALS” Switch
The toggle switch labeled “WELDING TERMINALSALWAYS ON” and “WELDING TERMINALSREMOTELY CONTROLLED” is used to control theoperation of the welder output contactor.
With the switch in the “ALWAYS ON” position, theoutput contactor is closed at LOW and HIGH idle.
With the switch in the “REMOTELY CONTROLLED”position, the contactor is open at LOW idle and HIGHidle until a control cable is attached to the welderamphenol connector from a wire feeder. Under thiscondition, contactor closes when the wire feedertrigger is depressed and opens when the trigger isreleased.
“IDLER” Switch
The idler switch has two positions, “HIGH” and“AUTO”.
When in “HIGH” position, the engine will runcontinuously at high idle.
When in “AUTO” / idle position, the idleroperates as follows:
a. WeldingLow idle and in the “WELDING TERMINALS ALWAYS ON” mode -Stick Welding only. When the electrode touches work, thewelding arc is initiated and the engine accelerates tofull speed.
Low idle and in the “WELDING TERMINALS REMOTELYCONTROLLED” mode -Wire Welding Only Pressing the guntrigger closes the Ranger 9 output contactor andcauses the engine to accelerate to full speed.
After the gun trigger is released and/or weldingceases (and no auxiliary power is being drawn), theengine will return to low idle after approximately 10 to14 seconds.
REMOTE CONTROL” Switch
-16 -
b. Auxiliary Power - With the engine running at lowidle and auxiliary power for lights or tools is drawn(approximately 100-150 watts or greater) from thereceptacles, the engine will accelerate to high speed.If no power is being drawn from the receptacles (andnot welding) for 10-14 seconds, the idler reduces theengine speed to low idle.
• Do not touch electrically live partsof electrode with skin or wetclothing.
• Keep flammable material away.
• Insulate yourself from work andground. Wear eye, ear, and bodyprotection.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
WARNING
Stopping the Engine
Remove all welding and auxiliary power loads andallow engine to run at low idle speed for a few minutesto 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 8because the fuel tank is mounted below the engine.
Break-in Period
It is normal for any engine to use a greater amount ofoil until the break-in is accomplished. Check the oillevel twice a day during the break-in period (approxi-mately 50 running hours)).
IMPORTANT: IN ORDER TO ACCOMPLISH THISBREAK-IN, THE UNIT SHOULD BE SUBJECTED TOMODERATE LOADS, WITHIN THE RATING OF THEMACHINE. AVOID LONG IDLE RUNNING PERIODS.REMOVE LOADS AND ALLOW ENGINE TO COOLBEFORE SHUTDOWN.
The engine manufacturer’s recommendation for therunning 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 theoutput “CONTROL” or remote output control to max(10) and the “RANGE” switch to the setting that isclosest to the recommended current for the electrodebeing used and make a trial weld. A fine adjustmentof the welding can be made by adjusting the output“CONTROL” or remote control. For the best arcstability, always use setting that results in the highestsetting of the output or remote control and the lowestsetting of the “RANGE” switch.
The Ranger 9 can be used with a broad range of ACand DC stick electrodes. See “Welding Tips 1”included with the Ranger 9 for electrodes within therating of this unit and recommended welding currentsof each. See the following table for welding currentranges:
CURRENT RANGES (AC and DC STICK WELDING- 5 to 10 ON CONTROL DIAL)
TIG (Constant Current) Welding
The Ranger 9 can be used in a wide variety of ACand DC Tungsten Inert Gas (TIG) welding applicationsfor AC TIG welding up to 200 amps and DC TIGwelding up to 250 amps.
The K930-1 TIG Module installed on a Ranger 9provides high frequency and shielding gas control forAC and DC GTAW (TIG) welding processes. The TIGModule allows full range output control. Afterflow timeis adjustable from 0 to 55 seconds.
When using the Ranger 9 for AC TIG welding ofaluminum, the TIG Module is to be set for CONTINU-OUS HF. The following settings and electrodes arerecommended:
When AC TIG welding, the actual maximum weldingcurrent is 40 to 80 amps higher than the currentmarked on the RANGE SWITCH dial. This is a resultof 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) electrodesand solid wires for MIG welding (gas metal arcwelding).
Some recommended Innershield electrodes are:NR-211MP, NR-311, NR-203 series as well as,Lincore® 33 and 55 hardfacing electrodes. Diametersfrom .035 (0.9mm) up to and including 5/64” (2.0mm)can be used. 5/64” (2.0mm) NS-3M can be used inlimited applications. Cable length and other condi-tions can affect the ultimate results of this application.Request Lincoln publication N-675 for additional infor-mation.
-17 -
Pure (EWP)Tungsten Diameter
“Range”Switch Settings
WeldingCurrent
1/8
3/32
1/16
90, 120
45, 90
45, 90
100 to 200 amps
45 to 140 amps
45 to 100 amps
RANGE SETTINGON MACHINE
ACTUALCURRENT RANGE
4590120160200250
25 to 45 AMPS50 to 90 AMPS60 to 120 AMPS80 to 160 AMPS100 to 200 AMPS140 to 250 AMPS
KohlerCH20S
5 hr
OnanP218
25 hr
SUMMARY OF WELDING PROCESS
-18 -
CONTROLCABLEUSED
IDLEMODE
OUTPUTCONTROLSWITCH
WELDINGTERMINALS
SWITCH
ELECTRODEWHEN NOTWELDING TO START WELDINGPROCESS
STICK - CC
TIG - CCK930-1/K936-1(WITH AMPTROL)
WIRE FEED - CV,LN-25 WITH 42VREMOTE CON-TROL KIT
WIRE FEED - CV,LN-25 WITHINTERNALCONTACTOR
WIRE FEED - CV,LN-742
WIRE FEED - CV,LN-7
Touch electrode to work.Welding starts immediatelyand engine goes to high idle.
Press Amptrol. Weldingstarts immediately.
Press gun trigger, Ranger 9contactor closes. Weldingstarts immediately and enginegoes to high idle.
Press gun trigger, LN-25contactor closes. Weldingstarts immediately and enginegoes to high idle.
Press gun trigger, Ranger 9contactor closes. Weldingstarts immediately and enginegoes to high idle.
Press gun trigger, Ranger 9contactor closes. Weldingstarts immediately.
NO
YES
YES
NO
YES
YES
AUTO
AUTO
AUTO
AUTO
AUTO
HIGH
ATWELDER
REMOTE
REMOTE
ATWELDER
REMOTE
REMOTE
ALWAYSON
REMOTE
REMOTE
ALWAYSON
REMOTE
REMOTE
HOT
COLD
COLD
COLD
COLD
COLD
Recommended Outershield electrodes are: .045(1.1mm), .052 (1.3mm) and 1/16 (1.6mm) Outershield71 and 1/16” (1.16mm) Outershield 70. RequestLincoln publication GS-200 for additional information.
