Im925 11395

User Manual: 11395

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RANGER 10,000 PLUS

AND RANGER 10,000

LINCOLN

ELECTRIC

OPERATOR’S MANUAL

For Machines with Code Number 11394, 11395, 11398

IM925

January, 2007

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 act

and be careful.

• 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 Leader in Welding and Cutting Products •

CUS

This manual covers equipment which is no

longer in production by The Lincoln Electric Co.

Specications and availability of optional

features may have changed.

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.

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from vaporiz-

ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. If

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. 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

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER 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 available

from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

SAFETY

ARC RAYS 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 and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water 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 produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected

by various factors including proper use and positioning of

the equipment, maintenance of the equipment and the spe-

cific welding procedure and application involved. Worker

exposure level should be checked upon installation and

periodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

FOR ELECTRICALLY

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 Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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 Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

6.h. Also see item 1.c.

Mar. ‘93

SAFETY

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 circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés 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. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible

de la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

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 particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims

for material damaged in shipment must be made by the purchaser against the transportation company at the

time the shipment is received.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

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 Lincoln

Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-

sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-

mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,

with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or

correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any

warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control

of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in

applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com

for any updated information.

vi TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Machine Grounding.......................................................................................................A-2

Spark Arrester ...............................................................................................................A-2

Towing, Vehicle Mounting .............................................................................................A-2

Pre-Operation Engine Service..............................................................................................A-3

Fuel, Oil.........................................................................................................................A-3

Battery Connections......................................................................................................A-3

Welding Cable Connections..........................................................................................A-4

Angle of Operation ........................................................................................................A-4

Lifting, Additional Safety Precautions............................................................................A-4

High Altitude Operation .................................................................................................A-4

Muffler Relocation .........................................................................................................A-4

Location and Ventilation................................................................................................A-5

Stacking ........................................................................................................................A-5

Connection of Wire Feeders .........................................................................................A-5

Connection of Tig Module .............................................................................................A-5

Additional Safety Precautions,Welding Operation Output.............................................A-5

Auxiliary Power Receptacles, and Plugs .............................................................................A-6

Motor Starting and Extension Cord Length Table ................................................................A-6

Electrical Device Used with the Ranger 10,000 Plus, and Ranger 10,000 ..........................A-7

Auxiliary Power While Welding, Standby Power Connections ............................................A-8

Premises Wiring ...................................................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Controls Function and Operation .............................................................................B-1

Polarity, Range and Control Switch......................................................................................B-2

Start 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.....................................................................................................Section C

Optional Equipment...............................................................................................C-1

Recommended Equipment....................................................................................C-2

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Engine Maintenance ..........................................................................D-1,D2

Engine Adjustments...............................................................................................D-3

Slip Rings ..............................................................................................................D-3

Battery Maintenance .......................................................................................D-3

Engine Maintenance Parts..............................................................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Wiring Diagrams & Dimension Print..............................................................Section F

Wiring and Connection Diagrams ...........................................................F-1 Thru F-4

Dimension Print......................................................................................................F-5

________________________________________________________________________

Parts List.................................................................................................................P-481

________________________________________________________________________

A-1

INSTALLATION

RANGER 10,000 PLUS AND RANGER 10,000 & RANGER 10,000

A-1

TECHNICAL SPECIFICATIONS - RANGER 10,000 PLUS (K1419-5 ), (K2468-2)

RANGER 10,000 (K2160-4)

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) K1419-5

770 mm 485 mm 1067 mm 528 lbs. (240kg) K2468-2

505 lbs. (229kg) K2160-4

RATED OUTPUT @ 104°F (40°C)- GENERATOR

Welding Output

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

Auxiliary Power 1

RANGER 10,000

9,000 Watts Continuous, 60 Hz AC

10,000 Watts Peak, 60 Hz AC

120/240 Volts

RANGER 10,000 PLUS

9,000 Watts Continuous, 60 Hz AC

10,500 Watts Peak, 60 Hz AC

120/240 Volts

PHYSICAL DIMENSIONS

Make/Model

(K1419-5)

Kohler

CH23S

(K2468-2)

Subaru Robin

EH65

(K2160-4)

Honda

GX620KI

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.)

41(674)

Kohler

39.9 (653)

SUBARU ROBIN

37.5 (614)

Honda

Capacities

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

Fuel:

9 Gal (34 L)

Lubricating Oil

1.6 Qts. (1.6L)

Fuel:

9 Gal (34 L)

Lubricating Oil

1.9 Qts. (1.8L)

Horsepower

23 HP @

3600 RPM

Kohler

22 HP@

3600 RPM

SUBARU ROBIN

20 HP@

3600 RPM

Honda

Starting

System

12VDC

Battery

Electric Start

Group 58

Battery

(435 cold

Cranking

Amps)

1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.

When welding available auxiliary power will be reduced.

A-2

INSTALLATION

RANGER 10,000 PLUS AND 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-

ment to which this engine driven welder supplies

power must:

•be grounded to the frame of the welder using a

grounded type plug, or be double insulated.

Do not ground the machine to a pipe that carries

explosive or combustible material.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, it’s

frame must be electrically bonded to the metal frame

of the vehicle. Use a #8 or larger copper wire connect-

ed between the machine grounding stud and the

frame of the vehicle.

Where this engine driven welder is connected to

premises wiring such as that in your home or shop, it’s

frame must be connected to the system earth ground.

See further connection instructions in the section enti-

tled “Standby Power Connections”, as well as the arti-

cle on grounding in the latest National Electrical Code

and the local code.

