IM511-D
RANGER TM 9 OCTOBER, 2000
Multi-Process Gasoline Engine Driven Welder and Power Generator
For use with machines having Code Number 10378, 10379, 10539, 10540 and 10550
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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.
Date of Purchase:
R
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2000 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause
cancer, birth defects, or other reproductive harm.
cancer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you 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 the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot� when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot� parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
5.a. Welding may produce fumes and gases
� Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
� DC Manual (Stick) Welder.
fumes and gases.When welding, keep
� AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically “hot�.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
3.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
3.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate
8.b. Install equipment in accordance with the U.S. National
circuits. This can create fire hazards or overheat lifting
Electrical Code, all local codes and the manufacturer’s
chains or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
6. Eloigner les matériaux inflammables ou les recouvrir afin de
tions et les précautions de sûreté specifiques qui parraissent dans
prévenir tout risque d’incendie dû aux étincelles.
ce manuel aussi bien que les précautions de sûreté générales
suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc
échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension
de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours
la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue
endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans
de voir passer le courant de soudage par les chaines de
trous pour isoler les mains.
levage, câbles de grue, ou autres circuits. Cela peut provo-
b. Faire trés attention de bien s’isoler de la masse quand on
quer des risques d’incendie ou d’echauffement des chaines et
soude dans des endroits humides, ou sur un plancher
des câbles jusqu’� ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
9. Assurer une ventilation suffisante dans la zone de soudage.
grande partie du corps peut être en contact avec la
Ceci est particuliérement important pour le soudage de tôles
masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les
e. Ne jamais toucher simultanément les parties sous tension
vapeurs du solvant pour produire du phosgéne (gas
des porte-électrodes connectés à deux machines Ã
fortement toxique) ou autres produits irritants.
souder parce que la tension entre les deux pinces peut
être le total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se
protéger contre les chutes dans le cas ou on recoit un choc.
PRÉCAUTIONS DE SÛRETÉ POUR
Ne jamais enrouler le câble-électrode autour de n’importe
LES MACHINES À SOUDER À
quelle partie du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du 1. Relier à la terre le chassis du poste conformement au code de
rayonnement de l’arc et des projections quand on soude l’électricité et aux recommendations du fabricant. Le
ou quand on regarde l’arc. dispositif de montage ou la piece à souder doit être branché
b. Porter des vêtements convenables afin de protéger la peau à une bonne mise à la terre.
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste seront
soudage à l’aide d’écrans appropriés et non- effectués par un électricien qualifié.
inflammables.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS
Safety Precautions ............................................................................................................ii-iv
Introductory Information......................................................................................................v
General Description ............................................................................................................7
Specifications ....................................................................................................................7-8
Optional Features ...............................................................................................................9
Recommended Equipment ................................................................................................10
Installation Instructions....................................................................................................11-12
Machine Grounding .......................................................................................................11
Spark Arrester ...............................................................................................................11
Trailers ........................................................................................................................11-12
Pre-Operation Service .......................................................................................................12
Oil ..................................................................................................................................12
Fuel ...............................................................................................................................12
Battery Connection........................................................................................................12
Welding Output Cables .................................................................................................12
Location/Ventilation .......................................................................................................12
Operation ........................................................................................................................13-14
High Altitude Operation .................................................................................................13
Muffler Relocation .........................................................................................................13
Connection of Wire Feeders .........................................................................................13
Connection of K428 or K446 with K624-1 Remote Output Module ..............................13
Connection of K449 to the Ranger 9 ............................................................................13
Connection of LN-7 or LN-8 to the Ranger 9................................................................14
Connection of the LN-742 to the Ranger 9 ...................................................................14
Connection of the Magnum Spool Gun and SG Control Module to the Ranger 9........14
Remote Output Control .................................................................................................14
High Frequency Generator for TIG welding applications .............................................14
Operating Instructions .....................................................................................................15-17
Additional Safety Precautions .......................................................................................15
Welder Operation ..........................................................................................................15
Welder Controls, Functions, and Operation................................................................15-16
Engine Operation........................................................................................................16-17
Welding Processes .....................................................................................................17-18
Auxiliary Power ...........................................................................................................19-20
Standby Power Information and Connection to Premises Wiring Diagram ............... 20-21
Maintenance....................................................................................................................22-23
General Instructions ......................................................................................................22
Engine Adjustments ......................................................................................................22
Slip Rings ......................................................................................................................22
Battery ...........................................................................................................................23
Hardware .......................................................................................................................23
Troubleshooting ...............................................................................................................24-27
General Troubleshooting ...............................................................................................24
Electronic Idler Troubleshooting ....................................................................................25
Output System Troubleshooting..................................................................................26-27
Wiring Diagram ...............................................................................................................28-30
Connection Diagrams......................................................................................................31-35
Dimension Print .................................................................................................................36
Parts Pages ...............................................................................................................P230 Series
GENERAL DESCRIPTION SPECIFICATIONS
The Rangerâ„? 9, is a twin cylinder gasoline engine
AC STICK / TIG (CC) OUTPUT
driven multi-process arc welder and AC power
80
generator. It is built in a heavy gauge steel case for A 250 OUTPUT RANGE
durability on the job site. 70 B 45 OUTPUT RANGE
OUTPUT VOLTS AC
60
RECOMMENDED PROCESSES AND 50
EQUIPMENT
40
The Ranger 9 can be used for AC/DC Stick welding
(CC), DC Semiautomatic wire feed welding (CV),
30
AC/DC Tig welding (CC), and also offers a 9,000 Watt
AC 115/230 Volt, 60 Hertz power generator. 20 B
A
For AC/DC Stick welding, the range is 40-250 Amps. 10
There is a 100% duty cycle on all settings. The
0
Output selector covers six ranges with remote output
0 50 100 150 200 250 300 350
control for fine current adjustment. For use with a
OUTPUT AMPS
broad range of AC and DC electrodes including
Fleetweld® 5P.
For DC Semi-automatic wire feed welding, three
constant voltage wire feed welding settings are DC STICK / TIG (CC) OUTPUT
80
available giving a range of 40-250 Amps at 100% duty
A 250 OUTPUT RANGE
cycle. Excellent performance will be obtained with a
70
broad range of Innershield ® and Outershield ® B 45 OUTPUT RANGE
electrodes (FCAW). Excellent arc characteristics are OUTPUT VOLTS DC
60
available with MIG (GMAW). An output contactor is
provided for optimum semiautomatic welding. 50
40
AC and DC Tig welding can be done at all constant
current output settings.
30
The auxiliary power is provided by a 9,000 Watt, AC 20
115/230 Volt, 60 Hertz generator. It will operate AC
A
B
power tools. It will also power a 1.5 HP motor (if 10
started under no load). It is capable of lighting ninety
0
100 Watt incandescent bulbs, and can also be used
50 100 150 200 250 300 350 400 450
0
for standby emergency power.
OUTPUT AMPS
The Ranger 9 CSA machine (K1420-2) has four 15
amp circuit breakers for 115V auxiliary receptacles
and two 50 amp circuit breakers for 230V receptacles.
This machine is CSA approved. DC WIRE FEED (CV) OUTPUT
55
50
45
OUTPUT VOLTS DC
40
35
30
HIGH
25
20
15 MED
10 LOW
5
0
100 150 200 250 300 350 400
0 50
OUTPUT AMPS
-7-
SPECIFICATIONS
Machine
Rated DC Output * Dimensions
AC Power **
Product Ordering Auxiliary Power for
Description
Amps / Volts / Duty Cycle & Weight
Name Information Wire Feeders
Ranger 9 K1420-1 9,000 Watts 30.3 x 19.2 x 42.3 in
AC Constant Current
250 Amp 42V, 60 Hz, 8 Amps
(Onan) 60 Hz. DC
250A / 25V / 100%
AC/DC
K1420-2 (770 x 488 x 1075 mm)
Multi-Process 115V, 60 Hz, 8 Amps
CSA(Meets
80 Amps @
DC Constant Current
Arc Welder
Canadian 598 lbs (272 kg)
115V
250A / 25V / 100%
Standards)
with
DC Constant Voltage 40 Amps @
250A / 25V / 100%
9,000 Watts AC 230V
Auxiliary
Ranger 9 K1421-1 30.3 x 19.2 x 42.3 in
Max OCV @ 3700 RPM
Power
(Kohler) CSA
80V
(Meets
(770 x 488 x 1075 mm)
Canadian
Standards)
591 lbs (269 kg)
* Based on a 10 min. period.
** When welding, available AC auxiliary power will be reduced.
115V will operate either 60Hz or 50/60Hz power tools, lights, etc.
Engine
Product Description Horsepower Operating Displacement Ignition Capacities
Name Speeds
Ranger 9 2 Cylinder Full Load: 47.7 cu in 12V Battery, 430 Fuel:
(Onan P218) 4 Cycle 18 HP 3500 RPM (782 cc) Cold Cranking 9 Gal (34 L)
Air-Cooled @ 3600 RPM Amps, Toggle Start
Gasoline Engine. High Idle: Switch, Charging Lubricating Oil:
Aluminum Alloy 3700 RPM Ammeter, Manual 1.8 Qts (1.7 L)
Block with Cast Iron Choke
Liners, Electronic Low Idle:
Ignition 2200 RPM
Ranger 9 20 HP 38.1 cu in Fuel:
(Kohler Command @ 3600 RPM (624 cc) 9 Gal (34 L)
CH20S)
Lubricating Oil:
2.0 Qts (1.9 L)
-8-
OPTIONAL FEATURES
A) K768-2 Two Wheel Undercarriage G) K934-1 Bracket for Mounting a Gas Cylinder to a
K933-1 Undercarriage
For in-plant and yard towing. (For highway use,
consult applicable federal, state, and local laws Easily mounts on the back of the K933-1 Four Wheel
regarding possible requirements for brakes, lights, Undercarriage to carry a welding gas cylinder.
fenders, etc.) Two 4.80 x 12" four-ply tubeless tires.
Bed-plate mounting. Has stand for tow bar and grips
for hand pulling. Overall width 43.06" (1.09 m). H) K889-2 Two Wheel Undercarriage
For moving by hand. Two 4.00" x 8" industrial tires.
