Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Mar. ‘93 iv SAFETY 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 contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS; Wiring and Connection Diagrams
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 8 - INSTALLATION; INPUT - GASOLINE ENGINE
A-1 INSTALLATION RANGER 10,000 A-1 TECHNICAL SPECIFICATIONS - Ranger 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1) INPUT - GASOLINE ENGINE RATED OUTPUT @ 104°F (40°C)- WELDER 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) K2160-3528...
Page 9 - be grounded to the frame of the welder using a; is; CAUTION
A-2 INSTALLATION RANGER 10,000 A-2 SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or genera-tor creates it’s own power, it is not necessary to con-nect it’s frame to an earth ground, unless the machineis connected to premises wiring (your home, shop,etc.). To prevent...
Page 10 - BATTERY CONNECTIONS; : This machine is furnished with a wet charged; PRE-OPERATION SERVICE; LUBRICATION SYSTEM CAPACITY; • Do not leave unattended while; GASOLINE FUEL ONLY; GASOLINE
FUEL Fill the fuel tank with clean, fresh, lead-free gasoline.Observe fuel gauge while filling to prevent overfilling. OIL T h e R a n g e r 1 0 , 0 0 0 i s s h i p p e d w i t h t h e e n g i n ecrankcase filled with SAE 10W-30 oil. Check the oillevel before starting the engine. If it is not up to ...
Page 12 - LOCATION / VENTILATION; C O N N E C T I O N O F T H E L N - 2 5 T O T H E; Constant Current; INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS; WELDER OUTPUT
A-5 INSTALLATION RANGER 10,000 A-5 LOCATION / VENTILATION The welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid heated air coming out of the welder recirculating back to the cooling air inlet. Also, locate the welder sothat engine exha...
Page 13 - 20 V DUPLEX RECEPTACLES; RANGER 10,000 Extension Cord Length Recommendations; AUXILIARY POWER
A-6 INSTALLATION RANGER 10,000 A-6 120 V DUPLEX RECEPTACLES The 120V auxiliary power receptacles should only beused with three wire grounded type plugs or approveddouble insulated tools with two wire plugs. The current rating of any plug used with the systemmust be at least equal to the current load...
Page 14 - TABLE lll
A-7 INSTALLATION RANGER 10,000 A-7 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 spik...
Page 15 - STANDBY POWER CONNECTIONS; AUXILIARY POWER WHILE WELDING
A-8 INSTALLATION RANGER 10,000 A-8 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 asa standby power unit for 240V-3 wire, single ph...
Page 16 - Figure 1; CONNECTION OF RANGER 10,000 TO PREMISES WIRING
240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRALBUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 40 ...
Page 17 - ENGINE SWITCH; OPERATION; SAFETY PRECAUTIONS; GENERAL DESCRIPTION
W E L D E R C O N T R O L S - F U N C T I O N A N D OPERATION ENGINE SWITCH The engine switch is used to Start the Engine, SelectHigh Idle or Auto Idle while the engine is running, andstop the Engine. When placed in the “ OFF ” position, the ignition circuit is de-energized to shut down the engine. ...
Page 18 - POLARITY SWITCH; RANGER 10,000 APPROXIMATE FUEL CONSUMPTION
“ RANGE ” SWITCH The “ Range ” switch is used to select one of three amperage ranges with generous overlap for Stick/TIGwelding, or one Wire Feed welding range. Never change the “ RANGE ” Switch setting while welding. This will damage the switch.------------------------------------------------------...
Page 19 - STARTING/SHUTDOWN INSTRUCTIONS
B-3 OPERATION B-3 STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per-formed. Also, read the Engine Owner ’ s Manual before starting for the first time. Remove all loads connected to the AC power recepta-cles. Use the choke control as follows: KOHLER...
Page 20 - WELDING PROCESS; ARC GOUGING
B-4 OPERATION B-4 WELDING PROCESS For any electrodes the procedures should be keptwithin the rating of the machine. For electrode infor-mation see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING C o n n e c t w e l d i n g c a b l e s t o t h e " T O W O R K ” a n d " E...
