Lincoln Electric RANGER SVM168-B User manual

®
RANGER 10,000 /10,000 PLUS
SVM168-B
April, 2010
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
IN THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROU HOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
For use with machine code numbers Kohler 11041, 11151, 11394
Honda 11095, 11398
Robin/Subaru 11253. 11395
• Sales and Service through Subsidiaries and istributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
i
SAFETY
i
FOR EN INE
powered equipment.
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.
____________________________________________________
1.c. o not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. o
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi-
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. o not put your hands near the engine fan.
o not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDIN CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATIN .
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.
WARNIN
Mar ʻ95
ELECTRIC AND
MA NETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. o not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. o not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNIN S
iesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For iesel Engines The Above For Gasoline Engines
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
SAFETY
ii ii
FUMES AND ASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
AC IH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c. o not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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 manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MS S) and follow your
employerʼs safety practices. MS S forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
o not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
Jan ʻ09
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
SAFETY
iii iii
Jan ʻ09
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson avis Highway, Arlington, VA 22202.
WELDIN and CUTTIN
SPARKS can cause fire or
explosion.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. o not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
uring Welding, Cutting and Other Hot Work”, available from
NFPA,1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. o not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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SAFETY
RAN ER® 10,000 & RAN ER® 10,000 PLUS
iv iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. ans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayon-
nement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. es gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
vv
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Safety........................................................ i-iv
Installation....................................................SectionA
Operation.....................................................SectionB
Accessories ..................................................SectionC
Maintenance ..................................................SectionD
TheoryofOperation............................................SectionE
TroubleshootingandRepair ..................................... SectionF
ElectricalDiagrams ............................................Section
PartsManual ..................................................P-481Series
RETURN TO MAIN INDEX

RAN ER® 10,000 & RAN ER® 10,000 PLUS
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation ..............................................................................................................Section A
Technical Specifications............................................................................................A-2
Safety Precautions ....................................................................................................A-4
Machine Grounding...................................................................................................A-4
Spark Arrestor ...........................................................................................................A-4
Towing ............. .........................................................................................................A-4
Pre-Operation Service...............................................................................................A-5
Fuel ... ..................................................................................................................A-5
Oil.........................................................................................................................A-5
Battery Connections ............................................................................................A-5
Welding Output Cables .............................................................................................A-6
Angle of Operation ....................................................................................................A-6
High Altitude Operation.............................................................................................A-6
Location/Ventilation...................................................................................................A-7
Connection of Wire Feeders .....................................................................................A-7
Additional Safety Precautions...................................................................................A-7
Welder Operation ......................................................................................................A-7
Auxiliary Power..........................................................................................................A-8
120V Duplex Receptacles.........................................................................................A-8
Motor Starting ...........................................................................................................A-8
Electrical Devices used w/RANGER® 10,000 ..........................................................A-9
Auxiliary Power While Welding................................................................................A-10
Stand-by Power Connections.................................................................................A-10
Connection of RANGER® 10,000 to Premises Wiring (Drawing) ...........................A-11
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-2 A-2
TECHNICAL SPECIFICATIONS - RAN ER® 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1)
INPUT - ASOLINE EN INE
RATED OUTPUT @ 104°F (40°C)- WELDER
HEI HT WIDTH DEPTH WEI HT
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
RATED OUTPUT @ 104°F (40°C)- ENERATOR
Welding Output
AC Constant Current 225A / 25V / 100%
C Constant Current 210A / 25V / 100%
C Constant Voltage 200A / 20V / 100%
Auxiliary Power 1
9,000 Watts Continuous, 60 Hz AC
10,000 Watts Peak, 60 Hz AC
120/240 Volts
PHYSICAL DIMENSIONS
Make/Model
(K1419-4)
Kohler
CH20S
(K2160-3)
(K2160-4)
Honda
GX620KI
(K2468-1)
Subaru Robin
EH64
Description
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
Operating
Speed (RPM)
High Idle 3700
Full Load 3500
Low Idle 2200
Displacement
cu. in.
(cu.cm.)