Some recommended solid wires for MIG welding are:.030 (0.8mm), .035 (0.9mm) and .045 (1.1mm) L-50and L-56. Request Lincoln publication GS-100 foradditional information.
When using a wire feeder with contactor control, theelectrode will be “cold” until the gun trigger is pressed.To start the welding process, position the gun andclose the gun trigger. The contactor will close, the arcwill be initiated and the engine will accelerate to fullspeed. To stop welding, release the gun trigger andpull the gun away from the work. With the “IDLERSWITCH” in the “AUTO” position, the engine will goback to low idle in approximately 12 seconds (whenno auxiliary power is drawn).
NOTE: The LN-7 and the LN-8 must be operated inthe “HIGH” idle position.
-19 -
Auxiliary Power
The Ranger 9 can provide up to 9,000 watts of115/230 volts AC, single phase 60HZ power for contin-uous use. The front of the machine includes threereceptacles for connecting AC power plugs. TheK1420-1 has one 50 amp 115/230 volt NEMA 14-50R receptacle and two 20 amp 115 volt NEMA 5-20R receptacles. The K1420-2 CSA machine has one50 amp 115/230 volt NEMA 14-50R receptacle andtwo 15 amp 115 volt NEMA 5-15R receptacles. Donot connect any plugs that connect to the powerreceptacles in parallel.
Start the engine and set the “IDLER” control switch tothe desired operating mode. Set the “CONTROL” to10. Voltage is now correct at the receptalces forauxiliary power.
115/230 Volt Dual Voltage Receptacle
The 115/230 volt receptacle can supply up to 40 ampsof 230 volt power to a two wire circuit, up to 40 ampsof 115 volt power from each side of a three wire circuit(up to 80 amps total). Do not connect the 115 voltcircuits in parallel. Current sensing for the automaticidle feature is only in the leg of the three wire circuit asshown below.
Maximum Current Draw from 115V DuplexReceptacles - No Welding
Maximum Current Draw from Optional 115VGFCI Duplex Receptacles - No Welding
EACHHALF OF
EACH 115VDUPLEX
TOTALFROM
BOTH 115VDUPLEXES
EACHHALF OF
EACH 115VDUPLEX
TOTALFROM
BOTH 115VDUPLEXES
K1420-1 K1420-2 (CSA)and K1421-1 (CSA)
LOAD FROM115V / 230V
DUAL VOLTAGERECEPTACLE
0
2.2 KW
4.5 KW
6.7 KW
9.0 KW
20 *
20 *
20 *
20 *
0
78
60
40
20
0
15
15
15
15
0
60
60
40
20
0
EACHHALF OF
EACH 115VDUPLEX
TOTALFROM
BOTH 115VDUPLEXES
EACHHALF OF
EACH 115VDUPLEX
TOTALFROM
BOTH 115VDUPLEXES
K1420-1*(WITH GFCI’S)
K1420-2** andK1421-1**
(WITH GFCI’S)
LOAD FROM115V / 230V
DUAL VOLTAGERECEPTACLE
0
2.2 KW
4.5 KW
6.7 KW
9.0 KW
15
15
15
15
0
40
40
40
20
0
15
15
15
15
0
30
30
30
20
0
* Maximum current draw from each 115V GFCI Duplex is 20 amps.** Maximum current draw from each 115V GFCI Duplex is 15 amps.
* NEMA 5-20P plug required for 20 amp draw.
115V Duplex Receptacles
The 115V auxiliary power receptacles should only beused with three wire grounding type plugs or approveddouble insulated tools with two wire plugs.
GND
115 V
115 V
230 V
* Current Sensing for Automatic Idle(Receptacle viewed from front of machine.)
*
Most 1.5 HP motors can be started if there is no loadon the motor or other load connected to the machine,since the full load current rating of a 1.5HP motor isapproximately 20 amperes (10 amperes for 230 voltmotors). The motor may be run at full load whenplugged into only one side of the duplex receptacle.Larger motors through 2HP can be run provided thereceptacle rating as previously stated is not exceeded.This may necessitate 230V operation only.
It must be noted that the above auxiliary power ratingsare with no welding load. Simultaneous welding andpower loads are permitted by the following table. Thepermissible currents shown assume that current isbeing 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 connected to the auxiliary power receptacles.
OutputSelectorSetting
WeldingOutput
PermissiblePower Watts(Unity Power
Factor)
PermissibleAuxiliary Current in
Amperes @ 115V
PermissibleAuxiliary Current in
Amperes @ 230V
11162226
32.5
21.532.5
2028
526
2232445265
4365
4056
1052
NONE25003700500060007500
50007500
27506500
12006000
2502001601209045
20060
25080
250100
2502001601209045
CV LOW
CV MEDIUM
CV HIGH
Standby Power Connections
The Ranger 9 is suitable for temporary, standby oremergency power using the engine manufacturer'srecommended maintenance schedule.
The Ranger 9 can be permanently installed as astandby power unit for 230 volt, 3-wire, 40 ampereservice. Connections must be made by a licensedelectrician who can determine how the 115/230 voltpower can be adapted to the particular installation andcomply with all applicable electrical codes. Thefollowing information can be used as a guide by theelectrician for most applications (refer also to thePremises Wiring diagram shown).
IMPORTANT: When the Ranger 9 is connected to a 230 volt, 3-wire line, the unit should be operatedwith the idler switch in the “HIGH” idle position to avoidload sensing problems. If the machine is set forautomatic idle, the 230 volt circuit will sense loads andcause the engine to accelerate to high idle. However, since only one line of the circuit senses current, 115volt power drawn from only one line to neutral mayresult in the engine not going to high idle.
1. Install the double pole, double throw switchbetween the power company meter and thepremises disconnect.
Switch rating must be the same or greater than the customer’s premises disconnect and service overcurrent protection.
-20 -MAR 95
2. Take necessary steps to assure load is limited to the capacity of the Ranger 9 byinstalling a 40 amp, 230 volt double polecircuit breaker. Maximum rated load for eachleg of the 230 volt auxiliary is 40 amperes. Loading above 40 amps will reduce outputvoltage below the allowable - 10% of ratedvoltage which may damage appliances or other motor-driven equipment.
3. Install a 50 amp 115/230 volt plug (NEMAType 14-50) to the Double Pole CircuitBreaker using No. 8, 4 connector cable ofthe desired length. (The 50 amp 115/230 voltplug is available in the optional plug kit).
