Lincoln Electric IM511-D manual

OPERA TOR’S MANUAL For use with machines having Code Number 10378, 10379, 10539, 10540 and 10550 RANGER TM 9 Multi-P rocess Gasoline Engine Driven W elder and P o w er Generator IM511-D OCTOBER, 2000 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be inc[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ____________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durab le flame-resistant material to protect you[...]

FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S . National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U.S . National Elec[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ P our v otre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circu[...]

Thank You f or selecting a QU ALITY product by Lincoln Electric. W e want y ou to take pride in operating this Lincoln Electric Company product ••• as much pride as we hav e in br inging this product to y ou! Read this Operators Manual completel y bef ore attempting to use this equipment. Save this man ual and keep it handy f or quick ref ere[...]

T ABLE OF CONTENTS Saf ety Precautions ............................................................................................................i i-iv Introductor y Inf or mation ......................................................................................................v General Description ............................................[...]

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- 7 - GENERAL DESCRIPTION The Ranger ™ 9, is a twin cylinder gasoline engine driven multi-process arc w elder and A C pow er generator . It is built in a hea vy gauge steel case f or durability on the job site. RECOMMENDED PR OCESSES AND EQUIPMENT The Ranger 9 can be used f or A C/DC Stic k welding (CC), DC Semiautomatic wire f eed welding (CV), [...]

Ranger 9 (Kohler Command CH20S) 20 HP @ 3600 RPM 38.1 cu in (624 cc) Fuel: 9 Gal (34 L) Lubricating Oil: 2.0 Qts (1.9 L) Product Name Description Horsepower Operating Speeds Displacement Ignition Capacities Machine Engine * Based on a 10 min. period. ** When welding, available AC auxiliary power will be reduced. 115V will operate either 60Hz or 50/[...]

A) K768-2 T wo Wheel Under carriage F or in-plant and yard to wing. (F or highway use , consult applicable f ederal, state, and local la ws regarding possible requirements f or brakes , lights, f enders, etc.) T w o 4.80 x 12" f our-ply tubeless tires. Bed-plate mounting. Has stand f or tow bar and g rips f or hand pulling. Ov erall width 43.0[...]

RECOMMENDED EQUIPMENT STICK K702 Accessor y Kit which includes: • Electrode holder and cable • W ork clamp and cable • Headshield K857 Remote Control Kit is optional f or remote current control. WIRE FEED LN-25 (K428 or K446) with K624-1 42 V olt Remote Output Control Module - Requires K626-xx Control Cable . Provides "cold" electro[...]

INST ALLA TION INSTR UCTIONS Machine Gr ounding Because this por tab le engine driven welder or generator creates it’ s own pow er , it is not necessar y to connect it’ s frame to an ear th ground, unless the machine is connected to premises wiring (your home, shop , etc.). T o pre v ent dangerous electric shock, other equipment to which this e[...]

4. T ypical conditions of use, i.e ., tra v el speed; rough- ness of surf ace on which the trailer will be operated; en vironmental conditions; like maintenance. 5. Conf ormance with federal, state and local la ws . ( 1 ) ( 1 ) Consult applicable f ederal, state and local laws regarding specific requirements f or use on public highw a ys. PRE-OPERA[...]

-13 - Angle of Operation Engines are designed to run in the lev el condition which is where the optimum perf ormance is achiev ed. The maximum angle of operation f or the engine is 15 degrees from horizontal in an y direction. If the engine is to be operated at an angle, pro visions must be made f or checking and maintaining the oil le vel at the n[...]

d. Set the “POLARITY” s witch to either WIRE FEED DC+ or WIRE FEED DC- as required by the electrode being used. e. Set the “RANGE” s witch to either HIGH, MED or LO W as required by the process . f . Set the “WELDING TERMINAL ” Control switch to the “AL W A YS ON” position. g. Set the “IDLER” s witch to the “A UTO” position.[...]

W elder Controls - Function and Operation ENGINE “ON-OFF” Switch When placed in the “ON” position, this s witch energizes the engine ignition circuit. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine . ENGINE “ST ART” Push-Button Switch Energizes engine star ter motor . “POLARITY” S[...]

