RETURN TO MAIN MENU
IM819-B
â„?
RANGER 10,000 September, 2006
For Machines with Code Number 11041, 11095, 11151, 11253
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
R
C US
OPERATOR’S MANUAL
Copyright © 2005 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 can-
cancer, birth defects, or other reproductive harm.
cer, 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
purchase 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 2.c. Exposure to EMF fields in welding may have other health
parts 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.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
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
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
5.a. Welding may produce fumes and gases
the following equipment:
hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder.
fumes and gases.When welding, keep
� DC Manual (Stick) Welder.
your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode,
welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic
ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�.
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical
which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection
low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded.
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical
respirator may be required. Additional precautions are
(earth) ground.
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
3.g. Never dip the electrode in water for cooling. exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
3.h. Never simultaneously touch electrically “hot� parts of OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating prod-
yourself from a fall should you get a shock. ucts.
3.j. Also see Items 6.c. and 8. 5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
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 cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
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
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la 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 vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
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. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
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 ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er 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, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
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.
vi vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Safety Precautions ........................................................................................................A-2
Machine Grounding .......................................................................................................A-2
Spark Arrester ...............................................................................................................A-2
Towing, Vehicle Mounting .............................................................................................A-2
Pre-Operation Engine Service..............................................................................................A-3
Fuel, Oil .........................................................................................................................A-3
Battery Connections ......................................................................................................A-3
Welding Cable Connections ..........................................................................................A-4
Angle of Operation ........................................................................................................A-4
Lifting, Additional Safety Precautions............................................................................A-4
High Altitude Operation .................................................................................................A-4
Muffler Relocation .........................................................................................................A-4
Location and Ventilation ................................................................................................A-5
Stacking ........................................................................................................................A-5
Connection of Wire Feeders .........................................................................................A-5
Connection of Tig Module .............................................................................................A-5
Additional Safety Precautions,Welding Operation Output.............................................A-5
Auxiliary Power Receptacles, and Plugs .............................................................................A-6
Motor Starting and Extension Cord Length Table ................................................................A-6
Electrical Device Used with the Ranger 10,000 ...................................................................A-7
Auxiliary Power While Welding, Standby Power Connections ............................................A-8
Premises Wiring ...................................................................................................................A-9
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
General Description..............................................................................................................B-1
Welder Controls Function and Operation .............................................................................B-1
Polarity, Range and Control Switch......................................................................................B-2
Start in/Shutdown Instructions .....................................................................................................B-3
Starting the Engine........................................................................................................B-3
Safety Precautions ........................................................................................................B-3
Stopping the Engine ......................................................................................................B-3
Break-In Period .............................................................................................................B-3
Welding Process ..................................................................................................................B-4
Stick (Constant Current) Welding..................................................................................B-4
TIG (Constant Current) Welding ..................................................................................B-4
Wire Feed Welding Processes (Constant Voltage) ......................................................B-4
Arc Gouging ..................................................................................................................B-4
Summary of Welding Processes ...................................................................................B-5
________________________________________________________________________________
Accessories .....................................................................................................Section C
Optional Equipment ...............................................................................................C-1
Recommended Equipment ....................................................................................C-2
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Engine Maintenance ..........................................................................D-1,D2
Engine Adjustments...............................................................................................D-3
Slip Rings ..............................................................................................................D-3
Battery Maintenance .......................................................................................D-3
Engine Maintenance Parts..............................................................................D-3
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
________________________________________________________________________
Wiring Diagrams & Dimension Print..............................................................Section F
Wiring and Connection Diagrams ...........................................................F-1 Thru F-4
Dimension Print......................................................................................................F-5
________________________________________________________________________
Parts List ..................................................................................................................P481
________________________________________________________________________
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Ranger 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1)
INPUT - GASOLINE ENGINE
Description Operating Capacities
Displacement
Make/Model Starting
Horsepower
Speed (RPM) cu. in. System
(cu.cm.)
Fuel:
38(624)
(K1419-4) 20 HP @
9 Gal (34 L)
Kohler
Kohler 2 cylinder 3600 RPM
Lubricating Oil:
CH20S 12VDC
4 Cycle Kohler
2.0 Qts. (1.9 L)
Battery
Air-Cooled High Idle 3700
Electric Start
Gasoline
Group 58
Engine.
37.5 (614) Fuel:
Battery
Aluminum Alloy 20 HP@
(K2160-3)
Full Load 3500 9 Gal (34 L)
(435 cold
Honda
with Cast Iron 3600 RPM
Honda
Lubricating Oil
Cranking
Liners, Honda
GX620KI 1.9 Qts. (1.8L)
Amps)
Electronic
Low Idle 2200
Ignition
Fuel:
20.5 HP@
(K2468-1) 39.9 (653) 12 Gal (45.4 L)
3600 RPM
ROBIN/SUBARU Lubricating Oil
ROBIN/SUBARU
ROBIN/SUBARU
1.6 Qts. (1.6L)
EH64
RATED OUTPUT @ 104°F (40°C)- WELDER
Welding Output
AC Constant Current 225A / 25V / 100%
DC Constant Current 210A / 25V / 100%
DC Constant Voltage 200A / 20V / 100%
RATED OUTPUT @ 104°F (40°C)- GENERATOR
Auxiliary Power 1
9,000 Watts Continuous, 60 Hz AC
10,000 Watts Peak, 60 Hz AC
120/240 Volts
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-4
770 mm 485 mm 1067 mm 505 lbs. (229kg) K2160-3
528 lbs. (240kg) K2468-1
1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.
When welding available auxiliary power will be reduced.
RANGER 10,000
A-2 A-2
INSTALLATION
When this welder is mounted on a truck or trailer, it’s
SAFETY PRECAUTIONS
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect-
WARNING ed between the machine grounding stud and the
Do not attempt to use this equipment until you frame of the vehicle.
have thoroughly read the engine manufacturer’s
Where this engine driven welder is connected to
manual supplied with your welder. It includes
premises wiring such as that in your home or shop, it’s
important safety precautions, detailed engine
frame must be connected to the system earth ground.
starting, operating and maintenance instructions,
See further connection instructions in the section enti-
and parts lists.
------------------------------------------------------------------------ tled “Standby Power Connections�, as well as the arti-
ELECTRIC SHOCK can kill. cle on grounding in the latest National Electrical Code
� Do not touch electrically live parts or and the local code.
electrode with skin or wet clothing.
� Insulate yourself from work and In general, if the machine is to be grounded, it should
ground
be connected with a #8 or larger copper wire to a solid
� Always wear dry insulating gloves.
earth ground such as a metal water pipe going into
------------------------------------------------------------------------
the ground for at least ten feet and having no insulat-
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or ed joints, or to the metal framework of a building
vent exhaust outside. which has been effectively grounded. The National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
------------------------------------------------------------------------
stud marked with the symbol is provided on the
MOVING PARTS can injure.
front of the welder.
� Do not operate with doors open or
guards off.
� Stop engine before servicing. SPARK ARRESTER
� Keep away from moving parts.
------------------------------------------------------------------------
Some federal, state, or local laws may require that
See additional warning information at gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
front of this operator’s manual.
where unarrested sparks may present a fire hazard.