In general, if the machine is to be grounded, it should

be connected with a #8 or larger copper wire to a solid

earth ground such as a metal water pipe going into

the ground for at least ten feet and having no insulat-

ed joints, or to the metal framework of a building

which has been effectively grounded. The National

Electrical Code lists a number of alternate means of

grounding electrical equipment. A machine grounding

stud marked with the symbol is provided on the

front of 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 properly maintained.

An incorrect arrester may lead to damage to the

engine or adversely affect performance.

------------------------------------------------------------------------

TOWING

The recommended trailer for use with this equipment

for road, in-plant and yard towing by a vehicle(1) is

Lincoln’s K957-1. If the user adapts a non-Lincoln

trailer, he must assume responsibility that the method

of attachment and usage does not result in a safety

hazard nor damage the welding equipment. Some of

the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln

equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue

stress to the framework.

CAUTION

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, detailed engine

starting, operating and maintenance instructions,

and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

WARNING

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.

Observe fuel gauge while filling to prevent overfilling.

OIL

The RANGER 10,000 PLUS AND 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 certain that the oil filler cap

is tightened securely. Refer to the engine Owner’s

Manual for specific oil recommendations.

BATTERY CONNECTIONS

Use caution as the electrolyte is a strong

acid that can burn skin and damage eyes.

-----------------------------------------------------------------------

This welder is shipped with the negative battery cable

disconnected. Make sure that the Engine Switch is in

the “STOP” position and attach the disconnected

cable securely to the negative battery terminal before

attempting to operate the machine. If the battery is

discharged and does not have enough power to start

the engine, see the battery charging instructions in the

Battery section.

NOTE: This machine is furnished with a wet charged

battery; if unused for several months, the battery may

require a booster charge. Be careful to charge the bat-

tery with the correct polarity.

3. Proper placement of the equipment on the trailer to

insure stability side to side and front to back when

being moved and when standing by itself while

being operated or serviced.

4. Typical conditions of 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 PLUS AND RANGER 10,000

A-3

PRE-OPERATION SERVICE

READ the engine operating and maintenance

instructions supplied with this machine.

CAUTION

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Kohler CH23S - 2.0 Quarts (1.9 Liters)

Subaru Robin

EH65-1.6 Quarts (1.6 Liters)

Honda GX620KI-1.9 Quarts (1.8 Liters)

• Damage to the fuel tank may cause

fire or explosion. Do not drill holes

in the RANGER 10,000 PLUS AND

RANGER 10,000 base or weld to the

RANGER 10,000 PLUS AND

RANGER 10,000 base.

-----------------------------------------------------------------------

WARNING

CAUTION

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away

from tank.

• Do not leave unattended while

fueling.

• Wipe up spilled fuel and allow

fumes to clear before starting

engine.

• Do not overfill tank, fuel expan-

sion may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

WARNING

GASOLINE

can cause fire

or explosion.

VEHICLE MOUNTING

Improperly mounted concentrated loads may

cause unstable vehicle handling and tires or other

components to fail.

• Only transport this Equipment on serviceable

vehicles which are rated and designed for such

loads.

• Distribute, balance and secure loads so vehicle

is stable under conditions of use.

• Do not exceed maximum rated loads for compo-

nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of

vehicle.

• Follow vehicle manufacture’s instructions.

------------------------------------------------------------------------

WARNING

A-4

INSTALLATION

RANGER 10,000 PLUS AND 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 necessary. Loose con-

nections will result in overheating of the output studs.

When welding at a considerable distance from the welder,

be sure you use ample size welding cables. Listed below

are copper cable sizes recommended for the rated current

and duty cycle. Lengths stipulated are the distance from the

welder to work and back to the welder again. Cable sizes

are increased for greater lengths primarily for the purpose of

minimizing cable voltage drop.

ANGLE OF OPERATION

Internal combustion engines are designed to run in a level

condition which is where the optimum performance is

achieved. The maximum angle of operation for the engine is

15 degrees from horizontal in any direction. If the engine is

to be operated at an angle, provisions must be made for

checking and maintaining the oil at the normal (FULL) oil

capacity in the crankcase in a level condition.

When operating at an angle, the effective fuel capacity will

be slightly less than the specified 9 gallons.

LIFTING

The RANGER 10,000 PLUS AND RANGER 10,000 AND

RANGER 10,000 weighs approximately 575 lbs. with a full

tank of gasoline. A lift bail is mounted to the machine and

should always be used when lifting the machine.

HIGH ALTITUDE OPERATION

At higher altitudes, Welder output de-rating may be neces-

sary.

Kohler and Subaru Robin Models:

For maximum rating, de-rate the welder output 3.5% for

every 1000ft. (305m) above 3000ft. (914m).

Honda Model:

For maximum rating, de-rate the welder output 3.5% for

every 1000ft. (305m) above sea level.

If operation will consistently be at altitudes above 5,000 ft.

(1525m), 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. Contact your local authorized engine service shop

for high altitude jet kits that are available from the engine

manufacturer.

Do not operate with a high altitude jet installed at alti-

tudes below 5000 ft. This will result in the engine run-

ning too lean and result in higher engine operating tem-

peratures which can shorten engine life.

--------------------------------------------------------------------------------

Muffler Relocation

•Shut off welder and allow muffler to cool before touch-

ing muffler.

--------------------------------------------------------------------------------

The RANGER 10,000 PLUS AND RANGER 10,000 is

shipped with the exhaust coming out on the left side. The

exhaust can be changed to the opposite side by removing

the two screws that hold the exhaust port cover in place and

installing the cover on the opposite side. (Operating the

RANGER 10,000 PLUS AND RANGER 10,000 without the

cover in place will result in a higher noise level and no

increase in machine output.)