B) K886-1 Canvas Cover Overall width 29" (.74m).
To protect the Ranger 9 when not in use. Made from
attractive red canvas material that is flame retardant,
mildew resistant, and water repellent. I) K857 Remote Control
Consists of a control box with 25' (7.5 m) of four
C) K894-1 Spark Arrester Kit conductor cable. Permits remote adjustment of output
voltage.
Includes a heavy gauge steel, approved spark
arrester and clamp for easy mounting to muffler
exhaust pipe. J) K893-1 Caster for Two Wheel Undercarriage
Mounts to the front of the K889-2 Two-Wheel
D) K896-1 GFCI Receptacle Kit Undercarriage to allow easy movement on smooth
surfaces. Includes a 6" diameter hard rubber wheel
Includes two UL approved 115 Volt ground fault circuit with a convenient toe-on, toe-off locking brake.
interrupter duplex type receptacles with covers and
installation instructions. Replaces the two factory
installed 115 Volt duplex receptacles. Each recepta- K) K702 Accessory Kit
cle of each GFCI duplex is rated at 15 Amps but the
maximum total current from each GFCI duplex is Accessory Set includes 35 ft. 2 AWG electrode cable,
limited to 20 amps. 30 ft. 2 AWG work cable, headshield with number 12
filter, work clamp, and Cooltong ® 300 electrode
holder. Cables are rated at 250 Amps, 40% duty
E) K930-1 TIG Module cycle.
Provides high frequency and shielding gas control for
AC and DC GTAW (TIG) welding applications. L) K802-R Power Plug Kit
Compact case is designed for easy carrying,
complete with handle. High frequency bypass is built Provides four 115 Volt plugs rated at 15 Amps each
in. The K939-1 Docking Kit is available for mounting and one dual voltage, full KVA plug rated at 115/230
the TIG Module on top of the Ranger 9. The K936-1 Volts, 50 amps.
control cable is required.
M) K802-N Power Plug KIt
F) K933-1 Four Wheel Undercarriage
Provides four 115 Volt plugs rated at 20 Amps each
Allows movement of the Ranger 9 by hand without and one dual voltage, full KVA plug rated at 115/230
lifting. Easily assembles to the Ranger 9. It includes Volts, 50 Amps. (Not for use with K1420-2 CSA
two rugged, hard molded wheels and two durable machine and machines with GFCI receptacles.)
pneumatic tires. The spring loaded handle provides
convenient, comfortable steering. The k934-1 Bracket
is available for mounting a gas cylinder on the under-
carriage.
-9-
RECOMMENDED EQUIPMENT
WIRE FEED
STICK
LN-25 (K428 or K446) with K624-1 42 Volt Remote
K702 Accessory Kit which includes:
Output Control Module - Requires K626-xx Control
Cable. Provides "cold" electrode until gun trigger is
� Electrode holder and cable
pressed. Voltage control is at the feeder. K446
� Work clamp and cable
LN-25 includes gas solenoid.
� Headshield
LN-25 (K449) Includes internal contactor for across
K857 Remote Control Kit is optional for remote
the arc operation (no control cable). Provides "cold"
current control.
electrode until gun trigger is pressed. Includes gas
solenoid. K444-1 Remote Voltage Control Kit is
required for voltage control at the feeder.
LN-742 (K617-1 or K618-1) or LN-742H (K617-2 or
TIG K618-2), requires K619-xx Input Cable Assembly.
Provides "cold" electrode until gun trigger is pressed.
Magnumâ„? TIG Torch Includes gas solenoid. K589-1 Remote Control Kit
connects to the LN-742 to provide remote voltage and
Magnum Parts Kit and Argon gas
wire speed control or K857 Remote Voltage Control
K930-1 TIG Module
Kit connects to the Ranger 9 for voltage control at the
K936-1 Control Cable
feeder.
Optional:
LN-7 (K521) or LN-7 GMA (K440), requires K584-xx
Input Cable Assembly. Provides "cold" electrode until
K939-1 TIG Module Docking Kit
K963 Hand Amptrolâ„? gun trigger is pressed. K440 LN-7 GMA included gas
solenoid. K8567 Remote Voltage Control Kit is
K870 Foot Amptrol
required for voltage control at the feeder. Ranger 9
K814 Arc Start Switch
must be operated at "HIGH" idle.
Magnum Gun is required for gas-shielded welding.
Innershield Gun is required for gas-less welding.
- 10 -
INSTALLATION INSTRUCTIONS
In general, if the machine is to be grounded, it should
WARNING be connected with a #8 or larger copper wire to a
solid earth ground such as a metal water pipe going
Do not attempt to use this equipment until you
into the ground for at least ten feet and having no
have thoroughly read the engine manufacturer’s
insulated joints, or to the metal framework of a
manual supplied with your welder. It includes
important safety precautions, detailed engine building which has been effectively grounded. The
starting, operating and maintenance instructions, U.S. National Electrical Code lists a number of
and parts lists. alternate means of grounding electrical equipment. A
------------------------------------------------------------------------
machine grounding stud marked with the symbol
ELECTRIC SHOCK can kill.
is provided on the front of the welder.
� Do not touch electrically live parts or
electrode with skin or wet clothing.
Spark Arrester
� Insulate yourself from work and
ground
� Always wear dry insulating gloves. Some federal, state or local laws may require that
------------------------------------------------------------------------ gasoline engines be equipped with exhaust spark
ENGINE EXHAUST can kill.
arresters when they are operated in certain locations
� Use in open, well ventilated areas or
where unarrested sparks may present a fire hazard.
vent exhaust outside.
The standard muffler included with this welder does
not qualify as a spark arrester. When required by
------------------------------------------------------------------------ local regulations, the K894-1 arrester must be
MOVING PARTS can injure. installed and properly maintained.
� Do not operate with doors open or
guards off.
CAUTION
� Stop engine before servicing.
� Keep away from moving parts.
Use of an incorrect arrester may lead to engine
------------------------------------------------------------------------
damage or performance loss.
-----------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
Machine Grounding Undercarriages
Because this por table engine driven welder or The recommended undercarriage for use with this
equipment for in-plant and yard towing by a vehicle (1)
generator creates it’s own power, it is not necessary
to connect it’s frame to an earth ground, unless the is Lincoln’s K768-2. If the user adapts a non-Lincoln
machine is connected to premises wiring (your home, undercarriage, he must assume responsibility that the
shop, etc.).
method of attachment and usage does not result in a
safety hazard nor damage the welding equipment.
To prevent dangerous electric shock, other equipment
Some of the factors to be considered are as follows:
to which this engine driven welder supplies power
must:
(1) Consult applicable federal, state and local laws
regarding specific requirements for use on public
a. be grounded to the frame of the welder using a
highways.
grounded type plug, or
1. Design capacity of undercarriage vs. weight of
b. be double insulated.
Lincoln equipment and likely additional
attachments.
When this welder is mounted on a truck or trailer, it’s
2. Proper support of, and attachment to, the base of
frame must be securely connected to the metal frame
the welding equipment so there will be no undue
of the vehicle.
stress to the framework.
3. Proper placement of the equipment on the
Where this engine driven welder is connected to
undercarriage to ensure stability side to side and
premises wiring, such as that in your home or shop,
front to back when being moved and when standing
it’s frame must be connected to the system earth
by itself while being operated or serviced.
ground. See further connection instructions in the
section entitled Standby Power Connections in this
manual, as well as the article on grounding in the
latest U.S. National Electrical Code and the local
code.
-11 -
Battery Connection
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be
operated; environmental conditions; like This welder is shipped with the negative battery cable
maintenance. disconnected. Make sure that the Engine Switch is in
the “STOP� position and attach the disconnected
Conformance with federal, state and local laws.(1)
5. cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
(1) Consult applicable federal, state and local laws regarding discharged and does not have enough power to start
specific requirements for use on public highways. the engine, see the Maintenance-Battery section of
this manual for battery charging instructions.
PRE-OPERATION SERVICE Welding Output Cables
CAUTION With the engine off, connect the electrode and work
cables to the studs provided. These connections
READ the engine operating and maintenance instruc- should be checked periodically and tightened if
tions supplied with this machine. necessary.
------------------------------------------------------------------------
Listed below are copper cable sizes recommended for
WARNING the rated current and duty cycle. Lengths stipulated
are the distance from the welder to work and back to
GASOLINE fuel can cause fire or
the welder again. Cable sizes are increased for
explosion.
greater lengths primarily for the purpose of minimizing
� Stop engine while fueling.
cable voltage drop.
� 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 TOTAL COMBINED LENGTH OF
before starting engine. ELECTRODE AND WORK CABLES
250 Amps 250 Amps
40% Duty Cycle 100% Duty Cycle
2 AWG 1 AWG
0-50 Ft.
2 AWG 1 AWG
50-100 Ft.
Oil
1 AWG 1 AWG
100-150 Ft.
The Ranger 9 is shipped with the engine crankcase
filled with SAE 10W-30 oil. Check the oil level before 150-200 Ft. 1 AWG 1 AWG
starting the engine. It if is not up to the full mark on
the dipstick, add oil as required. Make certain that the 200-250 Ft. 1/0 AWG 1/0 AWG
oil filter cap is tightened securely. Refer to the engine
Operators Manual for specific oil recommendations.
Location / Ventilation
LUBRICATION SYSTEM CAPACITY
The welder should be located to provide an unrestrict-
(INCLUDING FILTER)
ed flow of clean, cool air to the cooling air inlets and
Onan P218 - 1.8 Quarts (1.7 Liters)
to avoid heated air coming out of the back of the
Kohler CH20S - 2.0 Quarts (1.9 Liters)
welder recirculating back to the cooling air inlets
below the exhaust. Also, locate the welder so that the
engine exhaust fumes are properly vented to an
outside area.
Fuel
Fill the fuel tank with clean, fresh lead-free gasoline.
The capacity is approximately 9 gallons (34 liters).
WARNING
Observe the fuel gauge while filling to prevent overfill-
ing. Damage to fuel tank may cause fire or explosion.
Do NOT drill holes in the Ranger 9 base or weld to
the Ranger 9 base.