-----------------------------------------------------------
The standard muffler included with this welder does
not qualify as a spark arrester. When required by local
regulations, the K894-1 spark arrester must be
MACHINE GROUNDING
installed and properly maintained.
Because this portable engine driven welder or genera-
tor creates it’s own power, it is not necessary to con-
CAUTION
nect it’s frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
An incorrect arrester may lead to damage to the
etc.).
engine or adversely affect performance.
------------------------------------------------------------------------
WARNING TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(1) is
To prevent dangerous electric shock, other equip-
Lincoln’s K957-1. If the user adapts a non-Lincoln
ment to which this engine driven welder supplies
trailer, he must assume responsibility that the method
power must:
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
� be grounded to the frame of the welder using a
the factors to be considered are as follows:
grounded type plug, or be double insulated.
1. Design capacity of trailer vs. weight of Lincoln
Do not ground the machine to a pipe that carries
equipment and likely additional attachments.
explosive or combustible material.
------------------------------------------------------------------------
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
RANGER 10,000
INSTALLATION
A-3 A-3
3. Proper placement of the equipment on the trailer to
FUEL
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced. Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operated;
environmental conditions. WARNING
� Damage to the fuel tank may cause
5. Conformance with federal, state and local laws(1)
fire or explosion. Do not drill holes
(1) Consult applicable federal, state and local laws regarding specific
in the RANGER 10,000 base or weld
requirements for use on public highways.
to the RANGER 10,000 base.
VEHICLE MOUNTING
-----------------------------------------------------------------------
WARNING OIL
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other LUBRICATION SYSTEM CAPACITY
components to fail. (INCLUDING FILTER)
Kohler CH20S - 2.0 Quarts (1.9 Liters)
� Only transport this Equipment on serviceable Honda GX620KI-1.9 Quarts (1.8 Liters)
vehicles which are rated and designed for such
Robin/Subaru EH6-1.6 Quarts (1.6 Liters)
loads.
� Distribute, balance and secure loads so vehicle The Ranger 10,000 is shipped with the engine
is stable under conditions of use. crankcase filled with SAE 10W-30 oil. Check the oil
� Do not exceed maximum rated loads for compo- level before starting the engine. If it is not up to the full
nents such as suspension, axles and tires. mark on the dip stick, add oil as required. Make cer-
� Mount equipment base to metal bed or frame of tain that the oil filler cap is tightened securely. Refer to
vehicle. the engine Owner’s Manual for specific oil recommen-
� Follow vehicle manufacture’s instructions. dations.
------------------------------------------------------------------------
PRE-OPERATION SERVICE CAUTION
BATTERY CONNECTIONS
CAUTION
Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
READ the engine operating and maintenance
-----------------------------------------------------------------------
instructions supplied with this machine.
This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
WARNING the “STOP� position and attach the disconnected
cable securely to the negative battery terminal before
� Stop engine while fueling.
attempting to operate the machine. If the battery is
� Do not smoke when fueling.
discharged and does not have enough power to start
� Keep sparks and flame away
the engine, see the battery charging instructions in the
from tank.
Battery section.
� Do not leave unattended while
fueling. NOTE: This machine is furnished with a wet charged
� Wipe up spilled fuel and allow battery; if unused for several months, the battery may
GASOLINE fumes to clear before starting require a booster charge. Be careful to charge the bat-
can cause fire engine. tery with the correct polarity.
or explosion. � Do not overfill tank, fuel expan-
sion may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
RANGER 10,000
A-4 A-4
INSTALLATION
WELDING OUTPUT CABLES ADDITIONAL SAFETY PRECAUTIONS
WARNING
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces- � Lift only with equipment of
sary. Loose connections will result in overheating of adequate lifting capacity.
the output studs.
� Be sure machine is stable
when lifting.
When welding at a considerable distance from the
� Do not lift this machine using
welder, be sure you use ample size welding cables. lift bale if it is equipped with a
Listed below are copper cable sizes recommended for heavy accessory such as trail-
the rated current and duty cycle. Lengths stipulated er or gas cylinder.
are the distance from the welder to work and back to FALLING � Do not lift machine if lift bale is
the welder again. Cable sizes are increased for
EQUIPMENT can damaged.
greater lengths primarily for the purpose of minimizing
cause injury. � Do not operate machine while
cable voltage drop.
suspended from lift bale.
TOTAL COMBINED LENGTH OF ------------------------------------------------------------------------
ELECTRODE AND WORK CABLES
HIGH ALTITUDE OPERATION
225 Amps
100% Duty Cycle
If the RANGER 10,000 will be consistently operated at
altitudes above 5000 ft, a carburetor jet designed for
1 AWG
0-100 Ft.
high altitudes should be installed. This will result in
100-200 Ft. better fuel economy, cleaner exhaust, and longer
1 AWG
spark plug life. It will not give increased power which
200-250 Ft. is decreased at higher altitudes. Engine horsepower is
1/0 AWG
reduced by 3.5% per 1000 feet for altitudes above 377
feet.
ANGLE OF OPERATION
CAUTION
Internal combustion engines are designed to run in a
Do not operate a RANGER 10,000 with a high alti-
level condition which is where the optimum perfor-
tude jet installed at altitudes below 5000 ft. This
mance is achieved. The maximum angle of operation
will result in the engine running too lean and
for the engine is 15 degrees from horizontal in any
result in higher engine operating temperatures
direction. If the engine is to be operated at an angle,
which can shorten engine life.
provisions must be made for checking and maintain-
-----------------------------------------------------------------------
ing the oil at the normal (FULL) oil capacity in the
Contact your local Kohler, Honda or Robin/Subaru
crankcase in a level condition.
Authorized Dealer for high altitude jet kits that are
available from the engine manufacturer.
When operating at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.
Muffler Relocation
LIFTING
WARNING
The RANGER 10,000 weighs approximately 575 lbs.
� Shut off welder and allow muffler to cool before
with a full tank of gasoline. A lift bail is mounted to the
touching muffler.
machine and should always be used when lifting the
------------------------------------------------------------------------
machine.
The RANGER 10,000 is shipped with the exhaust
coming out on the left side. The exhaust can be
changed to the opposite side by removing the two
screws that hold the exhaust port cover in place and
installing the cover on the opposite side. (Operating
the RANGER 10,000 without the cover in place will
result in a higher noise level and no increase in
machine output.)
RANGER 10,000
A-5 A-5
INSTALLATION
d. Position the “RANGE� switch to the “WIRE FEED�
LOCATION / VENTILATION
position.
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
e. Attach the single lead from the LN-25 control box
avoid heated air coming out of the welder recirculating
to the work using the spring clip on the end of the
back to the cooling air inlet. Also, locate the welder so
lead - it carries no welding current.
that engine exhaust fumes are properly vented to an
f. Place the engine switch in the “AUTO� position.
outside area.
g. Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL�
STACKING
at the welder.
NOTE: The welding electrode is energized at all
RANGER 10,000 machines cannot be stacked. times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL� is set below �3�, the LN-25
contactor may not pull in.
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
CONNECTION OF K930-2 TIG MODULE TO THE
RANGER 10,000.