CAUTION

WARNING

• Lift only with equipment of ade-

quate lifting capacity.

• Be sure machine is stable when

lifting.

• Do not lift this machine using lift

bale if it is equipped with a

heavy accessory such as trailer

or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

WARNING

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

0-100 Ft. (0-30.5m)

100-200 Ft. (30.5-61.0m)

200-250 Ft. (61.0-76.2m)

225 Amps

100% Duty Cycle

1 AWG

1/0 AWG

A-5

INSTALLATION

RANGER 10,000 PLUS AND RANGER 10,000

A-5

LOCATION / VENTILATION

The welder should be located to provide an unrestricted

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 out-

side area.

STACKING

RANGER 10,000 PLUS AND RANGER 10,000 machines

cannot be stacked.

CONNECTION OF LINCOLN ELECTRIC

WIRE FEEDERS

Shut off welder before making any electrical connec-

tions.

----------------------------------------------------------------------------

WIRE FEED (CONSTANT VOLTAGE)

CONNECTION OF LN-15 ACROSS-THE-ARC WIRE

FEEDER

The LN-15 has an internal contactor and the electrode is

not energized until the gun trigger is closed. When the

gun trigger is closed the wire will begin to feed and the

welding process is started.

a. Shut the welder off.

b. Connect the electrode cable from the LN-15 to

the“ELECTRODE” terminal of the welder. Connect the

work cable to the “TO WORK” terminal of the welder.

c. Set the Polarity switch to the desired polarity, either

DC (-) or DC (+).

d. Attach the single lead from the front of the LN-15 to

work using the spring clip at the end of the lead.

This is a control lead to supply current to the wire

feeder motor; it does not carry welding current.

e. Set the “RANGE” switch to the “WIRE FEED-CV”

position

f. Place the Engine switch in the “Auto Idle” position.

g. Adjust the wire feed speed at the LN-15 and adjust

the welding voltage with the output “CONTROL” at

the welder. Output “CONTROL” must be set above 3.

Note: LN-15 Control Cable model will not work with

the RANGER 10,000 PLUS AND RANGER 10,000.

CONNECTION OF THE LN-25 TO THE RANGER 10,000

a. Shut the welder off.

b. Connect the electrode cable from the LN-25 to

the“ELECTRODE” terminal of the welder. Connect

the work cable to the “TO WORK” terminal of the

welder.

c. Position the welder “Polarity” switch to the desired

polarity, either DC (-) or DC (+).

RANGER 10,000 PLUS AND 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 no welding current.

f. Place the engine switch in the “AUTO” position.

g. Adjust wire feed speed at the LN-25 and adjust the

welding voltage with the output “CONTROL” at the

welder.

NOTE: The welding electrode is energized at all times,

unless an LN-25 with built-in contactor is used. If the

output “CONTROL” is set below “3”, the LN-25 contactor

may not pull in.

CONNECTION OF K930-2 TIG MODULE TO THE

RANGER 10,000.

The TIG Module is an accessory that provides high fre-

quency and shielding gas control for AC and DC GTAW

(TIG) welding. See IM528 supplied with the

TIG Module for installation instructions.

Note: The TIG Module does not require the use of a high

frequency bypass capacitor. However, if the RANGER

10,000 PLUS or RANGER 10,000 is used with any other

high frequency equipment, the bypass capacitor must be

installed, order kit T12246.

INSTRUCTIONS

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case sides

in place as this provides maximum protection from mov-

ing parts and assures proper cooling air flow.

Read and understand all Safety Precautions before oper-

ating this machine. Always follow these and any other

safety procedures included in this manual and in the

Engine Owner’s Manual.

WELDER OPERATION

WELDER OUTPUT

• Maximum Open Circuit Voltage at 3700 RPM is

80 Volts RMS.

• Duty Cycle is the percentage of time the load is

being applied in a 10 minute period. For example, a

60% duty cycle represents 6 minutes of load and 4

minutes of no load in a 10 minute period. Duty Cycle

for the RANGER 10,000 PLUS AND RANGER

10,000

is 100%.

WARNING

A-6

INSTALLATION

RANGER 10,000 PLUS AND 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 STARTING

Most 1.5 hp AC single phase motors can be started if

there is no load on the motor or other load connected to

the machine, since the full load current rating of a 1.5 hp

motor is approximately 20 amperes (10 amperes for 240

volt motors). The motor may be run at full load when

plugged into only one side of the duplex receptacle.

Larger motors through 2 hp can be run provided the

receptacle rating as previously stated is not exceeded.

This may necessitate 240V operation only.

GND

120 V

120 V*

240 V

*Current Sensing for Automatic Idle.

(Receptacle viewed from front of Machine)

RANGER 10,000 PLUS AND RANGER 10,000 Extension Cord Length

Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Current

(Amps)

Voltage

Volts

120

240

Load

(Watts)

1800

2400

3600

4800

9000

(9)

(18)

(12)

(9)

(23)

(18)

150

100

(23)

(15)

(46)

(30)

(15)

125

225

175

(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 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;

one 50 amp 120/240 volt NEMA 14-50R receptacle

and two 20 amp 120 volt NEMA 5-20R receptacles.

Output voltage is within +/-10% at all loads up to rated

capacity. All auxiliary power is protected by cuircuit

breakers.

Do not connect any plugs that connect to the

power receptacles in parallel.

------------------------------------------------------------------------

Start the engine and set the “IDLER” control switch to

the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptacles for auxil-

iary power.