------------------------------------------------------------------------
-12 -
Angle of Operation Connection of Lincoln Electric
Wire Feeders
Engines are designed to run in the level condition
which is where the optimum performance is achieved. WARNING
The maximum angle of operation for the engine is 15
degrees from horizontal in any direction. If the engine Shut off welder before making any electrical
is to be operated at an angle, provisions must be connections.
made for checking and maintaining the oil level at the ------------------------------------------------------------------------
normal (FULL) oil capacity in the crankcase. Connection of K428 or K446 LN-25 with
K624-1 42 volt Remote Output Control
When operating the welder at an angle, the effective Module to the Ranger 9.
fuel capacity will be slightly less than the specified 10 Requires K626-xx Control Cable. Provides “cold� electrode
gallons. until gun trigger is pressed and also provides voltage control at
the feeder. The K446 LN-25 includes a gas solenoid. See the
High Altitude Operation appropriate connection diagram in rear of this manual.
If the Ranger 9 will be consistently operated at a. Shut off the welder.
altitudes above 5,000 feet, a carburetor jet designed
for high altitudes should be installed. This will result in b. Connect the electrode cable from the LN-25 to the
better fuel economy, cleaner exhaust, and longer “ELECTRODE� stud of the welder. Connect the
spark plug life. It will not give increased power which work cable to the “TO WORK� stud of the welder.
is decreased at higher altitudes. Engine horsepower is
reduced by 3.5% per 1000 feet for altitudes above 377 c. Connect the control cable from the LN-25 to the
feet. 14 pin amphenol on the Ranger 9.
High altitude jet kits are available from the engine
manufacturer. Order Onan kit part number 146-0458. d. Attach the single lead from the front of the LN-25
to the work using the spring clip on the end of the
CAUTION lead.
Do not operate a Ranger 9 with a high altitude jet installed
This is a control lead to supply the current to
at an altitude below 5,000 ft. This will result in the engine
the wire feeder motor; it does not carry welding
running too lean and result in higher engine temperatures
current.
which can shorten engine life.
------------------------------------------------------------------------
e. Set the “POLARITY� switch to either WIRE FEED
Muffler Relocation
DC+ or WIRE FEED DC- as required by the
WARNING electrode being used.
f. Set the “RANGE� switch to either HIGH, MED or
Shut off welder and allow muffler to cool before
LOW as required by the process.
touching muffler.
------------------------------------------------------------------------
g. Set the “WELDING TERMINALS� Control switch to
The Ranger 9 is shipped with the exhaust coming out on
the “REMOTELY CONTROLLED� position.
the left side of the machine. The exhaust can be changed
to the opposite side by removing the two screws that hold
h. Set the “IDLER� switch to the “AUTO� position.
the exhaust port cover in place and installing the cover on
the opposite side. (Operating the Ranger 9 without the
cover in place will result in a higher noise level and no
Connection of the K449 LN-25 to the
increase in machine output.)
Ranger 9.
a. Shut off the welder.
b. Connect the electrode cable from the LN-25 to the
“ELECTRODE� stud of the welder. Connect the
work cable to the “TO WORK� stud of the welder.
c. Attach the single lead from the front of the LN-25 to
work using the spring clip on the end of the lead.
This is a control lead to supply the current to the
wire feeder motor; it does not carry welding current.
-13 -
Connection of the Magnum Spool Gun
d. Set the “POLARITY� switch to either WIRE FEED
and SG Control Module to the Ranger 9
DC+ or WIRE FEED DC- as required by the
electrode being used.
a. Shut off the Welder.
e. Set the “RANGE� switch to either HIGH, MED or
b. Connect per the instructions on the appropriate
LOW as required by the process.
connection diagram in the rear of this manual.
f. Set the “WELDING TERMINAL� Control switch to
the “ALWAYS ON� position. c. Set the output control toggle switch to “CONTROL
AT WELDER� when not using remote control.
g. Set the “IDLER� switch to the “AUTO� position.
d. Set the “POLARITY� switch to WIRE FEED DC+.
Connection of the LN-7 or LN-8 to the
Ranger 9. e. Set the “RANGE� switch to either HIGH, MED or
LOW as required by the process.
a. Shut off the welder.
f. Set the “WELDING TERMINALS� Control switch to
b. Connect the LN-7 or LN-8 per the instructions on
the “REMOTELY CONTROLLED� position.
the appropriate connection diagram in the rear of this
manual.
g. Set the “IDLER� switch to the “HIGH� idle position.
c. Set the output control toggle switch to appropriate
position: “CONTROL REMOTE� for LN-8 and LN-7
Remote Output Control
with K857 attached; “CONTROL AT WELDER� for
LN-7 with no remote voltage control.
The Ranger 9 has a 6-pin and a 14-pin Amphenol
connector. These connectors are located above the
d. Set “POLARITY� switch to either WIRE FEED DC+
output studs. The 6-pin connector is intended to be
or WIRE FEED DC-.
used with the optional K857 Remote Output Control or
in the case of TIG welding applications, with the Foot
e. Set the “RANGE� switch to either HIGH, MED or
or Hand Amptrol. The 14-pin connector is used to
LOW as required by the process.
connect a wire feeder control cable. If the wire feeder
has a built-in power source output control, do not
f. Set the “WELDING TERMINALS� Control switch to
connect a remote output control to the 6-pin
the “REMOTELY CONTROLLED� position.
connector. When remote output control is used, the
output control toggle switch is to be set at “CONTROL
g. Set the “IDLER� switch to the “HIGH� idle position.
REMOTE�.
Connection of the LN-742 to the Ranger 9
High Frequency Generator for TIG
welding applications
a. Shut off the welder.
The K930-1 TIG Module is an accessory that provides
b. Connect per the instructions on the appropriate
high frequency and shielding gas control for AC and
connection diagram in rear of this manual.
DC GTAW (TIG) welding. See IM528 supplied with
the TIG Module for installation instructions.
c. Set the output control toggle switch to
“CONTROL AT WELDER� when not using
Note: The TIG Module does not require the use of a
remote control. When the LN-742 has a K589-1
high frequency bypass capacitor. If any other high
remote control attached, set output control to
frequency accessory is used with the Ranger 9, a
“REMOTE�.
bypass capacitor (Order Kit T12246) must be installed
in the Ranger 9.
d. Set “POLARITY� switch to either WIRE FEED
DC+ or WIRE FEED DC-.
e. Set “RANGE� switch to either HIGH, MED or
LOW as required by the process.
f. Set the “WELDING TERMINAL� control switch to
“REMOTELY CONTROLLED� position.
g. Set the “IDLER� switch to the “AUTO� position.
-14 -
OPERATING INSTRUCTIONS Welder Controls - Function and Operation
Explanation of Symbols that Appear on this Equipment
Additional Safety Precautions
Always operate the welder with the roof and case
sides in place as this provides maximum protection
Low Idle
OFF
ON High Idle
from moving parts and assures proper cooling air flow.
ENGINE “ON-OFF� Switch
Read carefully the Safety Precautions page in the
Instruction Manual before operating this machine.
When placed in the “ON� position, this switch
Always follow these and any other safety procedures
energizes the engine ignition circuit. When placed in
included in this manual and in the Engine Instruction
the “OFF� position, the ignition circuit is de-energized
Manual.
to shut down the engine.
Welder Operation
ENGINE “START� Push-Button Switch
Welder Output RANGER 9
Energizes engine starter motor.
Constant 250 amps AC @ 25 volts
Current 250 amps DC @ 25 volts
Constant 250 amps DC @ 25 volts
“POLARITY� Switch
Voltage
� Maximum Open Circuit Voltage at 3700 RPM is 80 volts.
Three STICK/TIG (constant current) polarity settings:
DC+, DC- and AC
� Duty Cycle: 100% for both welding and auxiliary power.
Two wire feed (constant voltage) settings:
DC+ and DC-
NOTE: The setting of this switch must match the
color band setting of the Range Switch (both switches
must be set for the same welding process).
Ranger 9 Approximate Fuel Consumption
CAUTION
Never change the “POLARITY� switch setting
while welding. This will damage the switch.
------------------------------------------------------------------------
ONAN P218 KOHLER
� RANGE� Switch
PERFORMER CH20S
.4 gallons/hour
.4 gallons/hour
Low Idle - No Load
STICK/TIG (constant current) 6 45,90,120,
(1.5 liters/hour)
(1.5 liters/hour)
2200 RPM
range settings 160,200,250
1.0 gallons/hour
.8 gallons/hour
High Idle - No Load
WIRE FEED (constant voltage) 3 LOW,MED,HIGH
(3.9 liters/hour)
(3.1 liters/hour)
3700 RPM
range settings
1.5 gallons/hour
1.6 gallons/hour
AC CC Weld Output
CAUTION
(5.7 liters/hour)
(6.2 liters/hour)
250 Amps @ 25 Volts
Never change the “RANGE� switch setting while
welding. This will damage the switch.
1.7 gallons/hour
1.8 gallons/hour
DC CC Weld Output
------------------------------------------------------------------------
(6.5 liters/hour)
(7.0 liters/hour)
250 Amps @ 25 Volts
CONTROL�
�
1.6 gallons/hour
1.7 gallons/hour
DC CV Weld Output
(6.2 liters/hour)
(6.5 liters/hour)
250 Amps @ 25 Volts
Provides a fine welding current adjustment within the
Range Switch settings in the STICK/TIG mode and
1.7 gallons/hour
1.8 gallons/hour
Auxiliary Power
welding voltage control with the Range switch set in
(6.5 liters/hour)
(7.0 liters/hour)
9000 kVA
the WIRE FEED mode.
-15 -
b. Auxiliary Power - With the engine running at low
“CONTROL AT WELDER /
idle and auxiliary power for lights or tools is drawn
REMOTE CONTROL� Switch (approximately 100-150 watts or greater) from the
receptacles, the engine will accelerate to high speed.
The toggle switch on the control panel labeled If no power is being drawn from the receptacles (and
“CONTROL AT WELDER� and “REMOTE CONTROL� not welding) for 10-14 seconds, the idler reduces the
gives the operator the option of controlling the output engine speed to low idle.
at the welder control panel or at a remote station.
