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Lincoln Electric RANGER 10,000, Operator'S Manual

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Lincoln Electric RANGER 10,000 Operator'S Manual Download Page 34

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KOHLER , HONDA AND ROBIN / SUBARUKOHLER

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SUBARU

Summary of Contents for RANGER 10,000

Page 1: ...ation 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 act and be careful R Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING 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 availa...

Page 3: ...ter 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 FUMES AND GASES can be dangerous 5 a Welding may produ...

Page 4: ...event 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 adjacent 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 Weldin...

Page 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile 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 l on pique le laitier 6...

Page 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Page 7: ... in Shutdown Instructions B 3 Starting the Engine B 3 Safety Precautions B 3 Stopping the Engine B 3 Break In Period B 3 Welding Process B 4 Stick Constant Current Welding B 4 TIG Constant Current Welding B 4 Wire Feed Welding Processes Constant Voltage B 4 Arc Gouging B 4 Summary of Welding Processes B 5 ________________________________________________________________________________ Accessories ...

Page 8: ...a GX620KI K2468 1 ROBIN SUBARU 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...

Page 9: ...f 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 regulations the K894 1 spark arrester must be installed and pro...

Page 10: ... 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 specific requirements for use on public highways A 3 INSTALLATION RANGER 10 000 A 3 PRE OPERATION SERVICE READ the engine operating and maintenance instructions supplied with this mac...

Page 11: ...ly operated at altitudes above 5000 ft 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 which is decreased at higher altitudes Engine horsepower is reduced by 3 5 per 1000 feet for altitudes above 377 feet Do not operate a RANGER 10 000 with a high alti tude jet insta...

Page 12: ... the TO WORK termi nal of the welder c Position the welder Polarity switch to the desired polarity either DC or DC RANGER 10 000 Constant Current 225 Amps AC 25 Volts 210 Amps DC 25 Volts Constant Voltage 200 Amps DC 20 Volts d Position the RANGE switch to the WIRE FEED 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 ...

Page 13: ... 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 fo...

Page 14: ...ITHOUT 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 s...

Page 15: ... 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 Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 120 240V plug is available in the opt...

Page 16: ...P 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 A 9 INSTALLATION RANGER 10 000 A 9 Connection of RANGER 10 000 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and a...

Page 17: ...acles 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 B 1 OPERATION RANGER 10 000 B 1 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 detai...

Page 18: ... Hour 1 3 Gallons Hour 4 9 Liters Hour 1 2 Gallons Hour 4 5 Liters Hour 1 4 Gallons Hour 5 3 Liters Hour ROBIN SUBARU 20 5 H P EH64 6 Gallons Hour 2 3 Liters Hour 8 Gallons Hour 3 0 Liters Hour 1 5 Gallons Hour 5 8 Liters Hour 1 6 Gallons Hour 6 1 Liters Hour 1 2 Gallons Hour 4 5 Liters Hour 1 6 Gallons Hour 6 1 Liters Hour HONDA 20 H P GX620KI 3 Gallons Hour 1 3 Liters Hour 7 Gallons Hour 2 8 Lit...

Page 19: ...auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the Ranger 10 000 because the fuel tank is mounted below the engine BREAK IN PERIOD It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil l...

Page 20: ...er welding is ceased will be increased if the AFTER FLOW CONTROL is set above 10 seconds NOTE For AC TIG Welding the maximum TIG welding output currents on each range setting will be approxi mately 50 higher than those marked on the nameplate This is due to the special nature of the AC TIG welding arc Do not AC TIG weld on the 225AC range setting The output current may exceed the rating of the Ran...

Page 21: ...ss gun trigger LN 25 INTERNAL CONTACTOR contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 TIG TIG MODULE WITH Yes High Cold Press Arc Start Switch WITH CONTACTOR KIT contactor closes CONTROL CABLE ARC welding starts immediately START SWITCH WIRE FEED LN 15 No High Cold Press gun trigger ACROSS the ARC LN 15 contactor closes has interna...

Page 22: ...ch is flame retardant mildew resis tant and water repellent K802 R Power Plug Kit provides four 120V plugs rated at 15 amps each and one dual voltage Full KVA plug rated at 120 240V 50 amps K802 N Power Plug Kit Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps K894 1 Spark Arrester Kit Includes a heavy gauge steel approved spark arrester a...

Page 23: ...sed Includes gas solenoid K1870 1 LN 15 Across the Arc Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding K126 2 Magnum 350 Innershield Gun for LN 25 LN 15 K1802 1 Magnum 300 MIG Gun for LN 25 includes Connector Kit K470 2 Magnum 300 MIG Gun for LN 15 requires K466 10 Magnum Gun Connector Kit K1500 1 Gun Receiver Bushing fo...