120/240 VOLT DUAL VOLTAGE RECEPTACLE

The 120/240 volt receptacle can supply up to 38 amps

of 240 volt power to a two wire circuit, up to 38 amps

of 120 volts power from each side of a three wire cir-

cuit (up to 76 amps total). Do not connect the 120 volt

circuits in parallel. Current sensing for the automatic

idle feature is only in one leg of the three wire circuit

as shown in the following column.

CAUTION

A-7

INSTALLATION

RANGER 10,000 PLUS AND RANGER 10,000

A-7

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-

mended for 100% fail-safe

operation. DO NOT RUN

THESE DEVICES WITHOUT

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 sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required,

and liabilities still exist. DO

NOT USE THESE DEVICES

WITH A RANGER 10,000 PLUS

& RANGER 10,000

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-

ed to the RANGER 10,000 PLUS AND RANGER 10,000.

A-8

INSTALLATION

RANGER 10,000 PLUS AND RANGER 10,000

A-8

STANDBY POWER CONNECTIONS

The RANGER 10,000 PLUS AND RANGER 10,000

are suitable for temporary, standby, or emergency

power using the engine manufacturer’s recommended

maintenance schedule.

The RANGER 10,000 PLUS AND RANGER 10,000

can be permanently installed as a standby power unit

for 240V-3 wire, single phase 38 ampere service.

(Connections must be made by a licensed electri-

cian who can determine how the 120/240V power

can be adapted to the particular installation and

comply with all applicable electrical codes.) The

following information can be used as a guide by

the electrician for most applications (refer also to

the connection diagram shown in Figure 1.)

-------------------------------------------------------------------------

1. Install a double pole, double throw switch between

the power company meter and the premises dis-

connect.

Switch rating must be the same or greater than the

customer’s premises disconnect and service over-

current protection.

2. Take necessary steps to assure load is limited to

the capacity of the RANGER 10,000 PLUS AND

RANGER 10,000 by installing a 38 amp 240V dou-

ble pole circuit breaker. Maximum rated load for the

240V auxiliary is 38 amperes. Loading above 38

amperes will reduce output voltage below the allow-

able -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 optional plug

kit.)

4. Plug this cable into the 50 amp 120/240V recepta-

cle on the RANGER 10,000 PLUS OR RANGER

10,000 case front.

WARNING

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted

by following Table I. The permissible currents shown

assume that current is being drawn from either the

120V or 240V supply (not both at the same time).

Also, the “Output Control” is set at “10” for maximum

auxiliary power.

TABLE I

SIMULTANEOUS WELDING AND POWER

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Factor) @ 120V *-or- @ 240V

Max. Stick or Wire

Feed Setting None 0 0

145 Stick Setting 3450 32 16

90 Stick Setting 6000 50** 25

NO WELDING 9000 76** 38

*Each duplex receptacle is limited to 20 amps.

**Not to exceed 40A per 120VAC branch circuit when

splitting the 240 VAC output.

240 Volt

60 Hz.

3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL

BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

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 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 PLUS AND RANGER 10,000

A-9

Connection of RANGER 10,000 PLUS OR RANGER

10,000 to premises wiring must be done by a

licensed electrician and must comply with the

National Electrical Code and all other applicable

electrical codes.

Figure 1

CONNECTION OF RANGER 10,000 PLUS OR RANGER 10,000 TO PREMISES WIRING

WARNING

WELDER CONTROLS - FUNCTION AND

OPERATION

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 motor is energized.

When in “HIGH IDLE” ( ) position, the engine will

run continuously at high idle.

When in “AUTO IDLE” ( / ) position, the

engine will run continuously and the idler operates as

follows:

•Welding

When the electrode touches the work, the welding

arc is initiated and the engine accelerates to full

speed.

After welding ceases (and no auxiliary power is

being drawn), the engine will return to low idle

after approximately 10 to 14 seconds.

•Auxiliary Power

With the engine running at low idle and auxiliary

power for lights or tools is drawn (approximately

100-150 watts or greater) from the receptacles,

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 PLUS AND 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, detailed engine

starting, operating and maintenance instructions,

and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door

closed and the side panels in place.

• Read carefully the Safety Precautions page

before operating this machine. Always follow

these and any other safety procedures included

in this manual and in the Engine Instruction

Manual.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The RANGER 10,000 PLUS AND RANGER 10,000

are twin-cylinder, gasoline driven, multiprocess arc

welders and AC power generators. They are built in

heavy gauge steel cases for durability on the job site.

“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” DIAL

Provides a fine welding current adjustment within the

Range Switch settings in the STICK mode and weld-

ing voltage control with the Range switch set in the

wire feed mode.

Process Range Setting Current Range

POLARITY SWITCH

Provides three selectable welding polarities:

AC, DC+ & DC-

Never change the Polarity switch setting while

welding. This will damage the switch.

------------------------------------------------------------------------

B-2

OPERATION

B-2

RANGER 10,000 PLUS AND RANGER 10,000

CAUTION

KOHLER

23 H.P. CH23S

.4 Gallons/Hour

(1.5 Liters/Hour)

.7 Gallons/Hour

(2.8 Liters/Hour)

1.2 Gallons/Hour

(4.6 Liters/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)

SUBARU ROBIN

22.5 H.P. EH65

.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 Liters/Hour)

1.3 Gallons/Hour

(5 Liters/Hour)

1.5 Gallons/Hour

(5.9 Liters/Hour)

1.2 Gallons/Hour

(4.5 Liters/Hour)

1.7 Gallons/Hour)

(6.5 Liters/Hour)

Low Idle - No Load

2200 RPM

High Idle - No Load

3700 RPM

AC CC Weld Output

225 Amps @ 25 Volts

DC CC Weld Output

210 Amps @ 25 Volts

DC CV Weld Output

200 Amps @ 20 Volts

Auxiliary Power

9000 Watts

RANGER 10,000 PLUS AND RANGER 10,000 APPROXIMATE FUEL CONSUMPTION

STICK/TIG

(constant current)

(3 range settings)

WIRE FEED

(constant voltage)

(one range setting)

90 Max.

145 Max.

210DC/225AC Max.