Starting/Shutdown Instructions
Remote connections are made at the 6-pin or 14-pin
amphenol connector. Starting the Engine
WARNING
For remote control, the toggle switch is set in the
“REMOTE CONTROL� position.
� Do not touch electrically live parts
For control at the welder control panel, the toggle of electrode with skin or wet
switch is set in the “CONTROL AT WELDER� position. clothing.
“WELDING TERMINALS� Switch
The toggle switch labeled “WELDING TERMINALS � Keep flammable material away.
ALWAYS ON� and “WELDING TERMINALS
REMOTELY CONTROLLED� is used to control the
operation of the welder output contactor. � Insulate yourself from work and
ground. Wear eye, ear, and body
With the switch in the “ALWAYS ON� position, the protection.
output contactor is closed at LOW and HIGH idle.
With the switch in the “REMOTELY CONTROLLED� � Keep your head out of the fumes.
position, the contactor is open at LOW idle and HIGH
idle until a control cable is attached to the welder � Use ventilation or exhaust to
amphenol connector from a wire feeder. Under this remove fumes from breathing zone.
condition, contactor closes when the wire feeder
trigger is depressed and opens when the trigger is Be sure all Pre-Operation Maintenance has been per-
released. formed. Also, read the Engine Owner’s Manual.
“IDLER� Switch Remove all loads connected to the AC power recepta-
cles. To start the engine, set the “Idler Control� switch
The idler switch has two positions, “HIGH� and in the Automatic ( / ) position.
“AUTO�.
Use the choke control as follows:
When in “HIGH� position, the engine will run Onan Engine - If the engine is cold, pull the choke
continuously at high idle. control out. Do not use the choke if the engine is warm
or hot.
/
When in “AUTO� idle position, the idler
operates as follows: Kohler Engine - Always pull the choke control out
when starting the engine; cold, warm or hot. Place the
a. Welding “Engine� switch in the “ON� position.
Low idle and in the “WELDING TERMINALS ALWAYS ON� mode -
Stick Welding only. When the electrode touches work, the Push the “START� button and crank the engine until it
welding arc is initiated and the engine accelerates to starts. Release the button as soon as the engine
full speed. starts. Do not push the “START� button while the
engine is running because this will cause damage to
Low idle and in the “WELDING TERMINALS REMOTELY the ring gear and/or starter motor. After the engine
CONTROLLED� mode -Wire Welding Only Pressing the gun has started, slowly return the choke control to the full
trigger closes the Ranger 9 output contactor and “in� position (choke open).
causes the engine to accelerate to full speed.
After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
After the gun trigger is released and/or welding
ceases (and no auxiliary power is being drawn), the
Allow the engine to warm up by letting it run at low idle
engine will return to low idle after approximately 10 to
for a few minutes.
14 seconds.
-16 -
Stopping the Engine CURRENT RANGES (AC and DC STICK WELDING
- 5 to 10 ON CONTROL DIAL)
Remove all welding and auxiliary power loads and RANGE SETTING ACTUAL
allow engine to run at low idle speed for a few minutes ON MACHINE CURRENT RANGE
to cool the engine. 45 25 to 45 AMPS
90 50 to 90 AMPS
Stop the engine by placing the “Engine� switch in the 120 60 to 120 AMPS
160 80 to 160 AMPS
“OFF� position. 200 100 to 200 AMPS
250 140 to 250 AMPS
A fuel shut off valve is not required on the Ranger 8
TIG (Constant Current) Welding
because the fuel tank is mounted below the engine.
Break-in Period The Ranger 9 can be used in a wide variety of AC
and DC Tungsten Inert Gas (TIG) welding applications
for AC TIG welding up to 200 amps and DC TIG
It is normal for any engine to use a greater amount of
welding up to 250 amps.
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi-
The K930-1 TIG Module installed on a Ranger 9
mately 50 running hours)).
provides high frequency and shielding gas control for
AC and DC GTAW (TIG) welding processes. The TIG
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
Module allows full range output control. Afterflow time
BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO
is adjustable from 0 to 55 seconds.
MODERATE LOADS, WITHIN THE RATING OF THE
MACHINE. AVOID LONG IDLE RUNNING PERIODS.
When using the Ranger 9 for AC TIG welding of
REMOVE LOADS AND ALLOW ENGINE TO COOL
aluminum, the TIG Module is to be set for CONTINU-
BEFORE SHUTDOWN.
OUS HF. The following settings and electrodes are
recommended:
The engine manufacturer’s recommendation for the
running time until the first oil change is as follows: Pure (EWP) “Range� Welding
Tungsten Diameter Switch Settings Current
Kohler Onan
1/8 90, 120 100 to 200 amps
CH20S P218
3/32 45, 90 45 to 140 amps
5 hr 25 hr
1/16 45, 90 45 to 100 amps
The oil filter is to be changed at the second oil change.
When AC TIG welding, the actual maximum welding
Refer to the Engine Owner’s Manual for more informa-
current is 40 to 80 amps higher than the current
tion.
marked on the RANGE SWITCH dial. This is a result
of a lower effective reactance due to the natural rectifi-
Welding Processes
cation that occurs with the AC TIG welding process.
Stick (Constant Current) Welding
Wire Feed (Constant Voltage) Welding
Connect welding cables to the “TO WORK� and
The Ranger 9 can be used with a broad range of flux-
“ELECTRODE� studs. Start the engine. Set the
cored wire (Innershield and Outershield) electrodes
"POLARITY� switch to the desired polarity. Set the
and solid wires for MIG welding (gas metal arc
output “CONTROL� or remote output control to max
welding).
(10) and the “RANGE� switch to the setting that is
closest to the recommended current for the electrode
Some recommended Innershield electrodes are:
being used and make a trial weld. A fine adjustment
NR-211MP, NR-311, NR-203 series as well as,
of the welding can be made by adjusting the output
Lincore® 33 and 55 hardfacing electrodes. Diameters
“CONTROL� or remote control. For the best arc
from .035 (0.9mm) up to and including 5/64� (2.0mm)
stability, always use setting that results in the highest
can be used. 5/64� (2.0mm) NS-3M can be used in
setting of the output or remote control and the lowest
limited applications. Cable length and other condi-
setting of the “RANGE� switch.
tions can affect the ultimate results of this application.
Request Lincoln publication N-675 for additional infor-
The Ranger 9 can be used with a broad range of AC
mation.
and DC stick electrodes. See “Welding Tips 1�
included with the Ranger 9 for electrodes within the
rating of this unit and recommended welding currents
of each. See the following table for welding current
ranges:
-17 -
Recommended Outershield electrodes are: .045 When using a wire feeder with contactor control, the
(1.1mm), .052 (1.3mm) and 1/16 (1.6mm) Outershield electrode will be “cold� until the gun trigger is pressed.
71 and 1/16� (1.16mm) Outershield 70. Request To start the welding process, position the gun and
Lincoln publication GS-200 for additional information. close the gun trigger. The contactor will close, the arc
will be initiated and the engine will accelerate to full
Some recommended solid wires for MIG welding are: speed. To stop welding, release the gun trigger and
.030 (0.8mm), .035 (0.9mm) and .045 (1.1mm) L-50 pull the gun away from the work. With the “IDLER
and L-56. Request Lincoln publication GS-100 for SWITCH� in the “AUTO� position, the engine will go
additional information. back to low idle in approximately 12 seconds (when
no auxiliary power is drawn).
NOTE: The LN-7 and the LN-8 must be operated in
the “HIGH� idle position.
SUMMARY OF WELDING PROCESS
WELDING ELECTRODE
CONTROL OUTPUT
TERMINALS WHEN NOT
CABLE IDLE CONTROL
PROCESS TO START WELDING
SWITCH SWITCH WELDING
USED MODE
Touch electrode to work.
AUTO AT Welding starts immediately
ALWAYS HOT
NO
STICK - CC
WELDER and engine goes to high idle.
ON
Press Amptrol. Welding
TIG - CC
AUTO REMOTE starts immediately.
REMOTE COLD
YES
K930-1/K936-1
(WITH AMPTROL)
Press gun trigger, Ranger 9
WIRE FEED - CV,
AUTO contactor closes. Welding
REMOTE REMOTE COLD
YES
LN-25 WITH 42V
starts immediately and engine
REMOTE CON-
goes to high idle.
TROL KIT
Press gun trigger, LN-25
WIRE FEED - CV,
AUTO contactor closes. Welding
AT ALWAYS COLD
NO
LN-25 WITH
starts immediately and engine
WELDER ON
INTERNAL
goes to high idle.
CONTACTOR
Press gun trigger, Ranger 9
WIRE FEED - CV,
AUTO contactor closes. Welding
REMOTE REMOTE COLD
YES
LN-742
starts immediately and engine
goes to high idle.
HIGH Press gun trigger, Ranger 9
REMOTE REMOTE COLD
YES
WIRE FEED - CV,
contactor closes. Welding
LN-7
starts immediately.
-18 -
115V Duplex Receptacles
Auxiliary Power
The 115V auxiliary power receptacles should only be
The Ranger 9 can provide up to 9,000 watts of
used with three wire grounding type plugs or approved
115/230 volts AC, single phase 60HZ power for contin-
double insulated tools with two wire plugs.
uous use. The front of the machine includes three
receptacles for connecting AC power plugs. The
Maximum Current Draw from 115V Duplex
K1420-1 has one 50 amp 115/230 volt NEMA 14-
Receptacles - No Welding
50R receptacle and two 20 amp 115 volt NEMA 5-
20R receptacles. The K1420-2 CSA machine has one
50 amp 115/230 volt NEMA 14-50R receptacle and K1420-1 K1420-2 (CSA)
and K1421-1 (CSA)
two 15 amp 115 volt NEMA 5-15R receptacles. Do
not connect any plugs that connect to the power LOAD FROM EACH TOTAL EACH TOTAL
receptacles in parallel. 115V / 230V HALF OF FROM HALF OF FROM
DUAL VOLTAGE EACH 115V BOTH 115V EACH 115V BOTH 115V
RECEPTACLE DUPLEX DUPLEXES DUPLEX DUPLEXES
Start the engine and set the “IDLER� control switch to
60
0 20 * 78 15
the desired operating mode. Set the “CONTROL� to
10. Voltage is now correct at the receptalces for
60
2.2 KW 20 * 60 15
auxiliary power.