WARNING
The TIG Module is an accessory that provides high
Shut off welder before making any electrical frequency and shielding gas control for AC and DC
connections. GTAW (TIG) welding. See IM528 supplied with the
------------------------------------------------------------------------ TIG Module for installation instructions.
WIRE FEED (CONSTANT VOLTAGE)
Note: The TIG Module does not require the use of a
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
high frequency bypass capacitor. However, if the
FEEDER
RANGER 10,000 is used with any other high frequen-
The LN-15 has an internal contactor and the electrode
cy equipment, the bypass capacitor must be installed,
is not energized until the gun trigger is closed. When
order kit T12246.
the gun trigger is closed the wire will begin to feed and
the welding process is started.
INSTRUCTIONS
a. Shut the welder off.
ADDITIONAL SAFETY PRECAUTIONS
b. Connect the electrode cable from the LN-15 to
the“ELECTRODE� terminal of the welder. Connect
the work cable to the “TO WORK� terminal of the Always operate the welder with the roof and case
welder. sides in place as this provides maximum protection
c. Set the Polarity switch to the desired polarity, either from moving parts and assures proper cooling air flow.
DC (-) or DC (+).
d. Attach the single lead from the front of the LN-15 Read and understand all Safety Precautions before
to work using the spring clip at the end of the lead. operating this machine. Always follow these and any
This is a control lead to supply current to the wire other safety procedures included in this manual and in
feeder motor; it does not carry welding current. the Engine Owner’s Manual.
e. Set the “RANGE� switch to the “WIRE FEED-CV�
position WELDER OPERATION
f. Place the Engine switch in the “High Idle� position.
WELDER OUTPUT
g. Adjust the wire feed speed at the LN-15 and adjust
� Maximum Open Circuit Voltage at 3700 RPM is
the welding voltage with the output “CONTROL� at
80 Volts RMS.
the welder. Output “CONTROL� must be set above 3.
� Duty Cycle is the percentage of time the load is
Note: LN-15 Control Cable model will not work with being applied in a 10 minute period. For example, a
the RANGER 10,000. 60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty Cycle
CONNECTION OF THE LN-25 TO THE RANGER for the RANGER 10,000 is 100%.
10,000
a. Shut the welder off.
RANGER 10,000
b. Connect the electrode cable from the LN-25 to
the“ELECTRODE� terminal of the welder.
Constant Current 225 Amps AC @ 25 Volts
Connect the work cable to the “TO WORK� termi-
210 Amps DC @ 25 Volts
nal of the welder.
c. Position the welder “Polarity� switch to the desired
Constant Voltage 200 Amps DC @ 20 Volts
polarity, either DC (-) or DC (+).
RANGER 10,000
A-6 A-6
INSTALLATION
GND
AUXILIARY POWER
The RANGER 10,000 can provide up to 9,000 watts of
120/240 volts AC, single phase 60Hz power for con-
tinuous use, and up to 10,000 watts of 120/240 volts
AC, single phase 60Hz power peak use. The front of
the machine includes three receptacles for connecting
the AC power plugs; one 50 amp 120/240 volt NEMA
120 V
14-50R receptacle and two 20 amp 120 volt NEMA 5-
20R receptacles. Output voltage is within +/-10% at all 240 V
loads up to rated capacity.
120 V*
CAUTION
*Current Sensing for Automatic Idle.
Do not connect any plugs that connect to the (Receptacle viewed from front of Machine)
power receptacles in parallel.
120 V DUPLEX RECEPTACLES
------------------------------------------------------------------------
The 120V auxiliary power receptacles should only be
Start the engine and set the “IDLER� control switch to
used with three wire grounded type plugs or approved
the desired operating mode. Set the “CONTROL� to
double insulated tools with two wire plugs.
10. Voltage is now correct at the receptacles for auxil-
iary power.
The current rating of any plug used with the system
must be at least equal to the current load through the
120/240 VOLT DUAL VOLTAGE RECEPTACLE
associated receptacle.
The 120/240 volt receptacle can supply up to 38 amps
of 240 volt power to a two wire circuit, up to 38 amps MOTOR STARTING
of 120 volts power from each side of a three wire cir-
cuit (up to 76 amps total). Do not connect the 120 volt Most 1.5 hp AC single phase motors can be started if
circuits in parallel. Current sensing for the automatic there is no load on the motor or other load connected
idle feature is only in one leg of the three wire circuit to the machine, since the full load current rating of a
as shown in the following column. 1.5 hp motor is approximately 20 amperes (10
amperes for 240 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stated
is not exceeded. This may necessitate 240V operation
only.
RANGER 10,000 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Current Voltage Load
(Amps) Volts (Watts) 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
120
15 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
120
20 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
240
15 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
240
20 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
240
38 9000 50 (15) 90 (27) 150 (46) 225 (69)
Conductor size is based on maximum 2.0% voltage drop.
RANGER 10,000
A-7 A-7
INSTALLATION
TABLE lll
ELECTRICAL DEVICE USE WITH THE RANGER 10,000.
Type Common Electrical Devices Possible Concerns
Resistive Heaters, toasters, incandescent NONE
light bulbs, electric range, hot
pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage
appliances with electrical control. regulation can cause the capac-
itative elements to fail. Surge
protection, transient protection,
and additional loading is recom-
mended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required,
and liabilities still exist. DO
NOT USE THESE DEVICES
WITH A RANGER 10,000
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-
ed to the RANGER 10,000.
RANGER 10,000
A-8 A-8
INSTALLATION
1. Install a double pole, double throw switch between
AUXILIARY POWER WHILE WELDING
the power company meter and the premises
disconnect.
Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
Switch rating must be the same or greater than
assume that current is being drawn from either the
the customer’s premises disconnect and service
120V or 240V supply (not both at the same time).
overcurrent protection.
Also, the “Output Control� is set at �10� for maximum
auxiliary power.
2. Take necessary steps to assure load is limited to
the capacity of the RANGER 10,000 by installing a
38 amp 240V double pole circuit breaker.
TABLE I
Maximum rated load for the 240V auxiliary is 38
SIMULTANEOUS WELDING AND POWER
amperes. Loading above 38 amperes will reduce
output voltage below the allowable -10% of rated
Output Selector Permissible Power Permissible Auxiliary
voltage which may damage appliances or other
Setting Watts (Unity Power Current in Amperes
@ 120V *-or- @ 240V
Factor) motor-driven equipment.
Max. Stick or Wire
3. Install a 50 amp 120/240V plug (NEMA type 14-50)
Feed Setting None 0 0
to the Double Pole Circuit Breaker using No. 8,
145 Stick Setting 3450 32 16
4 conductor cable of the desired length. (The
50 amp 120/240V plug is available in the
90 Stick Setting 6000 50** 25
optional plug kit.)
NO WELDING 9000 76** 38
4. Plug this cable into the 50 amp 120/240V
receptacle on the RANGER 10,000 case front.
* Each duplex receptacle is limited to 20 amps.
**Not to exceed 40A per 120VAC branch circuit when
splitting the 240 VAC output.
STANDBY POWER CONNECTIONS
The RANGER 10,000 is suitable for temporary, stand-
by, or emergency power using the engine manufactur-
er’s recommended maintenance schedule.
The RANGER 10,000 can be permanently installed as
a standby power unit for 240V-3 wire, single phase 38
ampere service.