15 to 25V

40 to 90 Amps

70 to 145 Amps

120 to 210 (DC) 225(AC)

Up to 200 Amps

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 ENGINE -Always pull the choke control out

when starting the engine; cold, warm or hot.

SUBARU ROBIN - If the engine is cold or the temper-

ature is low pull the choke out fully. If the engine is

warm or temperature is high, pull choke half out or

leave in completely.

HONDA ENGINE - If the engine is cold, pull the choke

control out. Do Not use the choke if the engine is

warm or hot.

Turn the engine switch to the “start”position and

crank the engine until it starts. Release the switch as

soon as the engine starts, slowly return the choke

control to the full “in” position (choke open),

and turn the switch to the Auto Idle( / )

position. Do not turn the switch to the “start” position

while the engine is running because this will cause

damage to the ring gear and/or starter motor

After running at high engine speed for 10-14 seconds,

the engine will go to low idle.

Allow the engine to warm up by letting it run at low idle

for a few minutes.

STOPPING THE ENGINE

Remove all welding and 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 PLUS AND 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

level twice a day during the break-in period (approxi-

mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS

BREAK-IN, THE UNIT SHOULD BE

SUBJECTED TO MODERATE

LOADS, WITHIN THE RATING OF

THE MACHINE. AVOID LONG IDLE

RUNNING PERIODS. REMOVE

LOADS AND ALLOW ENGINE TO

COOL BEFORE SHUTDOWN.

The engine manufacturer’s recommendation for the

running time until the first oil change is as follows:

The oil filter is to be changed at the second oil

change. Refer to the Engine Owner’s Manual for more

information.

RANGER 10,000 PLUS AND RANGER 10,000

• Do not touch electrically live parts

of electrode with skin or wet

clothing.

• Keep flammable material away.

• Insulate yourself from work and

ground. Wear eye, ear, and body

protection.

• Keep your head out of the fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

WARNING

HONDA

GX620KI

25 HRS.

or 20 HRS.

KOHLER SUBARU ROBIN

CH23S EH65

5 HRS. 25 HRS.

B-4

OPERATION

B-4

WELDING PROCESS

For any electrodes the procedures should be kept within

the rating of the machine. For electrode information see

the appropriate Lincoln publication.

STICK (CONSTANT CURRENT) WELDING

Connect welding cables to the "TO WORK” and "ELEC-

TRODE” studs. Start the engine. Set the "Polarity” switch

to the desired polarity. The “RANGE” switch markings

indicate the maximum current for that range as well as

the typical electrode size for that range. The “OUTPUT”

Control provides fine adjustment of the welding current

within the select range. For maximum output within a

selected range set the “OUTPUT” Control at 10. For min-

imum output within a selected range set the “OUTPUT”

Control at 5. (“OUTPUT” Control settings below 5 may

reduce arc stability) For best overall welding perfor-

mance set the “RANGE” Switch to the lowest setting and

the OUTPUT” Control near the maximum to achieve the

desired welding current.

RANGE SETTING TYPICAL CURRENT RANGE

ELECTRODE SIZE

The RANGER 10,000 PLUS AND RANGER 10,000 can

be used with a broad range of AC and DC stick elec-

trodes. See “Welding Tips 1” included with the RANGER

10,000 PLUS AND RANGER 10,000 for electrodes with-

in the rating of this unit and recommended welding cur-

rents of each.

TIG (CONSTANT CURRENT) WELDING

The K930-[ ] TIG Module installed on a RANGER 10,000

PLUS AND RANGER 10,000 provides high frequency

and shielding gas control for AC and DC GTAW (TIG)

welding processes. Output control is from the Ranger

10,000 Plus & Ranger 10,000. The output control on the

TIG Module is not functional. After flow time is adjustable

from 0 to 55 seconds.

When using the RANGER 10,000 PLUS AND RANGER

10,000 for AC TIG welding of aluminum, the following

settings and electrodes are recommended:

The K930-[ ] TIG Module should be used with the RANGER

10,000 PLUS AND RANGER 10,000 on high idle to maintain

satisfactory operation. It can be used in the AUTO position

but the delay going to low idle after 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 approximately 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 Ranger 10,000 PLUS & RANGER 10,000.

WIRE FEED WELDING PROCESSES

(CONSTANT VOLTAGE)

The Innershield®electrode recommended for use with the

RANGER 10,000 PLUS AND RANGER 10,000 is NR®-211-

MP. The electrode sizes and welding ranges that can be used

with the RANGER 10,000 PLUS AND RANGER 10,000 are

shown in the following table:

The RANGER 10,000 PLUS AND RANGER 10,000 is recom-

mended for limited “MIG” welding (GMAW - gas metal arc

welding). The recommended electrodes are .030” and .035” L-

50 and L-56. They must be used with a blended shielding gas

such as C25 (75% Argon - 25% CO2). The welding ranges

that can be used with the RANGER 10,000 PLUS AND

RANGER 10,000 are shown in the following table:

ARC GOUGING

The RANGER 10,000 PLUS AND RANGER 10,000 can be

used for limited arc gouging.