40
4.5 KW 20 * 40 15
20
6.7 KW 20 * 20 15
115/230 Volt Dual Voltage Receptacle 0
9.0 KW 0 0 0
The 115/230 volt receptacle can supply up to 40 amps * NEMA 5-20P plug required for 20 amp draw.
of 230 volt power to a two wire circuit, up to 40 amps
of 115 volt power from each side of a three wire circuit
Maximum Current Draw from Optional 115V
(up to 80 amps total). Do not connect the 115 volt
GFCI Duplex Receptacles - No Welding
circuits in parallel. Current sensing for the automatic
idle feature is only in the leg of the three wire circuit as
shown below. K1420-1* K1420-2** and
(WITH GFCI’S) K1421-1**
(WITH GFCI’S)
LOAD FROM EACH TOTAL EACH TOTAL
GND 115V / 230V HALF OF FROM HALF OF FROM
DUAL VOLTAGE EACH 115V BOTH 115V EACH 115V BOTH 115V
RECEPTACLE DUPLEX DUPLEXES DUPLEX DUPLEXES
30
0 15 40 15
30
2.2 KW 15 40 15
115 V
30
4.5 KW 15 40 15
230 V
20
6.7 KW 15 20 15
115 V *
0
9.0 KW 0 0 0
* Current Sensing for Automatic Idle
(Receptacle viewed from front of machine.) * Maximum current draw from each 115V GFCI Duplex is 20 amps.
** Maximum current draw from each 115V GFCI Duplex is 15 amps.
-19 -
Most 1.5 HP motors can be started if there is no load Standby Power Connections
on the motor or other load connected to the machine,
since the full load current rating of a 1.5HP motor is The Ranger 9 is suitable for temporary, standby or
approximately 20 amperes (10 amperes for 230 volt emergency power using the engine manufacturer's
motors). The motor may be run at full load when recommended maintenance schedule.
plugged into only one side of the duplex receptacle.
Larger motors through 2HP can be run provided the The Ranger 9 can be permanently installed as a
receptacle rating as previously stated is not exceeded. standby power unit for 230 volt, 3-wire, 40 ampere
This may necessitate 230V operation only. service. Connections must be made by a licensed
electrician who can determine how the 115/230 volt
It must be noted that the above auxiliary power ratings power can be adapted to the particular installation and
are with no welding load. Simultaneous welding and comply with all applicable electrical codes. The
power loads are permitted by the following table. The following information can be used as a guide by the
permissible currents shown assume that current is electrician for most applications (refer also to the
being drawn from either the 115 volt or 230 volt supply Premises Wiring diagram shown).
(not both at the same time).
NOTE: Voltage and permissible watts decrease as IMPORTANT: When the Ranger 9 is connected to
“CONTROL� is adjusted to settings less than a 230 volt, 3-wire line, the unit should be operated
10. It is recommended that at settings less with the idler switch in the “HIGH� idle position to avoid
than 10, only incandescent lighting loads be load sensing problems. If the machine is set for
connected to the auxiliary power receptacles. automatic idle, the 230 volt circuit will sense loads and
cause the engine to accelerate to high idle. However,
since only one line of the circuit senses current, 115
volt power drawn from only one line to neutral may
result in the engine not going to high idle.
1. Install the double pole, double throw switch
between the power company meter and the
premises disconnect.
Switch rating must be the same or greater
than the customer’s premises disconnect and
service overcurrent protection.
Welding Permissible Permissible Permissible
Output
Output Power Watts Auxiliary Current in Auxiliary Current in
Selector
(Unity Power Amperes @ 115V Amperes @ 230V
Setting
Factor)
250
250 NONE
200 11
200 2500 22
160 16
160 3700 32
120 22
120 5000 44
90 26
90 6000 52
45 32.5
45 7500 65
200 21.5
CV LOW 5000 43
60 32.5
7500 65
250 20
CV MEDIUM 2750 40
80 28
6500 56
250 5
CV HIGH 1200 10
100 26
6000 52
MAR 95 -20 -
2. Take necessary steps to assure load is
limited to the capacity of the Ranger 9 by
installing a 40 amp, 230 volt double pole
circuit breaker. Maximum rated load for each
leg of the 230 volt auxiliary is 40 amperes.
Loading above 40 amps will reduce output
voltage below the allowable - 10% of rated
voltage which may damage appliances or
other motor-driven equipment.
3. Install a 50 amp 115/230 volt plug (NEMA
Type 14-50) to the Double Pole Circuit
Breaker using No. 8, 4 connector cable of
the desired length. (The 50 amp 115/230 volt
plug is available in the optional plug kit).
4. Plug this cable into the 50 amp 115/230 volt
receptacle on the Ranger 9 case front.
CONNECTION OF RANGER 9 TO PREMISES WIRING
230 VOLT
GROUNDED CONDUCTOR
POWER
230 Volt 115 VOLT
60 Hz.
COMPANY
3-Wire
115 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
40 AMP
PROTECTION
230 VOLT
DOUBLE
POLE
50 AMP, 115/230 CIRCUIT
VOLT PLUG 230 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 115/230 VOLT
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
-21 -
MAINTENANCE Routine Maintenance
1. At the end of each day’s use, refill the fuel tank to
Safety Precautions minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
WARNING system. Also, check the crankcase oil level and
add oil if indicated.
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
2. OIL - Maintenance schedule for changing the oil
the machine . In some cases, it may be
and oil filter after break-in:
necessary to remove safety guards to perform
required maintenance. Remove guards only Kohler Onan
when necessary and replace them when the CH20S P218
maintenance requiring their removal is
complete. Always use the greatest care when Oil 100 hr 50 hr
working near moving parts.
Oil Filter 200 hr 100 hr
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
The above schedule is for normal operating condi-
following the instructions, take the machine to
tions. More frequent oil changes are required with
the nearest Lincoln Field Service Shop.
dusty, high temperature, and other severe operating
-----------------------------------------------------------------------
conditions. Refer to the maintenance section of the
ELECTRIC SHOCK can kill.
Engine Owner’s Manual for more information.
� Do not touch electrically live parts or
electrode with skin or wet clothing.
CAUTION
� Insulate yourself from work and
ground
� Always wear dry insulating gloves. Engine life will be reduced if the oil and oil filter
------------------------------------------------------------------------ are not changed according to the manufacturer’s
ENGINE EXHAUST can kill. recommendation.
� Use in open, well ventilated areas or
-----------------------------------------------------------------------
vent exhaust outside.
3. Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling
the foam pre-filter is every 25 hours and replace-
------------------------------------------------------------------------
MOVING PARTS can injure. ment of the air cleaner filter every 100 hours. More
� Do not operate with doors open or frequent servicing is required with dusty operating
guards off. conditions. Refer to maintenance section of the
� Stop engine before servicing.
Engine Owner’s Manual for more information.
� Keep away from moving parts.
------------------------------------------------------------------------
4. Refer to the maintenance section of the Engine
Owner’s Manual for the maintenance schedule for
See additional warning information at
spark plug servicing, cooling system servicing, and
front of this operator’s manual. fuel filter replacement.
-----------------------------------------------------------
CAUTION
Engine Adjustments
Make certain that the oil filler cap is securely
WARNING tightened after checking or adding oil. If the cap is
not tight, oil consumption can increase signifi-
OVERSPEED IS HAZARDOUS cantly which may be evidenced by white smoke
coming from the exhaust.
The maximum allowable high idle speed for this
------------------------------------------------------------------------
machine is 3750 RPM, no load. Do NOT tamper
5. Blow out the machine with low pressure air periodi-
with governor components or setting or make any
cally. In particularly dirty locations, this may be
other adjustments to increase the maximum
required once per week.
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
6. Output Ranger Selector and Polarity Switches:
maximum.
Switch contacts should not be greased. To keep
------------------------------------------------------------------------
contacts clean, rotate the switch through its entire
Adjustments to the engine are to be made only by a
range frequently. Good practice is to turn the han-
Lincoln Service Center or an authorized Field Service
dle from maximum to minimum setting twice each
Shop.
morning before starting to weld.
-22 -
Battery Charging Use correct polarity - Negative Ground.
To prevent BATTERY DISCHARGE, if you have an
WARNING ignition switch, turn it off when engine is not
running.
GASES FROM BATTERY can explode.
� Keep sparks, flame and cigarettes
� To prevent BATTERY BUCKLING, tighten nuts on
away.
battery clamp until snug.
------------------------------------------------------------------------
1. When replacing, jumping or otherwise
BATTERY ACID can burn eyes and connecting the battery to the battery cables,
skin. the proper polarity must be observed. Failure
� Wear gloves and eye protection and be to observe the proper polarity could result in
careful when boosting, charging or damage to the charging circuit. The positive
working near battery. (+) battery cable has a red terminal cover.
To prevent EXPLOSION when: 2. If the battery requires charging from an
a) Installing a new battery - disconnect the external charger, disconnect the negative
negative cable from the old battery first and battery cable first and then the positive
connect the negative cable to the new battery battery cable before attaching the
last. charger leads. Failure to do so can result
to damage to the internal charger
b) Connecting a battery charger - remove the components. When re-connecting the
battery from the welder by disconnecting the cables, connect the positive cable first and
negative cable first, then the positive cable and the negative cable last.
battery clamp. When reinstalling, connect the
negative cable last.
c) Using a booster - connect the positive lead to HARDWARE
the battery first, then connect the negative lead to
the ground lead on the base. Both English / Metric fasteners are used in this
welder.
To prevent ELECTRICAL DAMAGE when:
a) Installing a new battery.
b) Using a booster.
Engine Maintenance Parts
ONAN P218 KOHLER CH20S
Oil Filter ONAN 122-0645 KOHLER 1205001
FRAM PH3614 FRAM PH3614*
Air Filter ONAN 140-2628-01 KOHLER 4708303
Element FRAM CA140PL FRAM CA79
Air Filter ONAN 140-1496 KOHLER 2408302
Pre-Cleaner
Fuel Filter ONAN 149-2005 KOHLER 2505002
FRAM G1 FRAM G1
Spark Plugs ONAN 167-0263 CHAMPION RC12YC
(Resistor CHAMPION RS14YC (.030� GAP)
Type) (.025� GAP)
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.