WARNING
(Connections must be made by a licensed electri-
cian who can determine how the 120/240V power
can be adapted to the particular installation and
comply with all applicable electrical codes.) The
following information can be used as a guide by
the electrician for most applications (refer also to
the connection diagram shown in Figure 1.)
-------------------------------------------------------------------------
RANGER 10,000
A-9 A-9
INSTALLATION
Figure 1
CONNECTION OF RANGER 10,000 TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt 120 VOLT
60 Hz.
COMPANY
3-Wire
120 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
240 VOLT
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 120/240 VOLT
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
WARNING
Connection of RANGER 10,000 to premises wiring
must be done by a licensed electrician and must
comply with the National Electrical Code and all
other applicable electrical codes.
RANGER 10,000
B-1 B-1
OPERATION
SAFETY PRECAUTIONS
WELDER CONTROLS - FUNCTION AND
OPERATION
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes ENGINE SWITCH
important safety precautions, detailed engine The engine switch is used to Start the Engine, Select
starting, operating and maintenance instructions,
High Idle or Auto Idle while the engine is running, and
and parts lists.
stop the Engine.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or When placed in the “OFF� position, the ignition
electrode with skin or wet clothing. circuit is de-energized to shut down the engine.
� Insulate yourself from work and
ground When held in the “START� position, the engine
� Always wear dry insulating gloves.
starter motor is energized.
� Always operate the welder with the hinged door
When in “HIGH IDLE� ( ) position, the engine will
closed and the side panels in place.
run continuously at high idle.
� Read carefully the Safety Precautions page
When in “AUTO IDLE� ( / ) position, the
before operating this machine. Always follow
engine will run continuously and the idler operates as
these and any other safety procedures included
follows:
in this manual and in the Engine Instruction
Manual.
� Welding
------------------------------------------------------------------------
When the electrode touches the work, the welding
GENERAL DESCRIPTION
arc is initiated and the engine accelerates to full
The Rangerâ„?10,000 is a twin-cylinder, gasoline dri- speed.
ven, multiprocess arc welder and AC power genera-
tor. It is built in a heavy gauge steel case for durability After welding ceases (and no auxiliary power is
on the job site. being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.
� Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles,
the engine will accelerate to high speed. If no
power is being drawn from the receptacles (and
not welding) for 10-14 seconds, the idler reduces
the engine speed to low idle.
RANGER 10,000
B-2 B-2
OPERATION
� RANGE� SWITCH
The “Range� switch is used to select one of three
amperage ranges with generous overlap for Stick/TIG
welding, or one Wire Feed welding range.
Process Range Setting Current Range
STICK/TIG 90 Max. 40 to 90 Amps
(constant current) 145 Max. 70 to 145 Amps
(3 range settings) 210DC/225AC Max. 120 to 210 (DC) 225(AC)
WIRE FEED
(constant voltage) 15 to 25V Up to 200 Amps
(one range setting)
CAUTION
Never change the “RANGE� Switch setting while
welding. This will damage the switch.
------------------------------------------------------------------------
� CONTROL� DIAL
Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and weld-
ing voltage control with the Range switch set in the
wire feed mode.
POLARITY SWITCH
Provides three selectable welding polarities:
AC, DC+ & DC-
CAUTION
Never change the Polarity switch setting while
welding. This will damage the switch.
------------------------------------------------------------------------
RANGER 10,000 APPROXIMATE FUEL CONSUMPTION
KOHLER ROBIN / SUBARU
HONDA
20 H.P. CH20S 20.5 H.P. EH64
20 H.P. GX620KI
Low Idle - No Load .4 Gallons/Hour .6 Gallons/Hour
.3 Gallons/Hour
2200 RPM (1.5 Liters/Hour) (2.3 Liters/Hour)
(1.3 Liters/Hour)
High Idle - No Load .7 Gallons/Hour .8 Gallons/Hour
.7 Gallons/Hour
3700 RPM (2.8 Liters/Hour) (3.0 Liters/Hour)
(2.8 Liters/Hour)
AC CC Weld Output 1.2 Gallons/Hour 1.5 Gallons/Hour
1.3 Gallons/Hour
225 Amps @ 25 Volts (4.6 Liters/Hour) (5.8 Liters/Hour)
(5 Liters/Hour)
DC CC Weld Output 1.3 Gallons/Hour 1.6 Gallons/Hour
1.5 Gallons/Hour
210 Amps @ 25 Volts (4.9 Liters/Hour) (6.1 Liters/Hour)
(5.9 Liters/Hour)
DC CV Weld Output 1.2 Gallons/Hour 1.2 Gallons/Hour
1.2 Gallons/Hour
200 Amps @ 20 Volts (4.5 Liters/Hour) (4.5 Liters/Hour)
(4.5 Liters/Hour)
Auxiliary Power 1.4 Gallons/Hour) 1.6 Gallons/Hour)
1.7 Gallons/Hour)
9000 Watts (5.3 Liters/Hour) (6.1 Liters/Hour)
(6.5 Liters/Hour)
RANGER 10,000
B-3 B-3
OPERATION
STARTING/SHUTDOWN INSTRUCTIONS STOPPING THE ENGINE
STARTING THE ENGINE
Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
WARNING to cool the engine.
� Do not touch electrically live parts Stop the engine by placing the Engine switch in the
of electrode with skin or wet
“OFF� position.
clothing.
A fuel shut off valve is not required on the Ranger
10,000 because the fuel tank is mounted below the
engine.
� Keep flammable material away.
BREAK-IN PERIOD
� Insulate yourself from work and
ground. Wear eye, ear, and body
protection. It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi-
� Keep your head out of the fumes. mately 50 running hours).
� Use ventilation or exhaust to
remove fumes from breathing zone. IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
Be sure all Pre-Operation Maintenance has been per-
THE MACHINE. AVOID LONG IDLE
formed. Also, read the Engine Owner’s Manual before
RUNNING PERIODS. REMOVE
starting for the first time.
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
Remove all loads connected to the AC power recepta-
cles. Use the choke control as follows:
The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:
KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.
KOHLER HONDA ROBIN / SUBARU
HONDA ENGINE - IF the engine is cold, pull the
CH20S GX620KI EH64
choke control out. Do Not use the choke if the engine
is warm or hot.
5 HRS. First Month 25 HRS.
or 20 HRS.
Turn the engine switch to the “start� position and
crank the engine until it starts. Release the switch as
The oil filter is to be changed at the second oil
soon as the engine starts, slowly return the choke
change. Refer to the Engine Owner’s Manual for more
control to the full “in� position (choke open),
information.
and turn the switch to the Auto Idle( / )
position. Do not turn the switch to the “start� position
while the engine is running because this will cause
damage to the ring gear and/or starter motor
After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.