Set the Range switch to adjust output current to the desired

level for the gouging electrode being used according to the rat-

ings in the following table:

RANGER 10,000 PLUS AND RANGER 10,000

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.035 80 - 110 75A to 120A

.045 70 - 130 120A to 170A

.068 40 - 90 125A to 210A

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.030 75 - 300 50A to 130A

.035 100 - 250 90A to 175A

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE

DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90 or 145 80 - 150 Amps

3/32 90 or 145 45 - 130 Amps

1/16 90 40 - 80 Amps

SETTINGS FOR 1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE

DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90, 145, or 210 80 - 225 Amps

3/32 90 or 145 50 - 180 Amps

1/16 90 or 145 45 - 120 Amps

ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)

1/8 30 - 60 Amps

5/32 90 - 150 Amps

3/16 150 - 250 Amps

90 MAX.

145 MAX.

210(DC)/225(AC)

MAX.

3/32

1/8

5/32

40 TO 90 AMPS

70 TO 145 AMPS

120 TO 210(DC),

225(AC) AMPS

B-5

OPERATION

B-5

RANGER 10,000 PLUS AND 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

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 Auto Cold Press gun trigger.

ACROSS the ARC LN-15 contactor closes,

(has internal contactor) Welding starts immediately

Note: Output Control must

be set above “3”.

C-1

ACCESSORIES

C-1

RANGER 10,000 PLUS AND 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 Lunette Eye Hitch

K959-2 Fender & Light Kit

K965-1 Cable Storage Rack

K889-2 & -3 Two-Wheel Undercarriage - For moving

by hand. Overall Width 29 in (.74m) Both have pneu-

matic tires. Puncture proof tires included with K889-3.

K1737-1 FOUR WHEEL ALL-TERRAIN UNDER-

CARRIAGE - For moving by hand at construction

sites. Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY) - For mov-

ing by hand on a smooth surface. Heavy duty punc-

ture resistant pneumatic tires and front caster.

K1745-1 WELDING GAS CYLINDER LPG TANK

HOLDER

Holds Welding Gas Cylinder for use on K1770-1

Undercarriage. One or two may be installed on an

undercarriage.

K1788-1 ROLL CAGE - Gives added damage protec-

tion.

Attaches to K1737-1, K1770-1, and K957-1.

K886-1 Canvas Cover -To protect the RANGER

10,000 PLUS AND RANGER 10,000 when not in use.

Made from attractive red canvas material which is

flame retardant, mildew resistant, and water repellent.

K802R 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.

K802N 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 and clamp for easy

mounting to muffler exhaust pipe.

K1690-1 GFCI RECEPTACLE KIT -Includes one UL

approved120V ground fault circuit interrupter duplex type

receptacle with cover and installation instructions.

Replaces the factory installed 120V duplex receptacle.

Each receptacle of the GFCI Duplex is rated at 20 Amps,

the maximum total current from the GFCI Duplex is limit-

ed to the 20 Amps. Two kits are required.

K1816-1 FULL KVA ADAPTER KIT - Plugs into the

120/240V NEMA 14-50R receptacle on the case front

(which accepts 4-prong plugs) and converts it to a

NEMA 6-50R receptacle, (which accepts 3-prong

plugs.)

T12153-9 Full-KVA Power Plug - One dual voltage

plug rated at 120/240V, 50 amps.

K930-2 TIG Module - Provides high frequency and

shielding gas control.for AC and DC GTAW (TIG)

welding applications. Its compact case is designed foe

easy carrying, complete with a handle. High frequency

bypass is built in requires K938-1 Contactor Kit, K936-

4 Control Cable, and K814 Arc Start Switch.

K938-1 Contactor Kit - For use with TIG Module,

Provides a “cold” electrode until the triggering device

(Arc Start Switch) is pressed.

K936-4 Control Cable - Connects TIG Module to

Ranger 10,000.

K814 Arc Start Switch - Attaches to the TIG torch for

convenient finger control.

K937-45 Control Cable Extension - Allows TIG

Module to be operated at distances up to 200ft. from

the power source. Available in 45ft. (13.7m).

K939-1 Docking Kit - For Mounting the K930-2 TIG

Module on top of the Ranger 10,000.

C-2

ACCESSORIES

C-2

RANGER 10,000 PLUS AND RANGER 10,000

RECOMMENDED EQUIPMENT

STICK

K704 ACCESSORY SET - Includes 35 ft. (10m) of

electrode cable and 30 ft. (9.1m) of work cable, head-

shield, work clamp electrode holder. Cables are rated

at 400 amps, 100% duty cycle.

K875 Accessory Kit - For stick welding. Includes 20 Ft. (6.1m).

#6 electrode cable with lug, 15 Ft. (4.6m) #6 work cable with

lugs, headshield, filter plate, work clamp, and electrode holder

and sample pack of mild steel electrode. 150 amp capacity.

WIRE FEED

K449 LN-25 - Includes internal contactor for across

the arc operation (no control cable). Provides “cold”

electrode until gun trigger is pressed. 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 (for LN-15, K126-2)

Note: See Wire Feeder IM Manual for appropriate

Drive Roll & Guide Tube Kits.

TIG WELDING

K1783-9- PTA-26V TIG Torch.

KP509- Magnum Parts Kit and Argon gas.

K930-2- TIG Module.

Required TIG Equipment:

K938-1 Connector Kit

K936-4 Control Cable

K814 Arc Start Switch

Optional TIG Equipment:

K939-1 Docking Kit

K937-45 Control Cable Extension

PLASMA CUTTING:

K1580-1 Pro-Cut 55

Cuts mild steel using the 3-phase AC generator power

from the engine driven welder. Accepts 3-phase or 1-

phase input power. Requires the K1816-1 Full KVA

adapter kit, if connected for 1-phase input power.

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 near

moving parts.