-23 -
TROUBLESHOOTING
ENGINE
TROUBLE CAUSE WHAT TO DO
A. Engine will not crank or is hard to 1. Battery will not hold a charge. 1. Replace with known good one.
crank. Faulty battery.
2. No or insufficient charging current. 2. Check connection of lead from
voltage regulator on engine to
charging ammeter and battery
lead #208 and #209.
3. Loose battery cable connection(s). 3. Check and tighten connection at
battery, at starter, at engine foot,
or at frame.
4. Lead #216A from solenoid to start 4. Repair.
switch broken.
5. Spark plugs fouled. 5. Replace spark plugs.
B. Engine will not start or shuts down. 1. Low oil pressure. 1. Check oil level and add oil as req’d.
2. Out of fuel. 2. Add fuel to tank.
3. Fault in fuel system. 3. Repair.
4. #216 lead from start switch to P.C. 4. Repair.
board broke / (Onan engine).
5. Oil pressure switch faulty. 5. Replace
6. Generator terminal block connection 6. Repair. Check leads #208, 224A,
faulty. 224B, 212.
7. Faulty P.C. Board (Onan engine). 7. Replace.
C. Engine does not develop full 1. Fuel filter clogged. 1. Replace.
power. 2. Air filter clogged. 2. Replace.
D. Battery does not stay charged. 1. Faulty battery. 1. Replace with a new battery.
2. Faulty charging system. 2. Refer to Engine Operators Manual
for charging system service.
3. Loose or broken lead in charging 3. Refer to wiring diagram and check
circuit. related leads, especially #208 and
#209 leads.
-24 -
IDLER SYSTEM
WHAT TO DO
TROUBLE CAUSE
1. Set switch to “AUTO� position.
A. Engine will not idle down to low 1. Idler switch in “HIGH� idle position.
2. Remove all external loads.
speed. 2. External load on welder or auxiliary
power.
3. Repair.
3. Mechanical problem in idler solenoid
linkage.
4. Adjust solenoid as necessary.
4. Idler solenoid position out of adjust-
ment.
5. Check for broken leads #224D,
5. Faulty wiring in solenoid circuit.
214.
6. Refer to wiring diagram. Check
6. Contactor circuit #2 or #4 closed or
related leads and amphenol
shorted. Engine goes to high idle
connectors.
when contactor circuit closes.
7. Replace with known good one.
7. Faulty idler solenoid.
8. Check wiring, battery and battery
8. Low voltage at 224D to ground stud.
charging circuits.
(Voltage should be 12-14V DC).
9. Replace P.C. Board with known
9. Faulty P.C. Board PCB1.
good one.
B. Engine will not go to high idle
when attempting to weld.
1. Make sure work clamp is tightly
I. Scratch Start 1. Poor work lead connection to work.
connected to clean base metal.
2. Switch must be in “ALWAYS ON�
2. “WELDING TERMINALS� switch in
position to scratch start.
wrong position.
3. Check leads #247 and #250 for
3. No open circuit voltage on output
breaks. Check Switch S6 for faults.
studs.
4. Replace P.C. Board with known
good one.
4. Faulty P.C. Board PCB1.
1. Switch must be in “REMOTELY
II. When using wire feeder with con- 1. “WELDING TERMINALS� switch in
CONTROLLED� position.
trol cable plugged into amphenol wrong position.
2. Refer to schematic. Check wiring
connector or using amptrol when 2. Faulty wiring.
in #2 and #4 circuit.
trigger is depressed.
1. Check for broken leads in idler
C. Engine will not go to high idle 1. No signal from current sensor.
sensing circuit. #3 lead.
when using auxiliary power.
2. Idler may not respond with less
2. Auxiliary power lead less than 100
than 100 watt load. Set idler
watts.
switch to high idle.
3. Replace P.C. Board with known
3. Faulty idler P.C. Board
good one.
-25 -
OUTPUT SYSTEM
WHAT TO DO
TROUBLE CAUSE
1. Refer to wiring diagram and check
A. No welder or power output. 1. Open lead in flashing or field circuit.
related leads.
(#7 & #9; #200, #201 and #219)
2. Lift brushes and check rotor
2. Faulty rotor.
continuity between slip rings.
(Should be approx. 7.3â„?)
3. Disconnect lead #7 at D2 and
3. Faulty stator field.
check for continuity between
leads #7 and #9.
4. Replace with known good one.
4. Faulty field rectifier D2.
5. Refer to wiring diagram and check
5. Output contactor does not pull in.
related leads and contactor.
6. Replace P.C. Board with known
6. Faulty P.C. Board.
good one.
1. Place switch in “Output Control
B. Output control on welder not 1. Output control switch in wrong
at Welder�.
functioning. position.
2. Check and replace switch if faulty.
2. Output control switch defective.
3. Check and replace potentiometer
3. Output control potentiometer
if faulty.
defective.
4. Check for broken leads #75, #76,
4. Faulty wiring.
and #77 from P.C. Board and
#75A, #76D, and #77D from
potentiometer to remote switch.
5. Replace P.C. Board with known
5. Faulty P.C. Board
good one.
1. Place switch in “Remote� position.
C. Output control or remote not 1. Output control switch in wrong
functioning. position.
2. Repair.
2. Leads #75, #76, #77 broken at P.C.
Board or S4.
3. Repair.
3. Leads #75A, #76A, #77A broken at
S4 or amphenol.
4. Repair.
4. Remote control leads broken in
control cable.
5. Replace wire feeder with known
5. Faulty wire feeder.
good one.
6. Replace P.C. Board with known
6. Faulty P.C. Board.
good one.
1. Reset or replace.
D. Wire feeder does not work when 1. Wire feeder circuit breaker open or
connected to welder amphenol. faulty.
2. Repair.
2. Broken #31, #32, or #42 lead at
amphenol.
3. Check continuity on #31, #32, and
3. No 115V or 42V output from stator.
#42 at stator. Check buildup. If
O.K. , stator may be faulty.
Replace.
4. Repair or replace cable.
4. Faulty wiring in control cable.
5. Replace P.C. Board with known
5. Faulty wire feeder.
good one.
-26 -
OUTPUT SYSTEM
WHAT TO DO
TROUBLE CAUSE
1. Place switch S6 in “Always On�
E. Contactor does not pull in when 1. Welding terminal switch in wrong
position.
scratch starting when engine position.
2. Check for broken leads #224C,
goes to high idle. 2. Faulty wiring in contactor circuit.
#232A, and #224.
3. Check switch and leads #247,
and #250.
3. Faulty remote switch S6.
4. Replace contactor with known
good one.
4. Faulty contactor.
5. Replace P.C. Board with known
good one.
5. Faulty P.C. Board PCB1.
1. Place switch S6 in “REMOTELY
F. Contactor does not pull in when 1. “WELDING TERMINALS� switch
CONTROLLED� position.
using a wire feeder with a control in wrong position.
2. Check for broken leads #224,
cable plugged into amphenol. 2. Faulty wiring in contactor circuit.
#224C & #232A.
3. Refer to wiring diagram and
3. Faulty amphenol or bypass P.C.
check related leads (#2 and #4).
Board PCB2.
4. Replace contactor with known
4. Faulty contactor.
good one.
5. Replace P.C. Board with known
5. Faulty P.C. Board PCB1.
good one.
6. Replace.
6. Faulty control cable from wire
feeder or amphenol.
7. Repair or replace.
7. Faulty wire feeder.
1. Check that lead #232 is not
G. Contactor does not drop out. 1. Faulty wiring.
grounded.
2. Look for shorts to ground. Repair
2. Faulty amphenol or bypass P.C.
or replace.
Board PCB2.
3. Replace with known good one.
3. Faulty contactor.
4. Replace with known good one.
4. Faulty P.C. Board PCB1.
-27 -
RANGER 9 (ONAN) - WIRING DIAGRAM - CODE 10378 & 10539
3 TURNS
254A
254
L1
IDLER
(CHOKE)
CURRENT
S1 3 SENSOR
ELECTRODE POLARITY
3
SWITCH 6 12
PC
232
232
BOARD
224E
224E
S6
242
242 PCB1 WELDING TERMINAL
J2
240 240
ON CONTROL SWITCH
236
235 SHOWN IN
2C
224C
"ALWAYS ON"
CV- 247
247
77 POSITION
76 250
CV+ 5D
S2A (CLOSED 75
WITH S2 IN
1 7
C1, C2 OR C3
DC+ POSITION)
DC-
242 AM 1
235 245
4 8
AMMETER
AC
OUTPUT C3
100 C4 C5 200B
C2 +-
(+)
R1
RECTIFIER 214 208 209
25W
254 232A J1
224C
5A
208A
D1 236A 216
219
31,000 MFD 1 5
201A
CAPACITORS
236
236A 216
(-)
208B
"S3" SHOWN
E IN "RUN"
201A
REACTOR POSITION
219
OUTPUT
254A
5A
CONTACTOR 212
232 232A
240
S2 214 S7
200B
S1 START
224E C2
R6
R4
R2
25 OHM 3 BUTTON
C1
R3
R1 C3
R5
R2
216A
CR1 50W 3
77
OUTPUT
224C 241 RHEOSTAT
250
75
RANGE
224 SWITCH S5
W2 10K POT
MAX AUTO
S2 IDLER
R3 75A SWITCH
W1
CW 5D
76D
232A
77D 5C
ELECTRODE
WORK
SHOWN IN
IDLER
GND 76A "HIGH'
SOLENOID
C3
POSITION
HIGH
C2 S4 77
76 L2
C1
21
STATOR
IN LINE CONNECTORS
REMOTE SWITCH
(3 PLACES) 6 9
32 3 76D
42
31 7
(SHOWN IN SEE DIAGRAM "A" FOR
2C REMOTE POSITION)
GND-E
5 ENGINE TERMINAL
75A BLOCK CONNECTION.