RANGER 10,000
B-4 B-4
OPERATION
WELDING PROCESS SETTINGS FOR 1% THORIATED TUNGSTEN
For any electrodes the procedures should be kept TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE
within the rating of the machine. For electrode infor-
mation see the appropriate Lincoln publication. 1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps
STICK (CONSTANT CURRENT) WELDING The K930-[ ] TIG Module should be used with the Ranger
10,000 on high idle to maintain satisfactory operation. It
Connect welding cables to the "TO WORK� and can be used in the AUTO position but the delay going to
"ELECTRODE� studs. Start the engine. Set the low idle after welding is ceased will be increased if the
"Polarity� switch to the desired polarity. The “RANGE� AFTER FLOW CONTROL is set above 10 seconds.
switch markings indicate the maximum current for that
range as well as the typical electrode size for that NOTE: For AC TIG Welding, the maximum TIG welding
range. The “OUTPUT� Control provides fine adjust- output currents on each range setting will be approxi-
ment of the welding current within the select range. mately 50% higher than those marked on the nameplate.
For maximum output within a selected range set the This is due to the special nature of the AC TIG welding
“OUTPUT� Control at 10. For minimum output within a arc. Do not AC TIG weld on the 225AC range setting.
selected range set the “OUTPUT� Control at 5. (“OUT- The output current may exceed the rating of the Ranger
PUT� Control settings below 5 may reduce arc stabili- 10,000.
ty) For best overall welding performance set the
“RANGE� Switch to the lowest setting and the OUT- WIRE FEED WELDING PROCESSES
PUT� Control near the maximum to achieve the (CONSTANT VOLTAGE)
desired welding current.
The Innershield® electrode recommended for use with
the RANGER 10,000 is NR ®-211-MP. The electrode
RANGE SETTING TYPICAL CURRENT RANGE
sizes and welding ranges that can be used with the
ELECTRODE SIZE
RANGER 10,000 are shown in the following table:
3/32
90 MAX. 40 TO 90 AMPS
Diameter Wire Speed Approximate
1/8
145 MAX. 70 TO 145 AMPS
(in.) Range In./Min. Current Range
5/32
210(DC)/225(AC) 120 TO 210(DC),
MAX. 225(AC) AMPS .035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A
The RANGER 10,000 can be used with a broad range
of AC and DC stick electrodes. See “Welding Tips 1� The RANGER 10,000 is recommended for limited “MIG�
included with the RANGER 10,000 for electrodes with- welding (GMAW - gas metal arc welding). The recom-
in the rating of this unit and recommended welding mended electrodes are .030� and .035� L-50 and L-56.
currents of each. They must be used with a blended shielding gas such as
C25 (75% Argon - 25% CO2). The welding ranges that
TIG (CONSTANT CURRENT) WELDING can be used with the RANGER 10,000 are shown in the
following table:
The K930-[ ] TIG Module installed on a Ranger 10,000 Diameter Wire Speed Approximate
provides high frequency and shielding gas control for (in.) Range In./Min. Current Range
AC and DC GTAW (TIG) welding processes. Output
control is from the Ranger 10,000. The output control .030 75 - 300 50A to 130A
on the TIG Module is not functional. After flow time is .035 100 - 250 90A to 175A
adjustable from 0 to 55 seconds.
ARC GOUGING
When using the Ranger 10,000 for AC TIG welding of
aluminum, the following settings and electrodes are The Ranger 10,000 can be used for limited arc gouging.
recommended:
Set the Range switch to adjust output current to the
SETTINGS FOR PURE TUNGSTEN
desired level for the gouging electrode being used
TUNGSTEN RANGE SWITCH APPROXIMATE
according to the ratings in the following table:
DIAMETER (in.) SETTINGS CURRENT RANGE
ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)
1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/8 30 - 60 Amps
1/16 90 40 - 80 Amps
5/32 90 - 150 Amps
3/16 150 - 250 Amps
RANGER 10,000
B-5 B-5
OPERATION
SUMMARY OF WELDING PROCESSES
CONTROL ELECTRODE
CABLE IDLE WHEN NOT TO START
PROCESS USED MODE WELDING WELDING
STICK No AUTO Hot Touch electrode to work.
Welding starts immediately
and engine goes to high
idle.
WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding
starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above �3�
TIG, TIG MODULE WITH Yes High Cold Press Arc Start Switch
WITH CONTACTOR KIT contactor closes,
CONTROL CABLE, & ARC welding starts immediately.
START SWITCH
WIRE FEED, LN-15 No High Cold Press gun trigger.
ACROSS the ARC LN-15 contactor closes,
(has internal contactor) Welding starts immediately
Note: Output Control must
be set above �3�.
RANGER 10,000
C-1 C-1
ACCESSORIES
K802-R Power Plug Kit- provides four 120V plugs
OPTIONAL EQUIPMENT (Field Installed)
rated at 15 amps each and one dual voltage, Full
KVA plug rated at 120/240V, 50 amps.
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS - For road, off-road and in-plant
K802-N Power Plug Kit - Provides four 120V plugs
and yard towing. (For highway use, consult applicable
rated at 20 amps each and one dual voltage, full KVA
federal, state and local laws regarding requirements
plug rated at 120/240V, 50 amps.
for brakes, lights, fenders, etc.)
Order K957-1 Trailer
K894-1 Spark Arrester Kit - Includes a heavy gauge
K958-1 Ball Hitch
steel, approved spark arrester and clamp for easy
K958-2 Lunette Eye Hitch
mounting to muffler exhaust pipe.
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack
K1690-1 GFCI RECEPTACLE KIT - Includes one UL
approved120V ground fault circuit interrupter duplex type
K889-2 & -3 Two-Wheel Undercarriage - For moving
receptacle with cover and installation instructions.
by hand. Overall Width 29 in (.74m) Both have pneu-
Replaces the factory installed 120V duplex receptacle.
matic tires. Puncture proof tires included with K889-3. Each receptacle of the GFCI Duplex is rated at 20 Amps,
the maximum total current from the GFCI Duplex is limit-
K1631-1 Puncture Proof Wheel Kit - For converting ed to the 20 Amps. Two kits are required.
K889-2 or K933-1 to puncture proof pneumatic tires.
K1816-1 FULL KVA ADAPTER KIT - Plugs into the
K893-1 Caster for Undercarriage - Mounts to the 120/240V NEMA 14-50R receptacle on the case front
front of the K889-2 or 3 to allow easy movement on (which accepts 4-prong plugs) and converts it to a
smooth surfaces. Includes 6� diameter hard rubber NEMA 6-50R receptacle, (which accepts 3-prong
wheel and convenient toe-on, toe-off locking brake. plugs.)
K933-1 Four Wheel Undercarriage - For Hand T12153-9 Full-KVA Power Plug - One dual voltage
Moving. Rear pneumatic tires, front molded wheels. plug rated at 120/240V, 50 amps.
K934-1 Cylinder Brackets - For use with K933-1. K930-2 TIG Module - Provides high frequency and
For transporting one welding gas cylinder. shielding gas control.for AC and DC GTAW (TIG)
welding applications. Its compact case is designed foe
K1737-1 FOUR WHEEL ALL-TERRAIN UNDER- easy carrying, complete with a handle. High frequency
CARRIAGE - For moving by hand at construction bypass is built in requires K938-1 Contactor Kit, K936-
sites. Heavy duty puncture resistant pneumatic tires. 4 Control Cable, and K814 Arc Start Switch.