38(624)
Kohler
37.5 (614)
Honda
39.9 (653)
ROBIN/SUBARU
Capacities
Fuel:
9 Gal (34 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
Fuel:
9 Gal (34 L)
Lubricating Oil
1.9 Qts. (1.8L)
Fuel:
12 Gal (45.4 L)
Lubricating Oil
1.6 Qts. (1.6L)
Horsepower
20 HP @
3600 RPM
Kohler
20 HP@
3600 RPM
Honda
20.5 HP@
3600 RPM
ROBIN/SUBARU
Starting
System
12V C
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
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.
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-3 A-3
TECHNICAL SPECIFICATIONS - RAN ER 10,000 PLUS (K1419-5 ), (K2468-2)
INPUT - ASOLINE EN INE
RATED OUTPUT @ 104°F (40°C)- WELDER
HEI HT WIDTH DEPTH WEI HT
30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-5
770 mm 485 mm 1067 mm 528 lbs. (240kg) K2468-2
505 lbs. (229kg) K2160-4
RATED OUTPUT @ 104°F (40°C)- ENERATOR
Welding Output
AC Constant Current 225A / 25V / 100%
C Constant Current 210A / 25V / 100%
C Constant Voltage 200A / 20V / 100%
Auxiliary Power 1
RANGER 10,000
9,000 Watts Continuous, 60 Hz AC
10,000 Watts Peak, 60 Hz AC
120/240 Volts
RANGER 10,000 PLUS
9,000 Watts Continuous, 60 Hz AC
10,500 Watts Peak, 60 Hz AC
120/240 Volts
PHYSICAL DIMENSIONS
Make/Model
(K1419-5)
Kohler
CH23S
(K2468-2)
Subaru Robin
EH65
Description
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
Operating
Speed (RPM)
High Idle 3700
Full Load
3500
Low Idle 2200
Displacement
cu. in.
(cu.cm.)
41(674)
Kohler
39.9 (653)
SUBARU ROBIN
Capacities
Fuel:
9 Gal (34 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
Fuel:
9 Gal (34 L)
Lubricating Oil
1.6 Qts. (1.6L)
Horsepower
23 HP @
3600 RPM
Kohler
22 HP@
3600 RPM
SUBARU ROBIN
Starting
System
12V C
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
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.
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-4 A-4
SAFETY PRECAUTIONS
MACHINE ROUNDIN
Because this portable engine driven welder or genera-
tor creates itʼs own power, it is not necessary to con-
nect itʼs frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).
To prevent dangerous electric shock, other equip-
ment to which this engine driven welder supplies
power must:
•be grounded to the frame of the welder using a
grounded type plug, or be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, itʼs
frame must be electrically bonded to the metal frame of
the vehicle. Use a #8 or larger copper wire connected
between the machine grounding stud and the frame of
the vehicle.
Where this engine driven welder is connected to
premises wiring such as that in your home or shop, itʼs
frame must be connected to the system earth ground.
See further connection instructions in the section enti-
tled “Standby Power Connections”, as well as the arti-
cle on grounding in the latest National Electrical Code
and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The National Electrical
Code lists a number of alternate means of grounding
electrical equipment. A machine grounding stud
marked with the symbol is provided on the front of
the welder.
SPARK ARRESTER
Some federal, state, or local laws may require that
gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this welder does not
qualify as a spark arrester. When required by local reg-
ulations, the K894-1 spark arrester must be installed
and properly maintained.
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
TOWIN
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(1) is
Lincolnʼs K957-1. If the user adapts a non-Lincoln trail-
er, he must assume responsibility that the method of
attachment and usage does not result in a safety haz-
ard nor damage the welding equipment. Some of the
factors to be considered are as follows:
1. esign capacity of trailer vs. weight of Lincoln equip-
ment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
CAUTION
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
EN INE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVIN PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
WARNIN
WARNIN
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-5 A-5
FUEL
Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.