Page 21 - SUMMARY OF WELDING PROCESSES
B-5 OPERATION B-5 RANGER 10,000 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 immediatelyand engine goes to highidle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25 I...
Page 22 - ACCESSORIES; OPTIONAL EQUIPMENT; K893-1 Caster for Undercarriage
C-1 ACCESSORIES C-1 RANGER 10,000 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicablefederal, state and local laws regarding requirementsfor brakes, lights, fenders, etc.)Or...
Page 23 - RECOMMENDED EQUIPMENT; STICK
C-2 ACCESSORIES C-2 RANGER 10,000 RECOMMENDED EQUIPMENT STICK K 7 0 4 A c c e s s o r y K i t - F o r S t i c k W e l d i n g . I n c l u d e s 3 5 f t (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 am...
Page 24 - MAINTENANCE
Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be necessaryto remove safety guards to perform requiredm a i n t e n a n c e . R e m o v e g u a r d s o n l y w h e nnecessary and replace them when the mainte-n a n c e r e ...
Page 25 - OIL FILTER CHANGE
D-2 MAINTENANCE D-2 U s e 4 - s t r o k e m o t o r o i l t h a t m e e t s o r e x c e e d s t h erequirements for API service classification SG or SH.Always check the API SERVICE label on the oil con-tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tem...
Page 26 - ENGINE ADJUSTMENTS; HONDA
D-3 MAINTENANCE D-3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for thismachine is 3750 RPM, no load. Do NOT tamperwith governor components or setting or make anyo t h e r a d j u s t m e n t s t o i n c r e a s e t h e m a x i m u mspeed. Severe personal injury a...
Page 27 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 RANGER 10,000 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. CAUTION This Troubleshooting ...
Page 28 - PROBLEMS; Contact
E-2 TROUBLESHOOTING E-2 RANGER 10,000 Observe all Safety Guidelines detailed throughout this manual 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 troubleshootin...
Page 29 - Observe all Safety Guidelines detailed throughout this manual; for technical troubleshooting assistance before you proceed.; Engine does not develop full power.
E-3 TROUBLESHOOTING E-3 RANGER 10,000 Observe all Safety Guidelines detailed throughout this manual 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 troubleshootin...
Page 30 - LE; DIAGRAMS
S T ARTER CR1 S T ARTER SOLENOID 12 VOLT IDLER SOLENOID BATT ER Y AC AC B+ SW ITCH REGUL ATOR FLYWHEEL AL TERNATO R B- HOU R M ETE R 5E 5D 224 EN GINE C OMPONE NTS 224A 1 2 3 CON NE CTOR PIN NU M B ERS: 7 6 12 1 2 3 4 J1 N. A. B J2 SOLENOID FUEL SH UTOFF OI L PR ESS UR E TERMINAL BLOC K (SEE CONN.) ...
Page 31 - ER; Enhanced Diagram
F-2 DIAGRAMS F-2 RANGER 10,000 IDLER SOLENOID HOU R M ETE R 5E 5D 224 1 2 3 CON NE CTOR PIN NU M B ERS: 7 6 12 1 2 3 4 J1 J2 209A M20301 215 + ELE CT RI C AL SYMB OL S PER E1537 STATO R RE ACTO R S1 WO R K ELEC TR O D E CHOK E D1 S2 ROTOR PCB1 SLIP RING NEARE ST LA MINATION W1 W2 C1 S1 R1 R5 C1 L1 -...
Page 32 - RAN
F-3 DIAGRAMS F-3 RANGER 10,000 CR1 S T ARTER SOLENOID AC AC B+ REGUL ATOR FLYWHEEL AL TERNATOR B- 5E 5D 224 EN GINE C OMPO NENTS 224A 1 2 3 CONNE CTOR PIN NUM BERS: 7 6 12 1 2 3 4 J1 J2 209A 209A 224C 210 G ENE RATOR LEAD END (N O T E CAV IT Y NU MBER S) LOC A T IN G TAB TERMINAL BLOC K CONNE CTION ...
Page 35 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...