K1770-1 UNDERCARRIAGE (FACTORY) - For mov- K938-1 Contactor Kit - For use with TIG Module,
ing by hand on a smooth surface. One or two gas Provides a “cold� electrode until the triggering device
cylinders can be mounted on the rear of the undercar- (Arc Start Switch) is pressed.
riage with the installation of K1745-1 Cylinder
Holder(s). Heavy duty puncture resistant pneumatic K936-4 Control Cable - Connects TIG Module to
tires and front caster. Ranger 10,000.
K1745-1 GAS CYLINDER HOLDER K814 Arc Start Switch - Attaches to the TIG torch for
Holds Welding Gas Cylinder for use on K1770-1 convenient finger control.
Undercarriage. One or two may be installed on an
undercarriage. K937-45 Control Cable Extension - Allows TIG
Module to be operated at distances up to 200ft. from
K1788-1 ROLL CAGE - Gives added damage protec- the power source. Available in 45ft. (13.7m).
tion.
Attaches to K1737-1, K1770-1, and K957-1. K844-1 Water Valve Kit - For use with water cooled
TIG torch, Installs inside of TIG Module.
K886-1 Canvas Cover -To protect the RANGER
10,000 when not in use. Made from attractive red can- K939-1 Docking Kit - For Mounting the K930-2 TIG
vas material which is flame retardant, mildew resis- Module on top of the Ranger 10,000.
tant, and water repellent.
RANGER 10,000
C-2 C-2
ACCESSORIES
RECOMMENDED EQUIPMENT
STICK
K704 Accessory Kit - For Stick Welding. Includes 35 ft
(10.7m).
� 2/0 AWG electrode cable, 30 ft. (9.1m)
� 2/0 AWG work cable with lugs, headshield, filter plate, work
clamp, and electrode holder. 400 amp capacity.
K875 Accessory Kit - For stick welding. Includes 20 Ft. (6.1m).
#6 electrode cable with lug, 15 Ft. (4.6m) #6 work cable with
lugs, headshield, filter plate, work clamp, and electrode holder
and sample pack of mild steel electrode. 150 amp capacity.
WIRE FEED
K449 LN-25 - Includes internal contactor for across
the arc operation (no control cable). Provides “cold�
electrode until gun trigger is pressed. Includes gas
solenoid.
K1870-1 LN-15 Across the Arc
Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.
K126-2 Magnum 350 Innershield Gun (for LN-25, LN-
15).
K1802-1 Magnum 300 MIG Gun (for LN-25, includes
Connector Kit).
K470-2 Magnum 300 MIG Gun (for LN-15, requires
K466-10 Magnum Gun Connector Kit).
K1500-1 Gun Receiver Bushing (for LN-15, K126-2)
Note: See Wire Feeder IM Manual for appropriate
Drive Roll & Guide Tube Kits.
TIG WELDING
K1783-9- PTA-26V TIG Torch.
KP509- Magnum Parts Kit and Argon gas.
K930-2- TIG Module.
Required TIG Equipment:
K938-1 Connector Kit
K936-4 Control Cable
K814 Arc Start Switch
Optional TIG Equipment:
K939-1 Docking Kit
K937-45 Control Cable Extension
K844-1 Water Valve Kit
PLASMA CUTTING:
K1580-1- Pro-Cut 55 (Requires full KVA Adapter
K1816-1).
RANGER 10,000
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS
CAUTION
WARNING Make certain that the oil filler cap is securely tight-
ened after checking or adding oil. If the cap is not
Have qualified personnel do the maintenance
tight, oil consumption can increase significantly
work. Turn the engine off before working inside
which may be evidenced by white smoke coming
the machine. In some cases, it may be necessary
from the exhaust.
to remove safety guards to perform required
maintenance. Remove guards only when
� OIL - Maintenance schedule for changing the oil and
necessary and replace them when the mainte-
oil filter after break-in :
nance requiring their removal is complete.
Always use the greatest care when working near KOHLER HONDA ROBIN / SUBARU
moving parts. CH20S GX620KI EH64
6 Months
Do not put your hands near the engine cooling Oil 100 HRS. 100 HRS. 100 HRS.
blower fan. If a problem cannot be corrected by 1 Year or
following the instructions, take the machine to Oil Filter 200 HRS. 200 HRS. 200 HRS.
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
The above schedule is for normal operating condi-
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts tions. More frequent oil changes are required with
or electrode with skin or wet dusty, high temperature and other severe operating
clothing. conditions. Refer to the maintenance section of the
� Insulate yourself from work and
Engine Owner's Manual for more information.
ground
� Always wear dry insulating gloves.
NOTE: 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.
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
------------------------------------------------------------------------ and complete draining.
MOVING PARTS can injure.
� Do not operate with doors open or � Remove the oil filler cap and dipstick. Remove the
guards off. yellow cap from the oil drain valve and attach the
� Stop engine before servicing.
flexible drain tube supplied with the machine. Push
� Keep away from moving parts.
in and twist the drain valve counterclockwise. Pull
------------------------------------------------------------------------
the valve out and drain the oil into a suitable contain-
See additional warning information
er.
throughout this operator’s manual and
� Close the drain valve by pushing in and twisting
the Engine manual as well. clockwise. Replace the yellow cap.
------------------------------------------------------------
� Refill to the upper limit mark on the dipstick with the
Read the Safety Precautions in the front of this manual recommended oil. Tighten the oil filler cap securely.
and the engine instruction manual before working on
this machine. ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
Keep all equipment safety guards, covers, and devices � 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler
in position and in good repair. Keep hands, hair, cloth- �1.6 US qt. (1.3 IMP qt., 1.5 liter)-Honda GX620KI
ing, and tools away from gears, fans, and all other �1.5 US qt. (1.2 IMP qt., 1.4 liter)-Robin / Subaru
moving parts when starting, operating, or repairing the
equipment. With oil filter replacement:
� 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler
Routine Maintenance �1.9 US qt. (1.6 Imp qt. , 1.8 liter)-Honda GX620KI
� At the end of each day’s use, refill the fuel tank to �1.6 US qt. (1.4 IMP qt., 1.6 liter)-Robin / Subaru
minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and
add oil if indicated.
RANGER 10,000
D-2 D-2
MAINTENANCE
AIR CLEANER AND OTHER MAINTENANCE
Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
� Air Cleaner - With normal operating conditions, the
Always check the API SERVICE label on the oil con-
maintenance schedule for cleaning and re-oiling
tainer to be sure it includes the letters SG or SH.
the foam pre-filter is every 25 hours and replace-
ment of the air cleaner filter every 100 hours.
SAE 10W-30 is recommended for general, all-tempera-
More frequent servicing is required with dusty
ture use, -5 F to 104 F (-20 C to 40 C).
operating conditions. Refer to the maintenance
section of the Engine Owner’s Manual for more
See Engine Owner’s Manual for more specific informa-
information.
tion on oil viscosity recommendations.
� Refer to the maintenance section of the Engine
Wash your hands with soap and water after handling
Owner’s Manual for the maintenance schedule,
used oil.
spark plug servicing, cooling system servicing, and
fuel filter replacement.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
� Blow out the machine with low pressure air period-
it in a sealed container to your local service station or
ically. In particularly dirty locations, this may be
recycling center for reclamation.
required once a week.
Do not throw it in the trash, pour it on the ground or
� Output Ranger Selector and Polarity Switches:
down a drain.
Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
OIL FILTER CHANGE
range frequently. Good practice is to turn the han-
dle from maximum to minimum setting twice each
1. Drain the engine oil. morning before starting to weld.
2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.
3. Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.
4. Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil fil-
ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.
5. Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.
6. Start the engine and check for oil filter leaks.
7. Stop the engine, and check the oil level. If neces-
sary, add oil to the upper limit mark on the dipstick.
RANGER 10,000
D-3 D-3
MAINTENANCE
ENGINE ADJUSTMENTS
WARNING
GASES FROM BATTERY can explode.
OVERSPEED IS HAZARDOUS � Keep sparks, flame and cigarettes away from battery.
To prevent EXPLOSION when:
WARNING � INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
last.
The maximum allowable high idle speed for this � CONNECTING A BATTERY CHARGER - Remove bat-
machine is 3750 RPM, no load. Do NOT tamper tery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When rein-
with governor components or setting or make any stalling, connect negative cable last. Keep well venti-
other adjustments to increase the maximum lated.
speed. Severe personal injury and damage to the � USING A BOOSTER - connect positive lead to battery
machine can result if operated at speeds above first then connect negative lead to engine foot.
maximum.
BATTERY ACID CAN BURN EYES AND SKIN.
------------------------------------------------------------------------ � Wear gloves and eye protection and be careful when
Adjustments to the engine are to be made only by a working near battery. Follow instructions printed on
battery.
Lincoln Service Center or an authorized Field Service
Shop.
BATTERY
SLIP RINGS
1. When replacing, jumping, or otherwise connecting
the battery to the battery cables, the proper
A slight amount of darkening and wear of the slip rings
polarity must be observed. Failure to observe
and brushes is normal. Brushes should be inspected
the proper polarity could result in damage to the
when a general overhaul is necessary.If brushes are
charging circuit. The positive (+) battery cable
to be replaced, clean slip rings with a fine emery
has a red terminal cover.
paper.
2. If the battery requires charging from an external
charger, disconnect the negative battery cable
CAUTION first and then the positive battery cable before
attaching the charger leads. Failure to do so
Do not attempt to polish slip rings while engine is
can result in damage to the internal charger
running.
components. When reconnecting the cables,
------------------------------------------------------------------------
connect the positive cable first and the negative
cable last.
HARDWARE
Both English and Metric fasteners are used in this
welder.
ENGINE MAINTENANCE PARTS
KOHLER C20S HONDA GX620KI ROBIN / SUBARU EH64
KOHLER 1205001 HONDA ROBIN / SUBARU
Oil Filter FRAM PH3614* 15410-ZJ4-999A 248-65801-00, FRAM PH4967
Air Filter KOHLER 4708303 HONDA ROBIN / SUBARU
Element FRAM CA79 17210-ZJ1-841 263-32610-A1
Air Filter KOHLER 2408302 HONDA N/A
Pre-Cleaner 17218-ZJ1-840
Fuel Filter KOHLER 2505002 HONDA ROBIN / SUBARU
FRAM G1 16910-ZE8-015 011-00600-20
Spark Plugs CHAMPION RC12YC CHAMPION -J16CR-U ROBIN / SUBARU
(Resistor (.030� GAP) NGK-ZGR5A X65-01407-30
Type) 030in, (76 mm) Gap NGK-BPR4EY
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.
RANGER 10,000
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER 10,000
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
No welder or output power. 1. Open in miscellaneous leads.
2. Open lead in flashing or field
circuit.
3. Faulty rotor.
4. Faulty Potentiometer (R1).
5. Faulty stator Field winding.
6. Faulty Field rectifier (D2).
If all recommended possible areas of
7. Faulty P.C. Board. misadjustment have been checked
and the problem persists, Contact
Engine will not idle down to low 1. Idler switch on High Idle. your local Lincoln Authorized
speed. Field Service Facility.
2. Insufficient voltage present
between terminals #213 and
#5E. (Voltage should be 12V
DC).
3. External load on welder or
auxiliary power.
4. Faulty wiring in solenoid circuit.
5. Faulty idler solenoid.
6. Faulty P.C. Board.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work.
2. No voltage signal from the
current sensor.
3. No open circuit voltage on
output studs.
4. Faulty P.C. Board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER 10,000
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Engine will not go to high idle when 1. No voltage signal from the
using auxiliary power. current sensor.
2. Auxiliary power load less than
100 to 150 watts.
3. Faulty P.C. Board.
Engine will not crank or is hard to 1. Battery will not hold a charge.
crank. Faulty Battery. If all recommended possible areas of
misadjustment have been checked
2. No or insufficient charging and the problem persists, Contact
current. your local Lincoln Authorized
Field Service Facility.
3. Loose battery cable
connection(s).
Engine shuts down. 1. Out of fuel.
2. Low oil level.
Engine does not develop full power. 1. Fuel filter clogged.
2. Air filter clogged.
Engine is hard to start. 1. Spark plugs do not have
specified gap.
2. Spark plugs are fouled.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER 10,000
F-1
RANGER 10,000 (KOHLER) (CSA) WIRING DIAGRAM FOR 11041
LEADS 3 AND 6:
2 TURNS THRU TOROID IN
213 OPPOSITE DIRECTIONS
1 TURN
6
3
S3
261 CCW
254
260
OUTPUT R1
GROUND SCREW CONTROL
L1
209A
ON UPPER CASEFRONT CHOKE
211
+ 10 76A 75A
77A
S2
D1
208C 8
-
213A
1 2 PCB1
+ 5D 254 J2
CB7 3
D2 4
GND-I
25A S1
WORK
5F
- 12 7
S2 E
R1 8
J1
10
GND-E R3 R5 C1
IDLER ELECTRODE 1
6
210 S1
SOLENOID
5E
GND-G
215
224
77A
75A
224
219
76A
W2
200A
7 9
REACTOR 6
224A 215A
+
HOUR METER C1
GND-C
GROUND SCREW
215 GND-D STATOR
W1
ON LOWER CASEFRONT
5D
3
3 9
6 7
5E
GND-E
75A 77A
224A 6
209 76A
208 211 3
12 VOLT
224C 5
209A +
BATTERY
GND-D
J5
TERMINAL BLOCK
BBB 12 34 6A
(SEE CONN.) P5
R J2
W -
R
V 120V
6 CB1 GND-G
ENGINE 40A
U
FOOT
210
200A
GND-H 12 3B 5
RANGER 10,000
CR1 219
N.A.
OIL 5L 5K
DIAGRAMS
STARTER
PRESSURE +
6B
SOLENOID ENGINE
SWITCH J4 11
CROSS 120V/240V
IGNITION REGULATOR SUPPORT
MODULE CB4
STARTER
AC B+ AC GND-C
B- 20A
FUEL ROTOR
11 J3
SHUTOFF
CB2 120V
SOLENOID
5K CB3
40A 5
FLYWHEEL ALTERNATOR 20A SLIP RING NEAREST LAMINATION
5L
ENGINE COMPONENTS SILVER COLORED 3A 3A
TERMINALS
(WHITE WIRES)
GENERATOR LEAD END
(NOTE CAVITY NUMBERS)
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE. CONNECTOR PIN NUMBERS:
4 3
LEAD COLOR CODE: 12 7
211 (CAVITY #3)
B = BLACK OR GRAY U = BLUE
224C (CAVITY #4)
R = RED OR PINK V = VIOLET 2 1 2 1
3
6
LOCATING TAB
W = WHITE J2 J1
208 (CAVITY #2)
TERMINAL BLOCK
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
CONNECTION
ELECTRICAL SYMBOLS PER E1537 A
M20226
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.