Starting/Shutdown Instructions Starting the Engine Be sure all Pre-Operation Maintenance has been per- f ormed. Also, read the Engine Owner’ s Manual. Remov e all loads connected to the A C power recepta- cles. T o start the engine, set the “Idler Control” switch in the A utomatic ( / ) position. Use the choke control as f ollows: Onan Engine[...]

Stopping the Engine Remov e all welding and auxiliary power loads and allow engine to run at low idle speed f or a fe w minutes to cool the engine. Stop the engine by placing the “Engine” s witch in the “OFF” position. A fuel shut off v alve is not required on the Ranger 8 because the fuel tank is mounted below the engine . Break-in P eriod[...]

SUMMAR Y OF WELDING PROCESS -18 - CONTROL CABLE USED IDLE MODE OUTPUT CONTROL SWITCH WELDING TERMINALS SWITCH ELECTRODE WHEN NO T WELDING T O ST ART WELDING PROCESS STICK - CC TIG - CC K930-1/K936-1 (WITH AMPTROL) WIRE FEED - CV , LN-25 WITH 42V REMO TE CON- TROL KIT WIRE FEED - CV , LN-25 WITH INTERNAL CONT ACT OR WIRE FEED - CV , LN-742 WIRE FEED[...]

-19 - A uxiliary P ower The Ranger 9 can provide up to 9,000 w atts of 115/230 volts A C, single phase 60HZ po wer f or contin- uous use. The front of the machine includes three receptacles f or connecting A C pow er plugs. The K1420-1 has one 50 amp 115/230 volt NEMA 14- 50R receptacle and two 20 amp 115 v olt NEMA 5- 20R receptacles. The K1420-2 [...]

Most 1.5 HP motors can be star ted if there is no load on the motor or other load connected to the machine, since the full load current rating of a 1.5HP motor is appro ximately 20 amperes (10 amperes f or 230 v olt motors). The motor ma y be run at full load when plugged into only one side of the duple x receptacle. Larger motors through 2HP can b[...]

2. T ake necessary steps to assure load is limited to the capacity of the Ranger 9 by installing a 40 amp , 230 v olt doub le pole circuit breaker . Maximum rated load f or each leg of the 230 v olt auxiliar y is 40 amperes . Loading abov e 40 amps will reduce output v oltage below the allo wab le - 10% of rated v oltage which ma y damage appliance[...]

MAINTENANCE Safety Precautions -22 - Have qualified per sonnel do the maintenance work. T urn the engine off before w orking inside the machine. In some cases, it may be necessary to remove safety guar ds to perf orm required maintenance. Remove guards onl y when necessary and replace them when the maintenance requiring their remov al is complete. [...]

Use correct polarity - Negative Ground . T o pre v ent BA TTER Y DISCHARGE, if you ha v e an ignition s witch, turn it off when engine is not running. • T o prev ent BA TTER Y BUCKLING, tighten nuts on batter y clamp until sn ug. ------------------------------------------------------------------------ 1. When replacing, jumping or otherwise conne[...]

TR OUBLESHOO TING ENGINE TR OUBLE A. Engine will not crank or is hard to crank. B. Engine will not start or shuts down. C . Engine does not de v elop full power . D . Batter y does not sta y charged. CA USE 1. Batter y will not hold a charge . F aulty batter y . 2. No or insufficient charging current. 3. Loose batter y cab le connection(s). 4. Lead[...]

IDLER SYSTEM TR OUBLE A . Engine will not idle do wn to lo w speed. B. Engine will not go to high idle when attempting to weld. I. Scratch Star t II. When using wire f eeder with con- trol cable plugged into amphenol connector or using amptrol when trigger is depressed. C . Engine will not go to high idle when using auxiliar y po wer . CA USE 1. Id[...]

OUTPUT SYSTEM TR OUBLE A. No welder or po wer output. B. Output control on w elder not functioning. C . Output control or remote not functioning. D . Wire feeder does not work when connected to welder amphenol. CA USE 1. Open lead in flashing or field circuit. 2. F aulty rotor . 3. F aulty stator field. 4. F aulty field rectifier D2. 5. Output cont[...]

OUTPUT SYSTEM TR OUBLE E. Contactor does not pull in when scratch star ting when engine goes to high idle. F . Contactor does not pull in when using a wire f eeder with a control cable plugged into amphenol. G. Contactor does not drop out. CA USE 1. W elding terminal switch in wrong position. 2. F aulty wir ing in contactor circuit. 3. F aulty remo[...]