OIL
The RANGER® 10,000 and the RANGER® 10,000
PLUS are shipped with the engine crankcase filled
with SAE 10W-30 oil. Check the oil level before start-
ing the engine. If it is not up to the full mark on the dip
stick, add oil as required. Make certain that the oil filler
cap is tightened securely. Refer to the engine Ownerʼs
Manual for specific oil recommendations.
BATTERY CONNECTIONS
Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
-----------------------------------------------------------------------
This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is dis-
charged and does not have enough power to start the
engine, see the battery charging instructions in the
Battery section.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat-
tery with the correct polarity.
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operated;
environmental conditions.
5. Conformance with federal, state and local laws(1)
(1) Consult applicable federal, state and local laws regarding specif-
ic requirements for use on public highways.
PRE-OPERATION SERVICE
READ the engine operating and maintenance
instructions supplied with this machine.
CAUTION
LUBRICATION SYSTEM CAPACITY
(INCLU ING FILTER)
Kohler CH20S / CH23S - 2.0 Quarts (1.9 Liters)
Honda GX620KI - 1.9 Quarts (1.8 Liters)
Robin Subaru EH64 /EH65 - 1.6 Quarts (1.6 Liters)
• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in or weld to the RAN ER® 10,000
or the RAN ER® 10,000 PLUS
base.
-----------------------------------------------------------------------
WARNIN
CAUTION
• Sto engine while fueling.
• Do not smoke when fueling.
• Kee s arks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wi e u s illed fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel ex an-
sion may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
WARNIN
ASOLINE
can cause fire
or explosion.
VEHICLE MOUNTIN
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacture’s instructions.
------------------------------------------------------------------------
WARNIN
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-6 A-6
WELDIN OUTPUT CABLES
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces-
sary. Loose connections will result in overheating of the
output studs.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated are
the distance from the welder to work and back to the
welder again. Cable sizes are increased for greater
lengths primarily for the purpose of minimizing cable
voltage drop.
AN LE OF OPERATION
Internal combustion engines are designed to run in a
level condition which is where the optimum perfor-
mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintaining
the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.
When operating at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.
LIFTIN
The RANGER® 10,000 and the RANGRER 10,000
PLUS weigh approximately 575 lbs. with a full tank of
gasoline. A lift bail is mounted to the machine and
should always be used when lifting the machine.
TOTAL COMBINED LEN TH OF
ELECTRODE AND WORK CABLES
0-100 Ft.
100-200 Ft.
200-250 Ft.
225 Amps
100% Duty Cycle
1 AW
1 AW
1/0 AW
HI H ALTITUDE OPERATION
At higher altitudes, Welder output de-rating may be neces-
sary.
Kohler and Subaru Robin Models:
For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above 3000ft. (914m).
Honda Model:
For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above sea level.
If operation will consistently be at altitudes above 5,000 ft.
(1525m), a carburetor jet designed for high altitudes should
be installed. This will result in better fuel economy, cleaner
exhaust and longer spark plug life. It will not give increased
power. Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine manu-
facturer.
Do not operate with a high altitude jet installed at alti-
tudes below 5000 ft. This will result in the engine running
too lean and result in higher engine operating tempera-
tures which can shorten engine life.
--------------------------------------------------------------------------------
Muffler Relocation
•Shut off welder and allow muffler to cool before touch-
ing muffler.
--------------------------------------------------------------------------------
The RANGER® 10,000 PLUS AN RANGER® 10,000 are
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 PLUS AN RANGER® 10,000 without
the cover in place will result in a higher noise level and no
increase in machine output.)
CAUTION
WARNIN
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when
lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer
or gas cylinder.
FALLIN • Do not lift machine if lift bale is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
WARNIN
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-7 A-7
LOCATION / VENTILATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
STACKIN
RANGER® 10,000 machines cannot be stacked.
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Shut off welder before making any electrical
connections.
------------------------------------------------------------------------
WIRE FEED (CONSTANT VOLTA E)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER
The LN-15 has an internal contactor and the electrode
is not energized until the gun trigger is closed. When
the gun trigger is closed the wire will begin to feed and
the welding process is started.
a. Shut the welder off.
b.