Do not put your hands near the engine cooling

blower fan. If a problem cannot be corrected by

following the instructions, take the machine to

the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts

or electrode with skin or wet

clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas

or vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information

throughout this operator’s manual and

the Engine manual as well.

------------------------------------------------------------

Make certain that the oil filler cap is securely tight-

ened after checking or adding oil. If the cap is not

tight, oil consumption can increase significantly

which may be evidenced by white smoke coming

from the exhaust.

• OIL - Maintenance schedule for changing the oil and

oil filter after break-in :

The above schedule is for normal operating condi-

tions. More frequent oil changes are required with

dusty, high temperature and other severe operating

conditions. Refer to the maintenance section of the

Engine Owner's Manual for more information.

NOTE:Engine 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 counterclockwise. Pull

the valve out and drain the oil into a suitable contain-

er.

• Close the drain valve by pushing in and twisting

clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the

recommended oil. Tighten the oil filler cap securely.

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

• 1.7 qt. (1.6 liter)-Kohler

• 1.5 qt. (1.4 liter)-Subaru Robin

• 1.6 qt. (1.5 liter)-Honda GX620KI

With oil filter replacement:

• 2.0 qt. (1.9 liter)-Kohler

• 1.6 qt. (1.6 liter)-Subaru Robin

• 1.9 qt. (1.8 liter)-Honda GX620KI

WARNING

D-1

MAINTENANCE

D-1

RANGER 10,000 PLUS AND RANGER 10,000

SAFETY PRECAUTIONS CAUTION

Read the Safety Precautions in the front of this manual

and the engine instruction manual before working on

this machine.

Keep all equipment safety guards, covers, and devices

in position and in good repair. Keep hands, hair, cloth-

ing, and tools away from gears, fans, and all other

moving parts when starting, operating, or repairing the

equipment.

Routine Maintenance

• At the end of each day’s use, refill the fuel tank to

minimize moisture condensation in the tank.

Running out of fuel tends to draw dirt into the fuel

system. Also, check the crankcase oil level and

add oil if indicated.

KOHLER

SUBARU ROBIN

CH23S EH65

Oil 100 HRS. 100 HRS.

Oil Filter 200 HRS. 200 HRS.

HONDA

GX620KI

6 Months

100 HRS.

1 Year or

200 HRS.

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 for more specific informa-

tion on oil viscosity recommendations.

Wash your hands with soap and water after handling

used oil.

Please dispose of used motor oil in a manner that is

compatible with the environment. We suggest you take

it in a sealed container to your local service station or

recycling center for reclamation.

Do not throw it in the trash, pour it on the ground or

down a drain.

OIL FILTER CHANGE

1. Drain the engine oil.

2. Remove the oil filter, and drain the oil into a suitable

container. Discard the used oil filter.

3. Clean the filter mounting base, and coat the gasket

of the new oil filter with clean engine oil.

4. Screw on the new oil filter by hand, until the gasket

contacts the filter mounting base, then use an oil fil-

ter 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, the

maintenance schedule for cleaning and re-oiling

the foam pre-filter is every 25 hours and replace-

ment of the air cleaner filter every 100 hours.

More frequent servicing is required with dusty

operating conditions. Refer to the maintenance

section of the Engine Owner’s Manual for more

information.

• Refer to the maintenance section of the Engine

Owner’s Manual for the maintenance schedule,

spark plug servicing, cooling system servicing, and

fuel filter replacement.

• Blow out the machine with low pressure air period-

ically. In particularly dirty locations, this may be

required once a week.

• Output Ranger Selector and Polarity Switches:

Switch contacts should not be greased. To keep

contacts clean, rotate the switch through its entire

range frequently. Good practice is to turn the han-

dle from maximum to minimum setting twice each

morning before starting to weld.

RANGER 10,000 PLUS AND RANGER 10,000

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.

------------------------------------------------------------------------

Adjustments to the engine are to be made only by a

Lincoln Service Center or an authorized Field Service

Shop.

SLIP RINGS

A slight amount of darkening and wear of the slip rings

and brushes is normal. Brushes should be inspected

when a general overhaul is necessary.If brushes are

to be replaced, clean slip rings with a fine emery

paper.

Do not attempt to polish slip rings while engine is

running.

------------------------------------------------------------------------

BATTERY

1. When replacing, jumping, or otherwise connecting

the battery to the battery cables, the proper

polarity must be observed. Failure to observe

the proper polarity could result in damage to the

charging circuit. The positive (+) battery cable

has a red terminal cover.

2. If the battery requires charging from an external

charger, disconnect the negative battery cable

first and then the positive battery cable before

attaching the charger leads. Failure to do so

can result in damage to the internal charger

components. 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 PLUS AND 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.

• CONNECTING A BATTERY CHARGER - Remove bat-

tery from welder by disconnecting negative cable first,

then positive cable and battery clamp. When rein-

stalling, connect negative cable last. Keep well venti-

lated.

• USING A BOOSTER - connect positive lead to battery

first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when

working near battery. Follow instructions printed on

battery.

WARNING

CAUTION

KOHLER C23S SUBARU ROBIN EH65

KOHLER 1205001 SUBARU ROBIN

Oil Filter FRAM PH8172*248-65801-00, FRAM PH4967

Air Filter KOHLER 4708303 SUBARU ROBIN

Element FRAM CA79 263-32610-A1

Air Filter KOHLER 2408302 N/A

Pre-Cleaner

Fuel Filter KOHLER 2405010 SUBARU ROBIN

011-00600-20

Spark Plugs CHAMPION RC12YC SUBARU ROBIN

(Resistor (.030” GAP) X65-01407-30

Type) NGK-BPR4EY

HONDA GX620KI

HONDA

15410-ZJ4-999A

HONDA

17210-ZJ1-841

HONDA

17218-ZJ1-840

HONDA

16910-ZE8-015

CHAMPION -J16CR-U

NGK-ZGR5A

030in, (76 mm) Gap

*Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.