4. Plug this cable into the 50 amp 115/230 voltreceptacle on the Ranger 9 case front.
CONNECTION OF RANGER 9 TO PREMISES WIRING
-21 -
230 Volt60 Hz.3-WireService
POWER
COMPANY
METER
230 VOLT
115 VOLT
115 VOLT
LOADN
NEUTRALBUS
GROUND
PREMISESDISCONNECT AND
SERVICEOVERCURRENT
PROTECTION
GND
N
NOTE: No. 8 COPPER CONDUCTOR CABLE SEENATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
230 VOLT
GROUNDED CONDUCTOR
40 AMP230 VOLT
DOUBLEPOLE
CIRCUITBREAKER
DOUBLE POLE DOUBLE THROWSWITCH RATING TO BE THE SAMEAS OR GREATER THAN PREMISESSERVICE OVERCURRENTPROTECTION.
50 AMP, 115/230VOLT PLUG
NEMA TYPE 14-50
50 AMP, 115/230 VOLTRECEPTACLE
MAINTENANCESafety Precautions
-22 -
Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may benecessary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance requiring their removal iscomplete. Always use the greatest care whenworking near moving parts.
Do not put your hands near the engine coolingblower fan. If a problem cannot be corrected byfollowing the instructions, take the machine tothe nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------ELECTRIC SHOCK can kill.• Do not touch electrically live parts or
electrode with skin or wet clothing.• Insulate yourself from work and
ground• Always wear dry insulating gloves.
------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or
guards off.• Stop engine before servicing.• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information atfront of this operator’s manual.
-----------------------------------------------------------
WARNING
Engine Adjustments
OVERSPEED IS HAZARDOUSThe maximum allowable high idle speed for thismachine is 3750 RPM, no load. Do NOT tamperwith governor components or setting or make anyother adjustments to increase the maximumspeed. Severe personal injury and damage to themachine can result if operated at speeds abovemaximum.------------------------------------------------------------------------Adjustments to the engine are to be made only by aLincoln Service Center or an authorized Field ServiceShop.
WARNING
Routine Maintenance1. 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 fuelsystem. Also, check the crankcase oil level andadd oil if indicated.
2. OIL - Maintenance schedule for changing the oiland oil filter after break-in:
The above schedule is for normal operating condi-tions. More frequent oil changes are required withdusty, high temperature, and other severe operatingconditions. Refer to the maintenance section of theEngine Owner’s Manual for more information.
Engine life will be reduced if the oil and oil filterare not changed according to the manufacturer’srecommendation.-----------------------------------------------------------------------3. Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oilingthe foam pre-filter is every 25 hours and replace-ment of the air cleaner filter every 100 hours. Morefrequent servicing is required with dusty operatingconditions. Refer to maintenance section of theEngine Owner’s Manual for more information.
4. Refer to the maintenance section of the EngineOwner’s Manual for the maintenance schedule forspark plug servicing, cooling system servicing, andfuel filter replacement.
Make certain that the oil filler cap is securelytightened after checking or adding oil. If the cap isnot tight, oil consumption can increase signifi-cantly which may be evidenced by white smokecoming from the exhaust.------------------------------------------------------------------------5. Blow out the machine with low pressure air periodi-
cally. In particularly dirty locations, this may berequired once per week.
6. Output Ranger Selector and Polarity Switches:Switch contacts should not be greased. To keepcontacts clean, rotate the switch through its entirerange frequently. Good practice is to turn the han-dle from maximum to minimum setting twice eachmorning before starting to weld.
CAUTION
CAUTION
Oil
Oil Filter
KohlerCH20S
100 hr
200 hr
OnanP218
50 hr
100 hr
Use correct polarity - Negative Ground.
To prevent BATTERY DISCHARGE, if you have an ignition switch, turn it off when engine is notrunning.
• To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug.
------------------------------------------------------------------------
1. When replacing, jumping or otherwiseconnecting the battery to the battery cables,the proper polarity must be observed. Failureto observe the proper polarity could result indamage to the charging circuit. The positive(+) battery cable has a red terminal cover.
2. If the battery requires charging from anexternal charger, disconnect the negativebattery cable first and then the positivebattery cable before attaching thecharger leads. Failure to do so can resultto damage to the internal chargercomponents. When re-connecting the cables, connect the positive cable first andthe negative cable last.
HARDWARE
Both English / Metric fasteners are used in thiswelder.
-23 -
GASES FROM BATTERY can explode.• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes andskin.
• Wear gloves and eye protection and becareful when boosting, charging orworking near battery.
To prevent EXPLOSION when:a) Installing a new battery - disconnect the
negative cable from the old battery first and connect the negative cable to the new battery last.
b) Connecting a battery charger - remove the battery from the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last.
c) Using a booster - connect the positive lead to the battery first, then connect the negative lead to the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:a) Installing a new battery.b) Using a booster.
WARNING
Battery Charging
ONAN P218 KOHLER CH20S
Oil Filter ONAN 122-0645 KOHLER 1205001FRAM PH3614 FRAM PH3614*
Air Filter ONAN 140-2628-01 KOHLER 4708303Element FRAM CA140PL FRAM CA79
Air Filter ONAN 140-1496 KOHLER 2408302Pre-Cleaner
Fuel Filter ONAN 149-2005 KOHLER 2505002FRAM 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.
Engine Maintenance Parts
TROUBLESHOOTING
ENGINE
TROUBLE
A. Engine will not crank or is hard tocrank.
B. Engine will not start or shuts down.
C. Engine does not develop fullpower.
D. Battery does not stay charged.
CAUSE
1. Battery will not hold a charge. Faulty battery.
2. No or insufficient charging current.
3. Loose battery cable connection(s).
4. Lead #216A from solenoid to startswitch broken.
5. Spark plugs fouled.
1. Low oil pressure.2. Out of fuel.3. Fault in fuel system.4. #216 lead from start switch to P.C.
board broke / (Onan engine).5. Oil pressure switch faulty.6. Generator terminal block connection
faulty.7. Faulty P.C. Board (Onan engine).
1. Fuel filter clogged.2. Air filter clogged.
1. Faulty battery.2. Faulty charging system.
3. Loose or broken lead in charging circuit.
WHAT TO DO
1. Replace with known good one.
2. Check connection of lead fromvoltage regulator on engine tocharging ammeter and batterylead #208 and #209.
3. Check and tighten connection atbattery, at starter, at engine foot,or at frame.
4. Repair.
5. Replace spark plugs.
1. Check oil level and add oil as req’d.2. Add fuel to tank.3. Repair.4. Repair.
5. Replace6. Repair. Check leads #208, 224A,
224B, 212.7. Replace.
1. Replace.2. Replace.
1. Replace with a new battery.2. Refer to Engine Operators Manual
for charging system service.3. Refer to wiring diagram and check
related leads, especially #208 and#209 leads.