-28 -
76A
77A 77A 224D
232A
AMPHENOL 1
CB1
2C 212 1
(10AMP)
(J) 31A
31A
OIL PRESSURE
115VAC 224 2
224B
SWITCH
(A) 32
3
208 3
3
(D) 4A 3
GREEN GND-D
PCB2
CONTACTOR 224A 4
5A
5E 5E
BYPASS PC
(C) 2A GND-E
5B
4 8 GREEN GND-G
TO SPARK
(H)
WORK 21 GND-C 5F
5
3A PLUGS
2A +
REMOTE CONTROL 201 201A
GND-D
4C 6
CAPACITOR
200B
(E) 77C 115 V
77C -
(-)
J5 219 + STARTER
76C IGNITION
(F) 76C 7 SOLENOID
BLACK
WHITE
J6
4A COIL AND
5C
75C
(G) 75C GROUND SCREW CONTACTOR
D2 BLOWER BAFFLE
9 AC AC 216A
1 -
5 209
5K 200B
31B
(I) SILVER
5B
5L
42VAC COLORED
ENGINE
42 IGNITION
(K) TERMINALS
HOUR METER
3B MODULE
GND-G
(B) GND-A 200A
3 6
GROUND
(+)
115 V
75B
FLYWHEEL
200 219
2B ALTERNATOR
REMOTE CONTROL
J7
(A) 77B 77B J4 (-) (+)
BLACK
WHITE
BLACK
WHITE
224A&B (CAVITY #4)
208 (CAVITY #3)
GND-C
76B
(B) 76B
SILVER 5L
LOCATING
COLORED SR
(C) 75B 76A
1 4 5
TERMINALS
TAB
4B SLIP
(D) 2B (+)
(+)
GREEN WELDER LEAD END
(+)
CONTACTOR VOLTAGE
RINGS
(NOTE CAVITY NUMBERS)
(E) 4B 2 4 REGULATOR STARTER 12V
800 MFD C1 212 (CAVITY #1) MOTOR
(F) GND-B (-)
76A
GROUND
125/250V. SINGLE 224B (CAVITY #2)
2C J3 201 AC B+ AC
RECEPTACLE B-
75A (-)
(-)
3B
77A DIAGRAM "A"
AMPHENOL 2 ROTOR FIELD
77A
3
1 ENGINE TERMINAL
4C
6 BLOCK CONNECTION
5K GND-H
5F
SLIP RING
NEAREST LAMINATION
BLACK
5E
SILVER
COLORED ENGINE
TERMINALS FOOT ENGINE
GROUND SCREW
NOTES: CROSS
BETWEEN AMPHENOL HOLES SUPPORT
ELECTRICAL SYMBOLS PER E1537
ALL CASE FRONT COMPONENTS VIEWED FROM REAR.
7-19-96G
L10248
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted
inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
RANGER 9 ONAN (CSA VERSION) - WIRING DIAGRAM - CODE 10379 & 10540
3 TURNS
254A
254
L1
IDLER
(CHOKE)
CURRENT
S1 3 SENSOR
ELECTRODE POLARITY
3
SWITCH 6 12
PC
232
232
BOARD
224E
224E
242
242 PCB1
J2
240 240
236
235
2C
224C
CV- 247 S6
WELDING TERMINAL
77
76 ON
250
CV+ CONTROL SWITCH
S2A (CLOSED 75
WITH S2 IN SHOWN IN
1 7
C1, C2 OR C3
"ALWAYS ON"
247
POSITION)
DC+
POSITION
5D
DC- 242 AM 1
235 245
4 8
AMMETER
AC
OUTPUT C3
100 C4 C5 200B
C2 +-
(+)
R1
RECTIFIER 214 208 209
25W
254 232A J1
224C
5A
208A
D1 236A 216
219
31,000 MFD 1 5
201A
CAPACITORS
236
236A 216
(-)
208B
"S3" SHOWN
E IN "RUN"
201A
REACTOR POSITION
219
OUTPUT
254A
5A
CONTACTOR 212
232 232A
240
S2 214 S7
200B
S1 START
224E C2
R6
R4
R2
25 OHM 3 BUTTON
C1
R3
R1 C3
R5
R2
216A
CR1 50W 3
77
OUTPUT
224C 241 RHEOSTAT
250
75
RANGE S5
SWITCH
224 W2 10K POT IDLER
MAX AUTO
S2 SWITCH
R3 75A
W1
CW 5D
76D
232A
77D 5C
ELECTRODE
WORK
SHOWN IN
GND 76A "HIGH'
C3
POSITION
HIGH
C2 L2
S4 IDLER
77
76
C1
21 SOLENOID
STATOR
IN LINE CONNECTORS
224D
REMOTE SWITCH
6
(3 PLACES) 9
32 3
42 76D
31 7
(SHOWN IN
-29 -
SEE DIAGRAM "A" FOR
2C REMOTE POSITION)
GND-E
5 ENGINE TERMINAL
75A BLOCK CONNECTION.
76A
77A 77A
232A
AMPHENOL 1
CB1
2C 212 1
(10AMP)
J 31A 3
31A
OIL PRESSURE
115VAC 224 2
224B
SWITCH
A 32 3
GND-E 208 3
GROUND SCREW
5E
D 5E
4A BLOWER BAFFLE
PCB2 GND-G
CONTACTOR 224A 4
5A
BYPASS PC
2A GND-C
C
5B
4 8 GND-D
TO SPARK
5F
WORK H 21
PLUGS
2A +
3E 3
REMOTE CONTROL
4C
CAPACITOR
E 77C 77C -
J5 + STARTER
76C IGNITION
F 76C SOLENOID
125/250V. SINGLE 201A
201
4A COIL AND
BLACK
5C
RECEPTACLE
75C 75C
G CONTACTOR
GREEN
1 216A
-
5 209
BLACK
BLACK
31B
I
5B
7
42VAC
GREEN
ENGINE
42 IGNITION
219
K
6 D2 HOUR METER
CB2 GND-D MODULE
9 AC AC
B GND-A 115 V (-)
(+)
3 6 GND-G
50A 5
CB4
GROUND CB6 200B
75B 15A FLYWHEEL
15A
J8
2B J6 ALTERNATOR
REMOTE CONTROL 115/230V 3C 3D 200A
A 77B 77B J4
(+)
(+)
SILVER SLIP
5K
76B
B 76B COLORED 200
BLACK
5L RINGS
12 BLACK TERMINALS
BLACK
76A BLACK
C 75B 1 4 11
BLACK
(+)
(-)
BLACK
4B
GREEN
D 2B POSITIVE SLIP (+)
11
BLACK
CONTACTOR VOLTAGE
GND-C 800 MFD C1 RING NEAREST
CB5 115 V
E CB7
4B 2 4 REGULATOR STARTER
BLACK
ROTOR FIELD
5K 12V
15A LAMINATION
15A 201 MOTOR
CB3
F 3E
GND-B 3D
76A J7
SILVER (-)
50A
GROUND 3C
2C J3
WHITE
3A COLORED AC B+ AC
3A B-
3B
SILVER
75A (-)
TERM.
77A 3B
WHITE
5
AMPHENOL 2 COLORED DIAGRAM "A"
77A
BLACK
3
1
WHITE
5L
BLACK
TERMINALS
4C ENGINE TERMINAL
BLACK
BLACK
GND-H
BLOCK CONNECTION
WHITE 5F
5E
224A&B (CAVITY #4)
208 (CAVITY #3)
ENGINE
LOCATING FOOT ENGINE
GROUND SCREW
NOTES: CROSS
TAB
BETWEEN AMPHENOL HOLES SUPPORT
WELDER LEAD END
ELECTRICAL SYMBOLS PER E1537
(NOTE CAVITY NUMBERS)
ALL CASE FRONT COMPONENTS VIEWED FROM REAR.
212 (CAVITY #1)
224B (CAVITY #2)
7-19-96G
L10249
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted
inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
RANGER 9 KOHLER (CSA VERSION) - WIRING DIAGRAM - CODE 10550
3 TURNS
254A
L1 254
IDLER
(CHOKE)
CURRENT
S1
3 SENSOR
ELECTRODE POLARITY
3
6 12
SWITCH
PC
232
232
BOARD
224E
224E
242
242 PCB1
J2
240 240
236
235
2C
224C
CV- 247 S6
WELDING TERMINAL
77
76 ON
250
CV+ CONTROL SWITCH
S2A (CLOSED 75
WITH S2 IN SHOWN IN
1 7
C1, C2 OR C3
"ALWAYS ON"
247
POSITION)
DC+
POSITION
5D
DC- 242 AM 1
235 245
4 8
AMMETER
AC
OUTPUT C3
100 C4 C5 200B
C2 +-
(+)
R1
RECTIFIER 214 208 209A
25W
254 232A J1
224C
5A 208A
D1 "S3" SHOWN
236A
219 IN "RUN"
31,000 MFD POSITION
1 5
201A
CAPACITORS
236
236A
(-)
208B
E 201A
REACTOR 221
219
OUTPUT
254A
5A 210
CONTACTOR 232 5H
232A
240
S2 214
S7
200B
S1
224E START
C2
R6
R4
R2
25 OHM 3
C1
R3
R1 C3
R5
R2
CR1 BUTTON
50W 3
77
OUTPUT
224C 241 RHEOSTAT
250 211
75
RANGE S5
SWITCH
224 W2 10K POT IDLER
MAX AUTO
S2 SWITCH
R3 75A
W1
CW 5D
76D
232A
77D 5C
ELECTRODE
WORK L2
SHOWN IN
IDLER
GND 76A "HIGH'
SOLENOID
C3
POSITION
HIGH
C2 S4 77
76
C1 SEE DIAGRAM "A" FOR
21 224D
ENGINE TERMINAL
STATOR
IN LINE CONNECTORS BLOCK CONNECTION.