Connect the electrode cable from the LN-15 to
the “ELECTRO E” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.
c. Set the Polarity switch to the desired polarity, either
C (-) or C (+).
d. Attach the single lead from the front of the LN-15
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
e. Set the “RANGE” switch to the “WIRE FEE -CV”
position
f. Place the Engine switch in the “High Idle” position.
g. Adjust the wire feed speed at the LN-15 and adjust
the welding voltage with the output “CONTROL” at
the welder.
Output “CONTROL” must be set above 3.
Note: LN-15 Control Cable model will not work with
the RANGER® 10,000.
CONNECTION OF THE LN-25
a. Shut the welder off.
b.
Connect the electrode cable from the LN-25 to
the “ELECTRO E” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.
c. Position the welder “Polarity” switch to the desired
polarity, either C (-) or C (+).
RAN ER® 10,000 and RAN ER® 10,000 PLUS
Constant Current 225 Amps AC @ 25 Volts
210 Amps C @ 25 Volts
Constant Voltage 200 Amps C @ 20 Volts
d. Position the “RANGE” switch to the “WIRE FEE ”
position.
e. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.
f. Place the engine switch in the “AUTO” position.
g. Adjust wire feed speed at the LN-25 and adjust the
welding voltage with the output “CONTROL” at the
welder.
NOTE: The welding electrode is energized at all 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 K930-2 TI MODULE TO THE
RAN ER® 10,000 OR RAN ER® 10,000 PLUS.
The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and C
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.
NOTE: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if
any other high frequency equipment is used, a
Bypass Capacitor Kit (T12246) must be
installed in the RANGER® 10,000.
.
INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the roof and case sides
in place as this provides maximum protection from
moving parts and assures proper cooling air flow.
Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Ownerʼs Manual.
WELDER OPERATION
WELDER OUTPUT
• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.
• uty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. uty Cycle
for the RANGER® 10,000 is 100%.
WARNIN
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-8 A-8
120 V DUPLEX RECEPTACLES
The 120V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.
The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle.
MOTOR STARTIN
Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a
1.5 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 pro-
vided the receptacle rating as previously stated is not
exceeded. This may necessitate 240V operation only.
GND
120 V
120 V*
240 V
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
RAN ER® 10,000 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current
(Amps)
15
20
15
20
38
Voltage
Volts
120
120
240
240
240
Load
(Watts)
1800
2400
3600
4800
9000
30
60
(9)
(18)
40
30
75
60
(12)
(9)
(23)
(18)
75
50
150
100
50
(23)
(15)
(46)
(30)
(15)
125
88
225
175
90
(38)
(27)
(69)
(53)
(27)
175
138
350
275
150
(53)
(42)
(107)
(84)
(46)
300
225
600
450
225
(91)
(69)
(183)
(137)
(69)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Conductor size is based on maximum 2.0% voltage drop.
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
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 RANGER® 10,000 PLUS can provide up to 9,000
watts of 120/240 volts AC, single phase 60Hz power
for continuous use, and up to 10,500 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 14-50R receptacle and two 20 amp 120 volt
NEMA 5-20R receptacles. Output voltage is within +/-
10% at all loads up to rated capacity.
Do not connect any plugs that connect to the
power receptacles in parallel.
------------------------------------------------------------------------
Start the engine and set the “I LER” control switch to
the desired operating mode. Set the “CONTROL” to
10. Voltage is now correct at the receptacles for auxil-
iary power.
120/240 VOLT DUAL VOLTA E 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
of 120 volts power from each side of a three wire cir-
cuit (up to 76 amps total). o not connect the 120 volt
circuits in parallel. Current sensing for the automatic
idle feature is only in one leg of the three wire circuit as
shown in the following column.
CAUTION
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-9 A-9
TABLE lll
ELECTRICAL DEVICE USE WITH THE RAN ER® 10,000 or RAN ER® 10,000 PLUS.
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 RAN ER® 10,000
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-
ed to the RANGER® 10,000 or RANGER® 10,000 PLUS.