-24 -
IDLER SYSTEM
TROUBLE
A. Engine will not idle down to lowspeed.
B. Engine will not go to high idlewhen attempting to weld.
I. Scratch Start
II. When using wire feeder with con-trol cable plugged into amphenolconnector or using amptrol whentrigger is depressed.
C. Engine will not go to high idle when using auxiliary power.
CAUSE
1. Idler switch in “HIGH” idle position.2. External load on welder or auxiliary
power.3. Mechanical problem in idler solenoid
linkage.4. Idler solenoid position out of adjust-
ment.5. Faulty wiring in solenoid circuit.
6. Contactor circuit #2 or #4 closed orshorted. Engine goes to high idlewhen contactor circuit closes.
7. Faulty idler solenoid.8. Low voltage at 224D to ground stud.
(Voltage should be 12-14V DC).9. Faulty P.C. Board PCB1.
1. Poor work lead connection to work.
2. “WELDING TERMINALS” switch inwrong position.
3. No open circuit voltage on outputstuds.
4. Faulty P.C. Board PCB1.
1. “WELDING TERMINALS” switch inwrong position.
2. Faulty wiring.
1. No signal from current sensor.
2. Auxiliary power lead less than 100watts.
3. Faulty idler P.C. Board
WHAT TO DO
1. Set switch to “AUTO” position.2. Remove all external loads.
3. Repair.
4. Adjust solenoid as necessary.
5. Check for broken leads #224D,214.
6. Refer to wiring diagram. Checkrelated leads and amphenolconnectors.
7. Replace with known good one.8. Check wiring, battery and battery
charging circuits.9. Replace P.C. Board with known
good one.
1. Make sure work clamp is tightlyconnected to clean base metal.
2. Switch must be in “ALWAYS ON”position to scratch start.
3. Check leads #247 and #250 forbreaks. Check Switch S6 for faults.
4. Replace P.C. Board with known good one.
1. Switch must be in “REMOTELYCONTROLLED” position.
2. Refer to schematic. Check wiringin #2 and #4 circuit.
1. Check for broken leads in idlersensing circuit. #3 lead.
2. Idler may not respond with less than 100 watt load. Set idlerswitch to high idle.
3. Replace P.C. Board with knowngood one.
-25 -
OUTPUT SYSTEM
TROUBLE
A. No welder or power output.
B. Output control on welder notfunctioning.
C. Output control or remote notfunctioning.
D. Wire feeder does not work whenconnected to welder amphenol.
CAUSE
1. Open lead in flashing or field circuit.
2. Faulty rotor.
3. Faulty stator field.
4. Faulty field rectifier D2.5. Output contactor does not pull in.
6. Faulty P.C. Board.
1. Output control switch in wrongposition.
2. Output control switch defective.3. Output control potentiometer
defective.4. Faulty wiring.
5. Faulty P.C. Board
1. Output control switch in wrongposition.
2. Leads #75, #76, #77 broken at P.C.Board or S4.
3. Leads #75A, #76A, #77A broken atS4 or amphenol.
4. Remote control leads broken incontrol cable.
5. Faulty wire feeder.
6. Faulty P.C. Board.
1. Wire feeder circuit breaker open orfaulty.
2. Broken #31, #32, or #42 lead at amphenol.
3. No 115V or 42V output from stator.
4. Faulty wiring in control cable.5. Faulty wire feeder.
WHAT TO DO
1. Refer to wiring diagram and checkrelated leads. (#7 & #9; #200, #201 and #219)
2. Lift brushes and check rotorcontinuity between slip rings.(Should be approx. 7.3Ω)
3. Disconnect lead #7 at D2 andcheck for continuity betweenleads #7 and #9.
4. Replace with known good one.5. Refer to wiring diagram and check
related leads and contactor.6. Replace P.C. Board with known
good one.
1. Place switch in “Output Controlat Welder”.
2. Check and replace switch if faulty.3. Check and replace potentiometer
if faulty.4. Check for broken leads #75, #76,
and #77 from P.C. Board and #75A, #76D, and #77D frompotentiometer to remote switch.
5. Replace P.C. Board with known good one.
1. Place switch in “Remote” position.
2. Repair.
3. Repair.
4. Repair.
5. Replace wire feeder with knowngood one.
6. Replace P.C. Board with knowngood one.
1. Reset or replace.
2. Repair.
3. Check continuity on #31, #32, and#42 at stator. Check buildup. IfO.K. , stator may be faulty.Replace.
4. Repair or replace cable.5. Replace P.C. Board with known
good one.
-26 -
OUTPUT SYSTEM
TROUBLE
E. Contactor does not pull in when scratch starting when engine goes to high idle.
F. Contactor does not pull in whenusing a wire feeder with a controlcable plugged into amphenol.
G. Contactor does not drop out.
CAUSE
1. Welding terminal switch in wrongposition.
2. Faulty wiring in contactor circuit.
3. Faulty remote switch S6.
4. Faulty contactor.
5. Faulty P.C. Board PCB1.
1. “WELDING TERMINALS” switchin wrong position.
