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®
IM925
RANGER 10,000 PLUS
January, 2007
AND RANGER 10,000
For Machines with Code Number 11394, 11395, 11398
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 ac
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 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. Us
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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 hos
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Machine Grounding.......................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 10,000 PLUS (K1419-5 ), (K2468-2) RANGER 10,000 (K2160-4) INPUT - GASOLINE ENGINE Description Operating Displacement Capacities Make/Model Horsepower Starting Speed (RPM) cu. in. System (cu.cm.) 41(674) Fuel: (K1419-5) 23 HP @ Kohler 9 Gal (34 L) Kohler 3600 RPM Lubricating Oil: CH23S 12VDC Kohler 2 cylinder 2.0 Qts. (1.9 L) Battery High Idle 3700 4 Cycle Electric Start Air-Cooled Group 58 Gasoline Fuel: Battery 22 HP@ (K2468-2) 39.9 (6
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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
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A-3 A-3 INSTALLATION 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 (1) � Damage to the fuel
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A-4 A-4 INSTALLATION WELDING OUTPUT CABLES WARNING � Lift only with equipment of ade- With the engine off, connect the electrode and work cables quate lifting capacity. to the studs provided. These connections should be � Be sure machine is stable when checked periodically and tightened if necessary. Loose con- lifting. nections will result in overheating of the output studs. � Do not lift this machine using lift bale if it is equipped with a When welding at a considerable distance from the w
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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 unrestricted flow of clean, cool air to the cooling air inlets and to avoid e. Attach the single lead from the LN-25 control box to heated air coming out of the welder recirculating the work using the spring clip on the end of the lead back to the cooling air inlet. Also, locate the welder so - it carries no welding current. that engine exhaust fu
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A-6 A-6 INSTALLATION GND AUXILIARY POWER 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 peak. The RANGER 10,000 (Honda 20 HP model) provides 10,000 watts peak. The front of the machine includes three receptacles for connecting the AC power plugs; 120 V one 50 amp 120/240 volt NEMA 14-50R receptacle and two 20 amp 120 volt NEMA 5-20R receptacles. 240 V Output voltage is within +/-10% at all loads up to
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A-7 A-7 INSTALLATION TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER 10,000 PLUS & 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- me
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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 dis- connect. Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown Switch rating must be the same or greater than the assume that current is being drawn from either the customer’s premises disconnect and service over- 120V or 240V supply (not both at the same time). current protection. Also, the “Ou
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A-9 A-9 INSTALLATION Figure 1 CONNECTION OF RANGER 10,000 PLUS OR 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 AM
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B-1 B-1 OPERATION SAFETY PRECAUTIONS WELDER CONTROLS - FUNCTION AND Do not attempt to use this equipment until you OPERATION 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. ---------------------------
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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.
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B-3 B-3 OPERATION STARTING/SHUTDOWN INSTRUCTIONS After running at high engine speed for 10-14 seconds, the engine will go to low idle. STARTING THE ENGINE Allow the engine to warm up by letting it run at low idle for a few minutes. WARNING STOPPING THE ENGINE � Do not touch electrically live parts of electrode with skin or wet Remove all welding and auxiliary power loads and clothing. allow engine to run at low idle speed for a few minutes to cool the engine. Stop the engine by placing the Engin
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B-4 B-4 OPERATION SETTINGS FOR 1% THORIATED TUNGSTEN WELDING PROCESS For any electrodes the procedures should be kept within TUNGSTEN RANGESWITCH APPROXIMATE DIAMETER (in.) SETTINGS CURRENT RANGE the rating of the machine. For electrode information see the appropriate Lincoln publication. 1/8 90, 145, or 210 80 - 225 Amps 3/32 90 or 145 50 - 180