ENGINE MAINTENANCE PARTS

E-1

TROUBLESHOOTING

E-1

RANGER 10,000 PLUS AND 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 possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP-

TOMS)”. This column describes possible symptoms

that the machine may exhibit. Find the listing that

best describes the symptom that the machine is

exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE 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 Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.

Unauthorized repairs performed on this equipment may result in danger to the technician and

machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical

Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

E-2

TROUBLESHOOTING

E-2

RANGER 10,000 PLUS AND 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

(SYMPTOMS) POSSIBLE

CAUSE RECOMMENDED

COURSE OF ACTION

No welder or output power.

Engine will not idle down to low

speed.

Engine will not go to high idle when

attempting to weld.

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 solenoid.

6. Faulty P.C. Board.

1. Poor work lead connection to

work.

2. No voltage signal from the

current sensor.

3. No open circuit voltage on

output studs.

4. Faulty P.C. Board.

If all recommended possible areas of

misadjustment have been checked

and the problem persists, Contact

your local Lincoln Authorized

Field Service Facility.

E-3

TROUBLESHOOTING

E-3

RANGER 10,000 PLUS AND 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

(SYMPTOMS) POSSIBLE

CAUSE RECOMMENDED

COURSE OF ACTION

Engine will not go to high idle when

using auxiliary 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 filter clogged.

2. Air filter clogged.

1. Spark plugs do not have

specified gap.

2. Spark plugs are fouled.

If all recommended possible areas of

misadjustment have been checked

and the problem persists, Contact

your local Lincoln Authorized

Field Service Facility.

F-1

DIAGRAMS

F-1

RANGER 10,000 PLUS AND RANGER 10,000

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Enhanced Diagram

F-2

DIAGRAMS

F-2

RANGER 10,000 PLUS AND RANGER 10,000

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Enhanced Diagram

F-3

DIAGRAMS

F-3

RANGER 10,000 PLUS AND RANGER 10,000

/ / L LN-15

RANGER 10,000 PLUS AND RANGER 10,000

RANGER 10,000 PLUS AND RANGER 10,000 AND LN-25 ACROSS T AND LN-25 ACROSS THE ARC CONNECTE ARC CONNECTION DIN DIAGRAM

ELECTRIC SHOCK can kill

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

before servicing.

Do not touch electrically live parts.

WARNING

MOVING PARTS can injure

Keep guards in place.

Keep away from moving parts.

Only qualified personnel should install,use

or service this

or service this equipmequipment.

M20266

A.02A.02

TO WORKTO WORK ELECTRODE

TOTO

ENGINEENGINE

WELDERWELDER

W WORK

LN-15 ORLN-15 OR -25

WIRE F

RE FEEDEREDER

TOTO W WORK

ELECTECTRODEODE CABL CABLE

WORK CLIP LEAD

N.N.A.A. WEWELDING CCABLABLE E MMUSTST B BE SIZ SIZED FD FOR R CUCURRRRENTENT D DUTY C CYCLCLE O OF AAPPLPLICAICATION.

N.B.B. USE USE POPOLARITY SSWITCH TCH TO SSET F FOR DDESISIRERED ELD ELECECTRODEODE P POLARITRITY. . POPOSISITIONON TTHE OUE OUTPUT S SELECTCTOR

SWITCH T TO T THE E WWIRERE FFEED ((CV)V) POPOSITSITION.

F-4

DIAGRAMS

F-4

RANGER 10,000 PLUS AND RANGER 10,000

KOHLER, HONDA AND SUBARU ROBIN

M20267

C.01

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

NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES.

42.25

NOTES

RANGER 10,000 PLUS AND RANGER 10,000

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS

CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A

ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-

STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

●Do not touch 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 Elektroden mit Ihrem

Körper oder feuchter Kleidung!

●Isolieren Sie sich von den

Elektroden und dem Erdboden!

●Não toque partes elétricas e elec-

trodos com a pele ou roupa molha-

da.

●Isole-se da peça e terra.

●Keep flammable materials away.

●Mantenga el material combustible

fuera del área de trabajo.

●Gardez à l’écart de tout matériel

inflammable.

●Entfernen Sie brennbarres Material!

●Mantenha inflamáveis bem guarda-

dos.

●Wear eye, ear and body protection.

●Protéjase los ojos, los oídos y el

cuerpo.

●Protégez vos yeux, vos oreilles et

votre corps.

●Tragen Sie Augen-, Ohren- und Kör-

perschutz!

●Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS

PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

●Keep your head out of fumes.

●Use ventilation or exhaust to

remove fumes from breathing zone.

●Los humos fuera de la zona de res-

piración.

●Mantenga la cabeza fuera de los

humos. Utilice ventilación o

aspiración para gases.

●Gardez la tête à l’écart des fumées.

●Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones

de travail.

●Vermeiden Sie das Einatmen von

Schweibrauch!

●Sorgen Sie für 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 com as tampas removidas.

●Desligue a corrente antes de fazer

serviço.

●Não toque as partes elétricas nuas.

●Do not operate with panel open or

guards off.

●No operar con panel abierto o

guardas quitadas.

●N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de

protection enlevés.

●Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in

Betrieb setzen!

●Mantenha-se afastado das partes

moventes.

●Não opere com os paineis abertos

ou guardas removidas.

• 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 Leader in Welding and Cutting Products •

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