2. Faulty wiring in contactor circuit.
3. Faulty amphenol or bypass P.C.Board PCB2.
4. Faulty contactor.
5. Faulty P.C. Board PCB1.
6. Faulty control cable from wirefeeder or amphenol.
7. Faulty wire feeder.
1. Faulty wiring.
2. Faulty amphenol or bypass P.C.Board PCB2.
3. Faulty contactor.4. Faulty P.C. Board PCB1.
WHAT TO DO
1. Place switch S6 in “Always On”position.
2. Check for broken leads #224C,#232A, and #224.
3. Check switch and leads #247,and #250.
4. Replace contactor with knowngood one.
5. Replace P.C. Board with knowngood one.
1. Place switch S6 in “REMOTELYCONTROLLED” position.
2. Check for broken leads #224,#224C & #232A.
3. Refer to wiring diagram and check related leads (#2 and #4).
4. Replace contactor with knowngood one.
5. Replace P.C. Board with knowngood one.
6. Replace.
7. Repair or replace.
1. Check that lead #232 is notgrounded.
2. Look for shorts to ground. Repairor replace.
3. Replace with known good one.4. Replace with known good one.
-27 -
-28 -
236
ELEC
TROD
EW
OR
K
241
GN
D
(+)
D1
(-)
R1
C2
25W
100
C3
C4
C5
224E
AM
MET
ER
209
AM
1
AU
TO
HIG
H
35
6
212
CA
PA
CIT
OR
AC
AC
B+
208
STA
RTE
R
REG
ULA
TOR
(+)
(-)
200A
219
200
SR
(+)
(-)
RO
TOR
FIE
LD(+)
(-)
(+) (-)
C1
800
MFD
CV-
CV+
DC
+ DC
-
AC
212
(CAV
ITY
#1)
208
(CA
VITY
#3)
+-
+ -
D2(-
)
(+)
CR1
209
AC
AC
LOC
ATI
NG
3132
429
7
PC
BO
AR
DP
CB
1
1
61
2
1
J1J2
4
58
CURR
ENT
SENS
OR
75A
AM
PH
ENO
L 2
14
58
1 13
46
2
34
J3
J4J5
31B
4232 21
5E GR
OU
ND
SC
REW
PCB2
BYPA
SS P
C
76
10K
PO
TR3
75A
CW
MA
X
ENGI
NEHO
UR M
ETER
115
V
5K
115
V
J6 J7
9
201A
200B
SH
OW
N IN
PO
SIT
ION
+ -
IDLE
R
SO
LEN
OID
12V
CO
NTA
CTO
RA
ND
219
3 TU
RNS
232
254A
235
21
2C75
A
5E3
76A
77A
31A
63A 55L
5L
3B
WHITE
WHITE
WHITE
BLACK BLACK
BLACK
GR
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BLA
CK
6
3B
5K
77A
76A
5E
7
3 3 5A 5F3
76D
77D
76D
76A
77A
224
200B
224C 5A 21
9
224E
76
224D
208A
254A 25
4 3 3 77
235
242
236
232
216A
224A
224B
5F
240 75
200B
232A 21
6
201A21
4
75
3
77
214
201A
216
219
232A
5A
224C
77
2C2A 4A77C
76C
75C
2B75B
77B
76B
4B
4B2B75B
76B
77B
75C
76C
77C
2A4A
(J)
(A)
(D)
(C)
(H)
(E)
(F)
(G)
(I) (K)
(B)
(A)
(B)
(C)
(D)
(E)
(F)
GN
D-C
GN
D-G
115V
AC
CO
NTA
CTO
R
WO
RK
REM
OTE
CO
NTR
OL
42VA
C
GR
OU
ND
REM
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CO
NTR
OL
CO
NTA
CTO
R
GR
OU
ND
GN
D-B
GN
D-A
77A
76A
4C
4C
250
50W
R2
242
S6
L2
CB
1
SO
LEN
OID
216A
S4
212
250
1 32 4
7
2C
2C
240
224A
&B (C
AVI
TY #
4)
232
254
247
C1
W1W
2
C2C3
R1
R2
R3R
4R
5R
6C
1C2 C
3
S2
REA
CTO
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SH
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N IN
"HIG
H'
PO
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ION
5C
5B
208
5C
5D
31A
224B
(CAV
ITY
#2)
232A 20
0B
GN
D-G
232A
"ALW
AYS
ON
" 24
7
208B
5B
5D
201
201
BET
WEE
N A
MP
HEN
OL
HO
LES
ON
5
224C22
4E 224
236A
236A
245
7-1
9-96
G
L1
0248
STA
RTE
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S:
31,0
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FDC
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125/
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ENG
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FOO
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DIN
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TRO
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HM24
0
GN
D-E
242
GR
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GN
D-D
GN
D-C
GN
D-E
GN
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GR
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VOLT
AG
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IGN
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NC
OIL
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NM
OD
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DIA
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INA
LB
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LB
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NEC
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(CLO
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WIT
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2 IN
C1,
C2
OR
C3
PO
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)
RA
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WIT
CH
S2
(10A
MP
)
TAB
CO
LOR
EDS
ILVE
R
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MIN
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CO
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R
TER
MIN
ALS
CO
LOR
EDS
ILVE
R
TER
MIN
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RA
NG
ER
9 (
ON
AN
) -
WIR
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DIA
GR
AM
- C
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E 1
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78
& 1
05
39
EL
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BO
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1537
AL
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: T
his
dia
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fo
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It m
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accu
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anua
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he s
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G
ive
the
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cod
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mb
er..
-29 -
236
ELEC
TROD
EW
OR
K
241
GN
D
(+)
D1
(-)
R1
C2
25W
100
C3
C4
C5
224E
AM
MET
ER
209
AM
1
AU
TO
HIG
H
35
6
212
CA
PA
CIT
OR
AC
AC
B+
208
STA
RTE
R
REG
ULA
TOR
(+)
(-)
CV-
CV+
DC
+ DC
-
AC
212
(CAV
ITY
#1)
208
(CA
VITY
#3)
+-
+ -
CR1
209
LOC
ATI
NG
3132
429
7
PC
BO
AR
DP
CB
1
1
61
2
1
J1J2
4
58
CU
RR
ENT
SEN
SOR
75A
AM
PH
ENO
L 2
14
58
1 13
46
2
34
J3
J4J5
31B
4232 21
5E GR
OU
ND
SC
REW
PCB2
BYPA
SS P
C
76
10K
PO
TR3
75A
CW
MA
X
ENGI
NEHO
UR M
ETER
SH
OW
N IN
PO
SIT
ION
+ -
IDLE
R
SO
LEN
OID
12V
CO
NTA
CTO
RA
ND
219
3 TU
RN
S
232
254A
235
21
2C75
A76
A77
A
31A
77A
76A
3 3 5A 5F3
76D
77D
76D
76A
77A
224
200B
224C 5A 21
9
224E
76
224D
208A
254A 25
4 3 3 77
235
242
236
232
216A
224A
224B
5F
240 75
200B
232A 21
6
201A
214
75
3
77
214
201A
216
219
232A
5A
224C
77
2C2A 4A77C
76C
75C
2B75B
77B
76B
4B
4B2B75B
76B
77B
75C
76C
77C
2A4A
115V
AC
CO
NTA
CTO
R
WO
RK
REM
OTE
CO
NTR
OL
42VA
C
GR
OU
ND
REM
OTE
CO
NTR
OL
CO
NTA
CTO
R
GR
OU
ND
GN
D-B
GN
D-A
4C
4C
250
50W
R2
242
S6
L2
CB
1
SO
LEN
OID
S4
250
1 32 4
7
2C
2C
240
224A
&B (C
AVI
TY #
4)
232
254
247
C1
W1W
2
C2C3
R1
R2
R3R
4R
5R
6C
1C2 C
3
S2
REA
CTO
RE
S1
STA
TOR
SH
OW
N IN
"HIG
H'
PO
SIT
ION
5C
5B
208
5C
5D
31A
224B
(CAV
ITY
#2)
232A
GN
D-D
232A
"ALW
AYS
ON
" 24
7
5B
5D
BET
WEE
N A
MP
HEN
OL
HO
LES
ON
224C22
4E 224
236A
236A
245
7-1
9-96
G
L1
0249
STA
RTE
R M
OTO
R
NO
TE
S:
31,0
00 M
FDC
AP
AC
ITO
RS
WEL
DER
LEA
D E
ND
(NO
TE C
AVI
TY N
UM
BER
S)
REM
OTE
SW
ITC
H(S
HO
WN
INR
EMO
TE P
OS
ITIO
N)
S1
ELEC
TRO
DE
PO
LAR
ITY
SW
ITC
H
OU
TPU
TC
ON
TAC
TOR
L1(C
HO
KE)
OU
TPU
TR
ECTI
FIER
S5
IDLE
RS
WIT
CH
AM
PH
ENO
L 1
GROU
ND S
CREW
BLOW
ER B
AFFL
E
OU
TPU
TR
HEO
STA
T
OIL
PR
ESS
UR
ES
WIT
CH
TO S
PA
RK
PLU
GS
FLYW
HEE
LA
LTER
NA
TOR
ENG
INE
FOO
TEN
GIN
EC
RO
SS
SU
PP
OR
T
GN
D-H
B-
WEL
DIN
G T
ERM
INA
LC
ON
TRO
L S
WIT
CH
25 O
HM24
0
GN
D-E
242
GN
D-E
VOLT
AG
E
IGN
ITIO
NC
OIL
IGN
ITIO
NM
OD
ULE
DIA
GR
AM
"A
"E
NG
INE
TE
RM
INA
LB
LO
CK
CO
NN
EC
TIO
N
SEE
DIA
GR
AM
"A
" FO
REN
GIN
E TE
RM
INA
LB
LOC
K C
ON
NEC
TIO
N.