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-10 A-10
STANDBY POWER CONNECTIONS
The RANGER® 10,000 or RANGER® 10,000 PLUS is
suitable for temporary, standby, or emergency power
using the engine manufacturerʼs recommended mainte-
nance schedule.
The RANGER® 10,000 or RANGER® 10,000 PLUS
can be permanently installed as a standby power unit
for 240V-3 wire, single phase 38 ampere service.
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 fol-
lowing information can be used as a guide by the
electrician for most applications. (Refer to the con-
nection diagram shown in Figure A.1.)
-------------------------------------------------------------------------
1. Install a double pole, double throw switch between
the power company meter and the premises
disconnect.
Switch rating must be the same or greater than
the customerʼs premises disconnect and service
overcurrent protection.
2. Take necessary steps to assure load is limited to
the capacity of the RANGER® 10,000 by installing
a 40 Amp 240V double pole circuit breaker.
Maximum rated load for the 240V auxiliary is 38
amperes. Loading above 38 amperes 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 120/240V plug (NEMA type 14-50)
to the ouble Pole Circuit Breaker using a 4 con
ductor cable that is properly sized for the ampacity
and length to be used.
(The 50amp 120/240V plug is available in the
optional plug kit.)
4. Plug this cable into the 50 amp 120/240V
receptacle on the RANGER® 10,000 case front.
WARNIN
AUXILIARY POWER WHILE WELDIN
Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time). Also,
the “Output Control” is set at “10” for maximum auxil-
iary power.
TABLE I
SIMULTANEOUS WELDIN AND POWER
Output Selector Permissible Power Permissible Auxiliary
Setting Watts (Unity Power Current in Amperes
Factor) @ 120V *-or- @ 240V
Max. Stick or Wire
Feed Setting None 00
145 Stick Setting 3450 32 16
90 Stick Setting 6000 50** 25
NO WEL ING 9000 76** 38
*Each duplex receptacle is limited to 20 amps.
** Not to exceed 40A per 120VAC branch circuit
when splitting the 240 VAC output.
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
INSTALLATION
A-11 A-11
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
4 CONDUCTOR COPPER CABLE
SEE NATIONAL ELECTRICAL CODE
FOR WIRE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
40 AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
Connection of RAN ER® 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.
Figure A.1
CONNECTION OF RAN ER® 10,000 OR RAN ER® 10,000 PLUS TO PREMISES WIRIN
WARNIN
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
NOTES
A-12 A-12
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation ................................................................................................................Section B
SafetyPrecautions ...................................................B-2
GeneralDescription ..................................................B-2
WelderControls .....................................................B-2
EngineSwitch.......................................................B-2
RangeSwitch .......................................................B-3
ControlsDial .......................................................B-3
FuelConsumption ...................................................B-3
EngineOperation ....................................................B-4
BeforeStartingtheEngine .........................................B-4
StartingtheEngine ...............................................B-4
StoppingtheEngine ..............................................B-4
Break-inPeriod ..................................................B-4
WeldingProcess(Stick/Tig) ............................................B-5
SummaryofWeldingProcesses ........................................B-6
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RAN ER® 10,000 & RAN ER® 10,000 PLUS
OPERATION
B-2 B-2
WELDER CONTROLS - FUNCTION AND
OPERATION
EN INE SWITCH
The engine switch is used to Start the Engine, Select
High Idle or Auto Idle while the engine is running, and
stop the Engine.
When placed in the “OFF” position, the ignition
circuit is de-energized to shut down the engine.
When held in the “START” position, the engine
starter motor is energized.
When in “HIGH I LE” ( ) position, the engine will
run continuously at high speed.
When in “AUTO I LE” ( / ) position, the
engine will run continuously and the idler operates as
follows:
• Welding
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.
After welding ceases (and no auxiliary power is
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.
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
• Always operate the welder with the hinged door
closed and the side panels in place.
• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.
------------------------------------------------------------------------
ENERAL DESCRIPTION
The RANGER®™10,000 and RANGER® 10,000 PLUS
are twin-cylinder, gasoline driven, multi-process arc
welders and AC power generators. They are built with
a heavy gauge steel case for durability on the job site.
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