-28 - 236 ELECTRODE WORK 241 GND (+) D1 (-) R1 C2 25W 100 C3 C4 C5 224E AMMETER 209 AM 1 AUTO HIGH 3 5 6 212 CAPACITOR AC AC B+ 208 STARTER REGULATOR (+) (-) 200A 219 200 SR (+) (-) ROTOR FIELD (+) (-) (+) (-) C1 800 MFD CV- CV+ DC+ DC- AC 212 (CAVITY #1) 208 (CAVITY #3) +- + - D2 (-) (+) CR1 209 AC AC LOCATING 31 32 42 9 7 PC BOARD PCB1 1 6 12 1 J[...]

-29 - 236 ELECTRODE WORK 241 GND (+) D1 (-) R1 C2 25W 100 C3 C4 C5 224E AMMETER 209 AM 1 AUTO HIGH 3 5 6 212 CAPACITOR AC AC B+ 208 STARTER REGULATOR (+) (-) CV- CV+ DC+ DC- AC 212 (CAVITY #1) 208 (CAVITY #3) +- + - CR1 209 LOCATING 31 32 42 9 7 PC BOARD PCB1 1 6 12 1 J1 J2 4 5 8 CURRENT SENSOR 75A AMPHENOL 2 1 4 5 8 1 1 3 4 6 2 3 4 J3 J4 J5 31B 42[...]

-30 - 236 ELECTRODE WORK 241 GND (+) D1 (-) R1 C2 25W 100 C3 C4 C5 224E AMMETER 209A AM 1 AUTO HIGH 3 5 6 221 AC AC B+ 208 STARTER REGULATOR (+) (-) CV- CV+ DC+ DC- AC 221 (CAVITY #1) 211 (CAVITY #3) +- CR1 209A LOCATING 31 32 42 9 7 PC BOARD PCB1 1 6 12 1 J1 J2 4 5 8 CURRENT SENSOR 75A AMPHENOL 2 1 4 5 8 1 1 3 4 6 2 3 4 J3 J4 J5 31B 42 32 21 5E PC[...]

– 31 – 12-16-93 M17090 ELECTRODE CABLE LN-25 WIRE FEEDER REMOTE CONTROL TO WORK ELECTRODE N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. TO WORK WORK CLIP LEAD WARNING Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. Keep guards in place. K[...]

– 32 – 12-16-93 M17092 ELECTRODE CABLE OPTIONAL K857 REMOTE CONTROL TO WORK ELECTRODE 6 PIN AMPHENOL 14 PIN AMPHENOL TO WORK TO WIRE FEED UNIT TO LN-7 INPUT CABLE PLUG CAUTION : ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET [...]

– 33 – 12-16-93 M17094 N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. SPARE 82 81 42 41 31 32 2 4 21 GND 75 76 77 31 32 2 4 21 GND N.C. K867 UNIVERSAL ADAPTER PLUG N.D. N.D. SPLICE LEADS AND INSULATE. TO WORK ELECTRODE TO WORK CAUTION : A B C 14 PIN AMPHENOL K196 INPUT CA[...]

12-16-93 M17214 ELECTRODE CABLE TO WORK ELECTRODE 14 PIN AMPHENOL TO WORK TO WIRE FEED UNIT CAUTION : ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WEL[...]

CRM23615 M17902 TO WORK ELECTRODE TO WORK CAUTION : ELECTRODE CABLE TO CONTROL MODULE WARNING Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. N.A. WEL[...]

– 36 – DIMENSION PRINT - Ranger 9 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 30.00 8.80 UNDERCARRIAGE MOUNTING HOLES 17.00 9.09 L 2.75 OF SHAFT 42.00 30.00 C 9.31 9.29 9.09 26.59 REQUIRED WITH KOHLER ENGINE) FOR OIL FILTER REMOVAL (NOT 12.75~.25 20.51 20.63 ~.25 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 30.28[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

– 39 – W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to re[...]

• Sales and Ser vice through Subsidiaries and Distributors W orldwide • Cle v eland, Ohio 44117-1199 U .S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectr ic.com • W orld's Leader in Welding and Cutting Products •[...]