IDLE
R
S2A
(CLO
SED
WIT
H S
2 IN
C1,
C2
OR
C3
PO
SIT
ION
)
RA
NG
ES
WIT
CH
S2
(10A
MP
)
200A
200
201
(+)
(-)
RO
TOR
FIE
LD
(+)
(-)
(+)
(-)
C1
800
MFD
D2 (+
)AC
AC
201
9
201A
200B
5E
7
77A
76A
115
V
SILV
ER
115/
230V
15A
CB6
15A
CB4
15A
15A
CB5
CB7
J6J8
5L5K
5
11
5K11
5 V
J73C
3D
GREEN
GREEN
GREEN
WHITE
BLACK
BLACK
GND-
G
GN
D-C
GND-
D
125/
250V
. SIN
GLE
RECE
PTAC
LE
GND-
C
GN
D-G
5E
IN L
INE
CO
NN
ECTO
RS
(3 P
LAC
ES)
5L
SLI
PR
ING
S
PO
SIT
IVE
SLI
PR
ING
NEA
RES
TLA
MIN
ATI
ON
5
3E
6
50A
CB2
50A
CB3
12
3D
WHITE
WH
ITE
WHITE
BLA
CK
BLACK
3A3B
3A3B
3C
BLACK
BLACK
BLACK
BLACK
11
BLA
CK
BLA
CK
BLACK
BLACK
BLACK
BLA
CK
BLA
CK
33E
HCDAJ E F G I K B A B C D E F
TERM
.CO
LORE
DSI
LVER
COLO
RED
TERM
INAL
S
SILV
ERCO
LORE
DTE
RMIN
ALS
TAB
RA
NG
ER
9 O
NA
N (C
SA V
ER
SIO
N) -
WIR
ING
DIA
GR
AM
- C
OD
E 1
0379
& 1
0540
EL
EC
TR
ICA
L S
YM
BO
LS
PE
R E
1537
AL
L C
AS
E F
RO
NT
CO
MP
ON
EN
TS
VIE
WE
D F
RO
M R
EA
R.
216A
212
208B
PO
SIT
ION
"S3"
SH
OW
NIN
"R
UN
"
S7 STA
RT
BU
TTO
N
NO
TE
: T
his
dia
gra
m is
fo
r re
fere
nce
onl
y.
It m
ay n
ot
be
accu
rate
fo
r al
l mac
hine
s co
vere
d b
y th
is m
anua
l. T
he s
pec
ific
dia
gra
m f
or
a p
artic
ular
co
de
is p
aste
din
sid
e th
e m
achi
ne o
n o
ne o
f th
e en
clo
sure
pan
els.
If
the
dia
gra
m is
ille
gib
le, w
rite
to
the
Ser
vice
Dep
artm
ent
for
a re
pla
cem
ent.
G
ive
the
equi
pm
ent
cod
e nu
mb
er..
-30 -
236
ELEC
TROD
EW
OR
K
241
GN
D
(+)
D1
(-)
R1
C2
25W
100
C3
C4
C5
224E
AMM
ETER
209A
AM 1
AUTO
HIG
H
35
6
221
ACAC
B+
208
STAR
TER
REG
ULA
TOR
(+)
(-)
CV-
CV+
DC
+ DC
-
AC
221
(CAV
ITY
#1)
211
(CAV
ITY
#3)
+-
CR1
209A
LOC
ATIN
G
3132
429
7
PCB
OAR
DPC
B1
1
61
2
1
J1J2
4
58
CU
RR
ENT
SEN
SOR
75A
AM
PHEN
OL
2
14
58
1 13
46
2
34
J3J4J5
31B
4232 21
5E
PCB2
BYPA
SS P
C
76
10K
PO
TR3
75A
CW
MAX
ENGI
NEHO
UR M
ETER
SHO
WN
IN
POSI
TIO
N
+ -
IDLE
R
SOLE
NO
ID
12V
CO
NTA
CTO
RAN
D
219
3 TU
RN
S
232
254A
235
21
2C75
A76
A77
A
31A
77A
76A
3 3 5A 5F
3
76D
77D
76D
76A
77A
224
200B
224C
5A
219
224E
76
224D
208A
254A 25
4 3 3 77
235
242
236
232
224C21
1
5F
240 75
200B
232A
201A
214
75
3
77
214
201A
219
232A
5A
224C
77
2C2A 4A77C
76C
75C
2B75B
77B
76B
4B
4B2B75B
76B
77B
75C
76C
77C
2A4A
115V
AC
CO
NTA
CTO
R
WO
RK
REM
OTE
CO
NTR
OL
42VA
C
GR
OU
ND
REM
OTE
CO
NTR
OL
CO
NTA
CTO
R
GR
OU
ND
GN
D-B
GN
D-A
4C
4C
250
50W
R2
242
S6
L2
CB
1
SOLE
NO
IDS4
250
1 32 4
7
2C
2C
240
232
254
247
C1
W1W
2
C2C3
R1
R2
R3R
4R
5R
6C
1C2 C
3
S2
REA
CTO
RE
S1
STAT
OR
SHO
WN
IN"H
IGH
'PO
SITI
ON
5C
5B
208
5C
5D
31A
208
(CAV
ITY
#2)
232A
GN
D-D
232A
"ALW
AYS
ON
" 24
7
5B
5D
ON
224C22
4E 224
236A
236A
245
2-2
0-98
N
L1
0889
STA
RTE
R M
OTO
R
NO
TE
S:
31,0
00 M
FDC
APAC
ITO
RS
WEL
DER
LEA
D E
ND
(NO
TE C
AVIT
Y N
UM
BER
S)
REM
OTE
SW
ITC
H(S
HO
WN
INR
EMO
TE P
OSI
TIO
N)
S1 ELEC
TRO
DE
POLA
RIT
YSW
ITC
H
OU
TPU
TC
ON
TAC
TOR
L1 (CH
OK
E)
OU
TPU
TR
ECTI
FIER
S5ID
LER
SWIT
CH
AM
PHEN
OL
1
GROU
ND S
CREW
BLOW
ER B
AFFL
E
OU
TPU
TR
HEO
STAT
OIL
PR
ESSU
RE
SWIT
CH
FLYW
HEE
LAL
TER
NAT
OR
ENG
INE
FOO
TEN
GIN
EC
RO
SSSU
PPO
RT
GN
D-H
B-
WEL
DIN
G T
ERM
INAL
CO
NTR
OL
SWIT
CH
25 O
HM24
0
GN
D-E
242
GN
D-E
VOLT
AGE
IGN
ITIO
NM
OD
ULE
DIA
GR
AM
"A
"E
NG
INE
TE
RM
INA
LB
LO
CK
CO
NN
EC
TIO
N
SEE
DIA
GR
AM "
A" F
OR
ENG
INE
TER
MIN
ALB
LOC
K C
ON
NEC
TIO
N.