F-1
F-2
RANGER 10,000 (HONDA) WIRING DIAGRAM FOR CODE 11095
LEADS 3 AND 6:
213A
2 TURNS THRU TOROID IN
213 OPPOSITE DIRECTIONS
1 TURN
6
3
S3
261 CCW
254
260
OUTPUT R1
GROUND SCREW CONTROL
L1
209A ON MIDDLE CASEFRONT CHOKE
211
+ 10 76A 75A
77A
S2
D1
208C
8
-
208C 213 210 211
1 2 PCB1
5D
OFF 254 J2
213A
CB7
AUTO X X X 3 4
GND-I
HONDA
25A S1
WORK
HIGH X X 5F
ENGINE 12 7
S2 E
210 R1 8
START X X X COMPONENTS J1
10
GND-E R3 R5 C1
IDLER ELECTRODE
X = CLOSED CIRCUIT 1
6
S1
SOLENOID
5E
GND-G
215
224
77A
75A
224
219
76A
W2
200A
7 9
REACTOR
224A 6
+
C1
GND-C
HOUR METER GROUND SCREW
215 GND-D STATOR
W1
ON LOWER CASEFRONT
5D
3
3 9
6 7
5E
GND-E
75A 77A
224A 6
76A
W 211 3
211B B/Y 5
209A +
+
GND-D
6A
D9 211B 209
J2
-
225A
-
211 120V
6 CB1 GND-G
B/Y
210 W STARTER ENGINE 40A
SOLENOID FOOT
OIL
RANGER 10,000
CR1
PRESSURE B/R 200A
GND-H 12 5
B/Y 3B 219
DIAGRAMS
SWITCH 5L 5K
IGNITION
MODULE FUEL +
6B
ENGINE
SHUTOFF
W/U J4 11
CROSS
SOLENOID 120V/240V
SUPPORT
GY WW CB4
GY GND-C 20A ROTOR
11 J3
CB2 120V
20 AMP
5K CB3
12 3 4 40A
56 STARTER
CHARGE COIL 5
20A SLIP RING NEAREST LAMINATION
5L
SILVER COLORED 3A 3A
RECTIFIER/REGULATOR TERMINALS
(WHITE WIRES)
MODULE B
HONDA ENGINE COMPONENTS
CONNECTOR PIN NUMBERS:
4 3 12 7
LEAD COLOR CODE:
B = BLACK OR GRAY B/Y = BLACK/YELLOW
B/R = BLACK/RED 2 1
W/U = WHITE/BLUE 2 1
3
6
GY = GREY J2 J1
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
Enhanced Diagram
A
M20301
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.
F-2
F-3
RANGER 10,000 WIRING DIAGRAM - FOR CODE 11151(KOHLER) AND CODE 11253 (ROBIN / SUBARU)
LEADS 3 AND 6:
2 TURNS THRU TOROID IN
1 TURN
6 CCW
OPPOSITE DIRECTIONS
254 3
L1
261 R1
CHOKE
260
OUTPUT
S2 10 CONTROL
213
+ 76A 75A
77A
S3
D1
GROUND SCREW
213A
ON UPPER
1 8
2 -
208C CASEFRONT
254
GND-I
211 1 2
209A
4 PCB1
J2
3 CB7 5D 3 4
WORK ELECTRODE
5F
25A S1
12
S2 E 7
GND-E
R1 8
210
J1
GROUND SCREW
213A 10
R3 R5 C1
GND-C
GND-D
GND-G
1
6
ON LOWER CASEFRONT
S1
IDLER
5E
215
224
77A
75A
219
76A
W2
SOLENOID
200A
7 9
REACTOR 6 3
HOUR C1
METER
215 STATOR
W1
+ 5D
224A
3 9 7
6
GND-E
224 5E
5
12 VOLT
208 211 BATTERY
224C 209A 209 +
TERMINAL BLOCK 6 6A
J5 J2
GND-D
(SEE CONN.) GND-G
3 4
2
1 120V
P5
CB1
40A
W R -
5F
R
V 12
224A
CB3
U ENGINE
224C 5L 5K
11 20A
J4
FOOT 6B 3B
120V/240V
GND-H
RANGER 10,000
200A
N.A. 219
210 CR1
SOLENOID
DIAGRAMS
+
GND-C
ENGINE
OIL J3
CROSS 5K
REGULATOR
PRESSURE 120V
SUPPORT
SWITCH 11 5
5L ROTOR
AC B+ AC FUEL
B- CB2 CB4
IGNITION SHUTOFF
STARTER 40A 20A
MODULE SOLENOID 3A
SLIP RING NEAREST LAMINATION
3
FLYWHEEL ALTERNATOR
SILVER COLORED TERMINALS
ENGINE COMPONENTS
GENERATOR LEAD END
CONNECTOR PIN NUMBERS: (NOTE CAVITY NUMBERS)
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
S3 OPERATION
12
4 3 7
LEAD COLOR CODE: 1 3 4
2
211 (CAVITY #3)
B = BLACK OR GRAY U = BLUE OFF
2 1
3
6
2 1 224C (CAVITY #4)
R = RED OR PINK V = VIOLET XX
AUTO X
J2 J1
W = WHITE LOCATING TAB
HIGH X X
208 (CAVITY #2)
START X XX
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR. TERMINAL BLOCK
X = CLOSED CIRCUIT
CONNECTION
ELECTRICAL SYMBOLS PER E1537
C
M20431
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.
F-3
F-4
THE
RANGER 10,000 / L
LN-15 AND LN-25 ACROSS T E ARC CONNECT N DI
CONNECTION DIAGRAM
WARNING
MOVING PARTS can injure
ELECTRIC SHOCK can kill
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 equipm
equipment.
Do not touch electrically live parts.
ENGINE
WELDER
LN-15 OR LN-25
WIRE FEEDER
RE F
WORK CLIP LEAD
ELECTRODE
TO WORK
RANGER 10,000
DIAGRAMS
W
TO WORK
TO W
WORK
ELECTRODE CABLE
CABL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT DUTY CYCLE OF APPLICATION.
E B SIZ D F R CU D C O
POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. PO
CH T F D EL P . POSITION THE OUTPUT SELECTOR
E OU S
N.B. USE PO
SWITCH T THE WIRE FEED (CV) PO
TO T E POSITION.
A.02
F-4
M20266
F-5
KOHLER , HONDA AND ROBIN / SUBARU
CENTERLINE OF SHAFT
22.15
CENTER OF GRAVITY WITH OIL IN
ENGINE AND FULL FUEL TANK
21.22
9.59
9.31
30.27
26.59
RANGER 10,000
DIAGRAMS
10.33
8.80 30.00
17.00
42.00
9.09 9.09
10.19
OIL FILTER REMOVAL
A. 0 1
M20267
F-5
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 moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments 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 elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
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 res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
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.
� 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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