REMOTE SWITCH
6 9
32 3
42 76D
31 7
(3 PLACES)
(SHOWN IN
2C 224A
GND-E
5 REMOTE POSITION)
75A 224C 210
-30 -
76A
77A 77A
232A
AMPHENOL 1
CB1 2C
(10AMP)
J 31A 3
31A
OIL PRESSURE
221 1
224
115VAC
A 32 3 SWITCH
2
208
GND-E GROUND SCREW
5E
D 5E
4A BLOWER BAFFLE
PCB2
3 R
GND-G 211
CONTACTOR BYPASS PC 5A
2A GND-C
C
5B 224C
4 8 4 R
GND-D
5F
WORK H 21
2A 3E 3 U
REMOTE CONTROL
4C
E 77C 77C
STARTER
J5 224A W
+
76C SOLENOID
F 76C 125/250V. SINGLE 201A
201
4A AND
IGNITION
RECEPTACLE
75C 75C
G
BLACK
CONTACTOR
MODULE
5C
GREEN
BLACK
BLACK
1 -
5 209A
31B
I
219 5B
7
42VAC
GREEN
42
K ENGINE
5H
6 D2
CB2 GND-D HOUR METER
9 AC AC
B GND-A (-)
115 V (+)
3 6 GND-G
50A 5
CB4
GROUND CB6 200B
75B 15A FLYWHEEL
15A
J8 FUEL
2B J6 ALTERNATOR
REMOTE CONTROL
115/230V 3C 3D 200A SHUTOFF
A 77B 77B J4
(+)
(+)
SILVER SLIP SOL.
5K
76B
B 76B COLORED 200
BLACK
5L RINGS
12 BLACK TERMINALS
76A BLACK
C 75B
BLACK
1 4 11
BLACK
(+) V
(-)
BLACK
4B (+)
GREEN
D 2B POSITIVE SLIP
11
CONTACTOR VOLTAGE
GND-C 800 MFD C1 RING NEAREST
CB5 115 V
E 4B CB7
2
BLACK
4 REGULATOR STARTER
BLACK
ROTOR FIELD
5K 15A LAMINATION 12V
15A 201 MOTOR
F CB3
GND-B 3E 3D
76A J7
SILVER (-)
50A
GROUND 3C
2C J3 3B
3A COLORED AC B+ AC
3A B-
SILVER
75A TERM.
WHITE
(-)
77A 3B
5
AMPHENOL 2
WHITE
COLORED DIAGRAM "A"
77A
BLACK
3
1 5L
WHITE
TERMINALS
4C
BLACK
ENGINE TERMINAL
BLACK
BLOCK CONNECTION 5F GND-H
BLACK
WHITE
5E
224C (CAVITY #4)
211 (CAVITY #3)
ENGINE
LOCATING ENGINE
FOOT
GROUND SCREW BETWEEN
NOTES: TAB CROSS
AMPHENOL HOLES SUPPORT
WELDER LEAD END
ELECTRICAL SYMBOLS PER E1537
(NOTE CAVITY NUMBERS)
ALL CASE FRONT COMPONENTS VIEWED FROM REAR.
221 (CAVITY #1)
208 (CAVITY #2)
2-20-98N
L10889
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted
inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
RANGER 9 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
6 PIN
14 PIN
OPTIONAL K444-1
AMPHENOL
AMPHENOL
REMOTE CONTROL
LN-25
WIRE FEEDER
ELECTRODE
TO WORK
WORK CLIP LEAD
TO WORK
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR
SWITCH TO A CV POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH
IN "OUTPUT CONTROL REMOTE" POSITION.
N.D. WELDING TERMINALS SWITCH MUST BE PLACED IN "ALWAYS ON" POSITION.
12-16-93
M17090
RANGER 9 / K867 / K775 / LN-7 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
SPARE
82
LN-7
81 N.D.
WIRE
42 FEEDER
41
31 31
32 32
2 2
14 PIN
AMPHENOL
4 4
21
ELECTRODE
TO WORK
21
K291 OR K404
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
GREEN
75 75
ELECTRODE CABLE
TO WIRE FEED UNIT 76 76
TO WORK 77 77
K775 OPTIONAL
CAUTION : N.E. REMOTE CONTROL
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.
N.F. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
12-16-93
M17091
� 31 �
RANGER 9 / LN-7 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-7 INPUT
CABLE PLUG
14 PIN
AMPHENOL
OPTIONAL K857
REMOTE CONTROL
6 PIN
ELECTRODE
K584-XX INPUT CABLE ASSEMBLY
TO WORK
AMPHENOL
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
12-16-93
M17092
RANGER 9 TO K867 ADAPTER CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN
N.C.
AMPHENOL
81
82 NOT USED ON RANGER POWER SOURCES
SPARE
2
K867 UNIVERSAL CONNECT TOGETHER FOR
N.D.
4
ADAPTER PLUG
WELDING OUTPUT
41
42 VAC
42
N.E.
31
115 VAC
32
ELECTRODE
TO WORK
GND POWER SOURCE FRAME CONNECTION
21 WIRE FEEDER VOLTMETER CONNECTION
ELECTRODE CABLE CONNECTS TO (WORK TERMINAL) OF POWER SOURCE
TO WIRE FEED UNIT 77 10K
76 REMOTE OUTPUT CONTROL
TO WORK MIN.
75
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET DESIRED POLARITY, POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
{ 2 TO
TO
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
WIRE
K867
RELAY TO CLOSE LEADS 2 & 4.
FEEDER
4
N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.
12-16-93
M17093
� 32 �
RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
SPARE
82 LN-8
WIRE
81 N.C.
FEEDER
42
41
31 31
32 32
2 2
14 PIN
AMPHENOL
4 4
21 21
ELECTRODE
TO WORK
K196
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
75 A
ELECTRODE CABLE
TO WIRE FEED UNIT 76 B
TO WORK 77 C
CAUTION : N.D.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION. PLACE WELDING TERMINALS SWITCH TO
"REMOTELY CONTROLLED " POSITION.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.
N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
12-16-93
M17094
RANGER 9 / LN-742 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-742 INPUT
CABLE PLUG
14 PIN
AMPHENOL
K592 CONTROL CABLE
ELECTRODE
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
12-16-93
M17100
� 33 �
RANGER 9 / LN-25 WITH 42 VOLT REMOTE OUTPUT
CONTROL MODULE CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-25 INPUT
CABLE PLUG
14 PIN
AMPHENOL
K626-XX INPUT CABLE ASSEMBLY
ELECTRODE
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
12-16-93
M17214
K915-1 AMPTROL ADAPTER FOR K799 HI-FREQ KITS
WARNING
POWER SOURCE
TURN THE ENGINE OR POWER SWITCH
OF THE WELDING POWER SOURCE "OFF" 6-PIN
PLUG
BEFORE CONNECTING OR DISCONNECTING
PLUGS TO WELDING POWER SOURCE.
ELECTRIC SHOCK
can kill
K915-1
K963 HAND
AMPTROL
+
-
AMPTROL ADAPTER
OR
6-SOCKET
*
BYPASS
RECEPTACLE CAPACITOR
KIT
K870 FOOT
AMPTROL
*
ELECTRODE LEAD
*
WORK SENSE LEAD
*
HI-FREQ KIT
INPUT POWER
5-PIN
THIS ADAPTER ALLOWS AN AMPTROL TO OPERATE A PLUG
K799 HI-FREQ KIT WHILE REMOTELY CONTROLLING THE
OUTPUT CURRENT OF A LINCOLN POWER SOURCE.
(THE POWER SOURCE MUST BE EQUIPPED WITH A
6-PIN REMOTE CONTROL AMPHENOL CONNECTOR.)
SEE THE HI-FREQ KIT AND POWER SOURCE INSTRUC-
TION MANUAL FOR INFORMATION ON PROPER SWITCH
K799 HI-FREQ KIT
AND CONTROL SETTINGS.
*
SEE INSTRUCTIONS INCLUDED WITH HI-FREQ
KIT FOR CONNECTION INFORMATION.
4-19-96D
S20909
� 34 �
RANGER 9 AND 10LX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
115V RECEPTACLE
K488 SG
CONTROL MODULE
RANGER
K487-25
SPOOL GUN
14 PIN WIRE FEEDER
6 PIN REMOTE K691-10
RECEPTACLE
RECEPTACLE INPUT CABLE
ELECTRODE
TO WORK
ELECTRODE CABLE
TO CONTROL MODULE
TO WORK
BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE
CAUTION :
CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.C. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE OUTPUT CONTROL SWITCH IN
"OUTPUT CONTROL REMOTE" POSITION.
N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
CRM23615
M17902
� 35 �
MAR 95
DIMENSION PRINT - Ranger 9
CENTER OF GRAVITY WITH OIL IN
C OF SHAFT
L ENGINE AND EMPTY FUEL TANK.
9.31 9.29
20.63 ~.25
20.51
30.28
26.59
� 36 �
2.75
FOR OIL FILTER
REMOVAL (NOT
12.75~.25
REQUIRED WITH
KOHLER ENGINE)
17.00
9.09 9.09
8.80 30.00
42.00
UNDERCARRIAGE MOUNTING HOLES
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa fuera del área de trabajo. cuerpo.
mojada.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
vêtements mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e G Mantenha inflamáveis bem G Use proteção para a vista, ouvido e
electrodos com a pele ou roupa guardados. corpo.
ATENÇÃO molhada.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de G Desconectar el cable de G No operar con panel abierto o
AVISO DE
respiración. alimentación de poder de la guardas quitadas.
G Mantenga la cabeza fuera de los máquina antes de iniciar cualquier
PRECAUCION
humos. Utilice ventilación o servicio.
aspiración para gases.
French
G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées. G Débranchez le courant avant
G Utilisez un ventilateur ou un ouverts ou avec les dispositifs de
l’entretien.
ATTENTION
protection enlevés.
aspirateur pour ôter les fumées des
zones de travail.
German
G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von G Strom vor Wartungsarbeiten
oder Innenschutzverkleidung in
Schweibrauch! abschalten! (Netzstrom völlig
WARNUNG
G Sorgen Sie für gute Be- und Betrieb setzen!
öffnen; Maschine anhalten!)
Entlüftung des Arbeitsplatzes!
Portuguese
G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça. G Não opere com as tampas removidas.
G Use ventilação e exhaustão para moventes.
G Desligue a corrente antes de fazer
ATENÇÃO
G Não opere com os paineis abertos
remover fumo da zona respiratória. serviço.
ou guardas removidas.
G Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 39 �
� World's Leader in Welding and Cutting Products �
� 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
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