IDLE
R
S2A
(CLO
SED
WIT
H S
2 IN
C1,
C2
OR
C3
POSI
TIO
N)
RAN
GE
SWIT
CH
S2
(10A
MP)
200A
200
201
(+)
(-)
RO
TOR
FIE
LD
(+)
(-)
(+) (-)
C1
800
MFD
D2 (+
)ACAC
201
9
201A
200B
5E
7
77A
76A
115
V
SILV
ER
115/
230V
15A
CB6
15A
CB4
15A
15A
CB5
CB7
J6J8
5L5K
5
11
5K11
5 V
J73C
3D
GREEN
GREEN
GREEN
WHITE
BLACK
BLACK
GND-
G
GN
D-C
GND-
D
125/
250V
. SIN
GLE
RECE
PTAC
LE
GND-
C
GN
D-G
5E
IN L
INE
CO
NN
ECTO
RS
(3 P
LAC
ES)
5L
SLI
PR
ING
S
PO
SIT
IVE
SLI
PR
ING
NEA
RES
TLA
MIN
ATI
ON
5
3E
6
50A
CB2
50A
CB3
12
3D
WHITE
WH
ITE
BLA
CK
BLACK
3A3B
3A3B
3C
BLACK
BLACK
BLACK
BLACK
11
BLA
CK
BLA
CK
BLACK
BLACK
BLACK
BLA
CK
BLA
CK
33E
HCDAJ E F G I K B A B C D E F
TERM
.CO
LORE
DSI
LVER
COLO
RED
TERM
INAL
S
SILV
ERCO
LORE
DTE
RMIN
ALS
TAB
EL
EC
TR
ICA
L S
YM
BO
LS
PE
R E
1537
AL
L C
AS
E F
RO
NT
CO
MP
ON
EN
TS
VIE
WE
D F
RO
M R
EA
R.
210
208B
POSI
TIO
N
"S3"
SH
OW
NIN
"R
UN
"
S7 STAR
TB
UTT
ON
GR
OU
ND
SC
REW
BET
WEE
NAM
PHEN
OL
HO
LES
224C
(CAV
ITY
#4)
V
211
221
5H
5H
210
224C
W
U
R R
FUEL
SHU
TOFF
SOL.
224A
224A
WHITE
RA
NG
ER
9 K
OH
LER
(CSA
VE
RSI
ON
) - W
IRIN
G D
IAG
RA
M -
CO
DE
105
50
NO
TE
: T
his
dia
gra
m is
fo
r re
fere
nce
onl
y.
It m
ay n
ot
be
accu
rate
fo
r al
l mac
hine
s co
vere
d b
y th
is m
anua
l. T
he s
pec
ific
dia
gra
m f
or
a p
artic
ular
co
de
is p
aste
din
sid
e th
e m
achi
ne o
n o
ne o
f th
e en
clo
sure
pan
els.
If
the
dia
gra
m is
ille
gib
le, w
rite
to
the
Ser
vice
Dep
artm
ent
for
a re
pla
cem
ent.
G
ive
the
equi
pm
ent
cod
e nu
mb
er..
– 31 –
12 -16-93
M17090
ELECTRODE CABLE
LN-25WIRE FEEDER
REMOTE CONTROL
TO WORK ELECTRODE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
TO WORK
WORK CLIP LEAD
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
TO WORK
6 PINAMPHENOL
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.
RANGER 9 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
14 PINAMPHENOL
N.D. WELDING TERMINALS SWITCH MUST BE PLACED IN "ALWAYS ON" POSITION.
OPTIONAL K444-1
12 -16-93
M17091
SPARE
82
81
42
41
31
32
2
4
21
GND
75
76
77
31
32
2
4
21
GNDK867 UNIVERSALADAPTER PLUG
75
76
77
GREEN
TO WORK ELECTRODE
TO WORK
14 P INAMPHENOL
CAUTION :
N.D.
N.E.
ELECTRODE CABLETO WIRE FEED UNIT
LN-7WIREFEEDER
K291 OR K404INPUT CABLE
K775 OPTIONALREMOTE CONTROL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.N.E. SPLICE LEADS AND INSULATE.
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.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
RANGER 9 / K867 / K775 / LN-7 CONNECTION DIAGRAM
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.F. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
– 32 –
12 -16-93
M17092
ELECTRODE CABLE
OPTIONAL K857REMOTE CONTROL
TO WORK ELECTRODE6 PINAMPHENOL
14 PINAMPHENOL
TO WORK
TO WIRE FEED UNIT
TO LN-7 INPUTCABLE PLUG
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTUREAPPLICATIONS. SEE OPERATING MANUAL.
N.A. 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" POSITIION.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
RANGER 9 / LN-7 CONNECTION DIAGRAM
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
K584-XX INPUT CABLE ASSEMBLY
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
12 -16-93
M17093
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.C.
76
8281
SPARE2441423132
GND21
77
75REMOTE OUTPUT CONTROL
N.D.
2
4
10K
MIN.
NOT USED ON RANGER POWER SOURCES
42 VAC
115 VACN.E.
POWER SOURCE FRAME CONNECTION
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION RELAY TO CLOSE LEADS 2 & 4.
K867 UNIVERSALADAPTER PLUG
14 PINAMPHENOL
{
TO WORK ELECTRODE
TO WORK
N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.
