Lincoln Electric IM819-B manual

RANGER ™ 10,000 OPERA TOR’S MANUAL For Machines with Code Number 11041, 11095, 11151, 11253 IM819-B September, 2006 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 IN[...]

FOR ENGINE 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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[...]

FOR ELECTRICALL Y 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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

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 contre la secousse électrique: a. Les[...]

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 and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ..........................[...]

A-1 INST ALLA TION RANGER 10,000 A-1 TECHNICAL SPECIFICA TIONS - Ranger 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1) INPUT - GASOLINE ENGINE RA TED 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) K2160-3 528 lbs. (240kg) K2468-1 RA TED OUTPUT @ 104°[...]

A-2 INST ALLA TION 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 machine is connected to premises wiring (your home, shop, etc.). To prevent dangerous electric shock, other equip- [...]

FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL The Ranger 10,000 is shipped with the engine crankcase filled with SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Make cer- tain that the[...]

A-4 INST ALLA TION RANGER 10,000 A-4 WELDING 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[...]

A-5 INST ALLA TION RANGER 10,000 A-5 LOCA TION / VENTILA TION 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[...]

A-6 INST ALLA TION RANGER 10,000 A-6 120 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 STA[...]

A-7 INST ALLA TION 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 spikes or high voltage appliances with electrical co[...]

A-8 INST ALLA TION 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 as a standby power unit for 240V-3 wire, single phase 38 ampere service. (Connections must be[...]

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 NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 40 AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE P[...]

WELDER CONTROLS - FUNCTION AND OPERA TION ENGINE 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 moto[...]

“ 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. Never change the “ RANGE ” Switch setting while welding. This will damage the switch. ------------------------------------------------------------------------ “ CONTROL ” D[...]

B-3 OPERA TION B-3 ST ARTING/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 ENGINE - Always pull the choke control out [...]

B-4 OPERA TION B-4 WELDING PROCESS For any electrodes the procedures should be kept within the rating of the machine. For electrode infor- mation see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK ” and "ELECTRODE ” studs. Start the engine. Set the "Polarity ” switch[...]

B-5 OPERA TION 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 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 st[...]

C-1 ACCESSORIES C-1 RANGER 10,000 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 Trailer K958-1 Ball Hitch K958-2 Lu[...]

C-2 ACCESSORIES C-2 RANGER 10,000 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 el[...]

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. 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 mainte- nance requiring their removal is complete. Always use the greatest care when working [...]

D-2 MAINTENANCE D-2 Use 4-stroke motor oil that meets or exceeds the requirements 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-tempera- ture use, -5 F to 104 F (-20 C to 40 C). See Engine Owner ’ s Manual f[...]

D-3 MAINTENANCE D-3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum. ---[...]

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 Guide is provided to help you locate and repair po[...]

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 troubleshooting assistance before you proceed. CAUTION PROBLEMS [...]

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 troubleshooting assistance before you proceed. CAUTION PROBLEMS [...]

STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATO R B- HOUR METER 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NU MBERS: 7 6 12 1 2 3 4 J1 N.A. B J2 SOLENOID FUEL SHUTOFF OIL PRESSURE TERMINAL BLOCK (SEE CONN.) 209A 209A 224C 210 B B GENERATOR LEAD END (NOTE CAVITY NUMBERS) LOCATING TAB[...]

F-2 DIAGRAMS F-2 RANGER 10,000 IDLER SOLENOID HOUR METER 5E 5D 224 1 2 3 CONNECTOR PIN NU MBERS: 7 6 12 1 2 3 4 J1 J2 209A M20301 215 + ELECTRIC AL SYMBOL S PER E1537 STATOR REACTOR S1 WO RK ELECTRODE CHOKE D1 S2 ROTOR PCB1 SLIP RING NEAREST LAMINATION W1 W2 C1 S1 R1 R5 C1 L1 - + + R3 STATOR REACTOR + 10 8 1 7 12 6 6 5 3 9 7 200A 219 3 ENGINE CROSS[...]

F-3 DIAGRAMS F-3 RANGER 10,000 CR1 STARTER SOLENOID AC AC B+ REGULATOR FLYWHEEL ALTERNATOR B- 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 J2 209A 209A 224C 210 GENERATOR LEAD END (NOTE CAVITY NUMBERS) LOCATING TAB TERMINAL BLOCK CONNECTION 208 208 (CAVITY #2) 211 (CAVITY #3) 224C (CAVITY #4) 1 3 2 4 211 C M20431 [...]

F-4 DIAGRAMS F-4 RANGER 10,000 RANGER 10,000 RANGER 10,000 / / L L N -15 AND LN-25 ACROSS T AND LN-25 ACROSS T H E ARC CONNECT E ARC CONNECT IO N DI N DI AG RA M ELECTRIC SHOCK can kill Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch elec trical ly live parts. W ARN ING MOVING PARTS can injure Ke[...]

F-5 DIAGRAMS F-5 RANGER 10,000 M2 02 67 A. A. 0 1 26.5 9 30.2 7 9.09 9.09 17.0 0 21.2 2 8.80 30.0 0 42.0 0 22.1 5 10.3 3 CE NTER OF GR AVITY WITH O IL IN ENG INE AN D FULL FU EL T AN K 9.31 CE NTERLI NE OF SH AFT 9.59 10.1 9 OIL FILTER REM OVAL KOHLER , HONDA AND ROBIN / SUBARU KOHLER , HONDA AND ROBIN / SUBARU[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese 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 PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA 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 remove fumes f[...]

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