Page 24: ... life will be reduced if the oil and oil filter are not changed according to the manufacturer s recommendation ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine Push in and twist the drain valve counterclockw...

Page 25: ...socket tool to tighten the filter an additional 1 2 to 7 8 turn 5 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap 6 Start the engine and check for oil filter leaks 7 Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER AND OTHER MAINTENANCE Air Cleaner With normal operating conditions th...

Page 26: ...When reconnecting the cables connect the positive cable first and the negative cable last HARDWARE Both English and Metric fasteners are used in this welder RANGER 10 000 WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECT...

Page 27: ...BLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Author...

Page 28: ... 1 Open in miscellaneous leads 2 Open lead in flashing or field circuit 3 Faulty rotor 4 Faulty Potentiometer R1 5 Faulty stator Field winding 6 Faulty Field rectifier D2 7 Faulty P C Board 1 Idler switch on High Idle 2 Insufficient voltage present between terminals 213 and 5E Voltage should be 12V DC 3 External load on welder or auxiliary power 4 Faulty wiring in solenoid circuit 5 Faulty idler s...

Page 29: ...y power Engine will not crank or is hard to crank Engine shuts down Engine does not develop full power Engine is hard to start 1 No voltage signal from the current sensor 2 Auxiliary power load less than 100 to 150 watts 3 Faulty P C Board 1 Battery will not hold a charge Faulty Battery 2 No or insufficient charging current 3 Loose battery cable connection s 1 Out of fuel 2 Low oil level 1 Fuel fi...

Page 30: ...N UPPER CASEFRONT 209 R R U V W ENGINE FOOT GND D GND C 5F 224A GND H TERMINALS 6 5 5L 120V 240V 5K GND D GND C J4 J3 J2 GND G 5 5L 5K 120V 120V 12 11 11 3A 3A CB1 40A 40A CB2 CB3 20A 20A CB4 3 SILVER COLORED WHITE WIRES RANGER 10 000 KOHLER CSA WIRING DIAGRAM FOR 11041 A CCW ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR N A GROUNDING THIS TERMINAL STOPS THE ENGINE 210 CB7 25A R RED OR PINK B B...

Page 31: ... SHOWN VIEWED FROM REAR 210 CB7 25A 254 3 1 2 3 4 261 260 1 TURN 211 213 208C 6A 6 LEADS 3 AND 6 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 6 6 7 9 J2 S2 E GND I GROUND SCREW ON LOWER CASEFRONT S3 211B D9 225A 211B GY GY 211 B Y B Y B R W W CHARGE COIL 20 AMP MODULE RECTIFIER REGULATOR 6 5 4 2 3 1 209 B MODULE IGNITION 211 W 210 B Y 209A PRESSURE OIL SHUTOFF FUEL SOLENOID 224A SWITCH SOLENOID STAR...

Page 32: ...N SUBARU CCW ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR N A GROUNDING THIS TERMINAL STOPS THE ENGINE 210 CB7 25A R RED OR PINK B BLACK OR GRAY V VIOLET U BLUE W WHITE LEAD COLOR CODE 254 3 1 2 3 4 261 260 1 TURN 211 213 208C 6A 6 LEADS 3 AND 6 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 6 7 9 J2 S2 E GND I P5 J5 GROUND SCREW ON LOWER CASEFRONT S3 3B 6B 213A 213A S3 OPERATION OFF AUTO HIGH STA...

Page 33: ...ace Keep away from moving parts Only qualified personnel should install use or service this or service this equipm equipment M20266 A 02 TO WORK ELECTRODE TO ENGINE WELDER W WORK LN LN 15 OR 25 WIRE F RE FEEDER TO W WORK ELECTRODE CABL CABLE WORK CLIP LEAD N A WELDING C C ABLE E M M UST B BE SIZ SIZED F D FOR R CU CURRENT D DUTY C CYCLE O OF A A PPLICATION N B USE USE PO POLARITY S S WITCH T CH TO...

Page 34: ... A 0 1 26 59 30 27 9 09 9 09 17 00 21 22 8 80 30 00 42 00 22 15 10 33 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK 9 31 CENTERLINE OF SHAFT 9 59 10 19 OIL FILTER REMOVAL KOHLER HONDA AND ROBIN SUBARU KOHLER HONDA AND ROBIN SUBARU ...

Page 35: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 36: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 37: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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