CAUTION :
N.B. USE POLARITY SWITCH TO SET DESIRED POLARITY, POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
CONNECT TOGETHER FOR
WELDING OUTPUT
WIRE FEEDER VOLTMETER CONNECTIONCONNECTS TO (WORK TERMINAL) OF POWER SOURCEELECTRODE CABLE
TO WIRE FEED UNIT
TOWIREFEEDER
TOK867
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
RANGER 9 TO K867 ADAPTER CONNECTION DIAGRAM
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
– 33 –
12 -16-93
M17094
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
SPARE
82
81
42
41
31
32
2
4
21
GND
75
76
77
31
32
2
4
21
GND
N.C.
K867 UNIVERSALADAPTER PLUG
N.D.
N.D. SPLICE LEADS AND INSULATE.
TO WORK ELECTRODE
TO WORK
CAUTION :
A
B
C
14 PIN
AMPHENOL
K196INPUT CABLE
LN-8WIREFEEDER
ELECTRODE CABLETO WIRE FEED UNIT
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM
"REMOTELY CONTROLLED " POSITION.PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION. PLACE WELDING TERMINALS SWITCH TO
N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
12 -16-93
M17100
ELECTRODE CABLE
TO WORK ELECTRODE
14 PINAMPHENOL
TO WORK
TO WIRE FEED UNIT
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTUREAPPLICATIONS. SEE OPERATING MANUAL.
K592 CONTROL CABLE
N.A. 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" POSITIION.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
RANGER 9 / LN-742 CONNECTION DIAGRAM
TO LN-742 INPUTCABLE PLUG
PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
12 -16-93
M17214
ELECTRODE CABLE
TO WORK ELECTRODE
14 PINAMPHENOL
TO WORK
TO WIRE FEED UNIT
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTUREAPPLICATIONS. SEE OPERATING MANUAL.
N.A. 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" POSITIION.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
RANGER 9 / LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM
K626-XX INPUT CABLE ASSEMBLY
TO LN-25 INPUTCABLE PLUG
WARNINGDo not operate with panels open.Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.Only qualified personnel should install,useor service this equipment.
– 34 –
4-19-96D
S20909
WARNING
can killELECTRIC SHOCK
- +
POWER SOURCE
6-PINPLUG
ELECTRODE LEADWORK SENSE LEAD
**
BYPASSCAPACITOR
KIT
*
HI-FREQ KITINPUT POWER
*
5-PINPLUG
K915-1AMPTROLADAPTER
6-SOCKETRECEPTACLE
K963 HAND
AMPTROL
K870 FOOT
AMPTROL
OR
*KIT FOR CONNECTION INFORMATION.SEE INSTRUCTIONS INCLUDED WITH HI-FREQ
THIS ADAPTER ALLOWS AN AMPTROL TO OPERATE A
OUTPUT CURRENT OF A LINCOLN POWER SOURCE.(THE POWER SOURCE MUST BE EQUIPPED WITH A6-PIN REMOTE CONTROL AMPHENOL CONNECTOR.)SEE THE HI-FREQ KIT AND POWER SOURCE INSTRUC-
AND CONTROL SETTINGS.TION MANUAL FOR INFORMATION ON PROPER SWITCH
OF THE WELDING POWER SOURCE "OFF"
TURN THE ENGINE OR POWER SWITCH
BEFORE CONNECTING OR DISCONNECTING
PLUGS TO WELDING POWER SOURCE.
K915-1 AMPTROL ADAPTER FOR K799 HI-FREQ KITS
K799 HI-FREQ KIT WHILE REMOTELY CONTROLLING THE
K799 HI-FREQ KIT
CRM23615
M17902
TO WORK ELECTRODE
TO WORK
CAUTION :
ELECTRODE CABLETO CONTROL MODULE
WARNINGDo not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEADbefore servicing.
Do not touch electrically live parts.
Keep guards in place.Keep away from moving parts.
Only qualified personnel should install,useor service this equipment.
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.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED INTHE ENGINE WELDER OPERATING MANUAL.
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
RANGER
14 PIN WIRE FEEDERRECEPTACLE
K488 SGCONTROL MODULE
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.
K487-25SPOOL GUN
K691-10INPUT CABLE
6 PIN REMOTERECEPTACLE
115V RECEPTACLE
RANGER 9 AND 10LX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM
N.C. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.
– 35 –MAR 95
– 36 –
DIM
EN
SIO
N P
RIN
T
- R
ang
er 9
CEN
TER
OF
GR
AVIT
Y W
ITH
OIL
INEN
GIN
E AN
D E
MPT
Y FU
EL T
ANK
.
30.0
08.
80
UN
DER
CAR
RIA
GE
MO
UN
TIN
G H
OLE
S
17.0
0
9.09
L
2.75
OF
SHAF
T
42.0
0
30.0
0
C
9.31
9.29
9.09
26.5
9
REQ
UIR
ED W
ITH
K
OH
LER
EN
GIN
E)
FOR
OIL
FIL
TER
R
EMO
VAL
(NO
T12
.75~
.25
20.5
1
20.6
3 ~.
25
CEN
TER
OF
GR
AVIT
Y W
ITH
OIL
INEN
GIN
E AN
D E
MPT
Y FU
EL T
ANK
.
30.2
8
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts orelectrode with skin or wet clothing.
● Insulate yourself from work andground.
● No toque las partes o los electrodosbajo carga con la piel o ropamojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni desvêtements mouillés entrer en contactavec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
● Isolieren Sie sich von denElektroden und dem Erdboden!
● Não toque partes elétricas eelectrodos com a pele ou roupamolhada.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustiblefuera del área de trabajo.
● Gardez à l’écart de tout matérielinflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bemguardados.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y elcuerpo.
● Protégez vos yeux, vos oreilles etvotre corps.
● Tragen Sie Augen-, Ohren- und Kör-perschutz!
● Use proteção para a vista, ouvido ecorpo.
– 39 –
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona derespiración.
● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un
aspirateur pour ôter les fumées deszones de travail.
● Vermeiden Sie das Einatmen vonSchweibrauch!
● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable dealimentación de poder de lamáquina antes de iniciar cualquierservicio.
● Débranchez le courant avantl’entretien.
● Strom vor Wartungsarbeitenabschalten! (Netzstrom völligöffnen; Maschine anhalten!)
● Não opere com as tampas removidas.● Desligue a corrente antes de fazer
serviço.● Não toque as partes elétricas nuas.
● Do not operate with panel open orguards off.
● No operar con panel abierto oguardas quitadas.
● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
● Mantenha-se afastado das partesmoventes.
● Não opere com os paineis abertosou guardas removidas.
• 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 •
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