Lincoln Electric RANGER 8 User Manual

	RETURN TO MAIN MENU			IM510-E
	RANGER	™	8

January, 2002

For Machines with Code Numbers 10373, 10374, 10375, 10376, 10535, 10536, 10537,10538, or 10541,10886

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 thoughtful 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.

Date of Purchase:

Serial Number:

Code Number:

Model:

R

Where Purchased:

OPERATOR’S MANUAL

Copyright © 2002 Lincoln Global Inc.

•World's Leader in Welding and Cutting Products •

•Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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 Gasoline Engines

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.

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 vaporizing 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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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.

Mar ‘95

ii		SAFETY		ii

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.

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.

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. 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 to form phosgene, a highly toxic gas, and other irritating products.

5.c. 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.d. 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.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

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 circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

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.

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.

Mar ‘95

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SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

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 rayonnement 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, pantalons 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 levage, 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 debrancher à l’interrupteur à la boite de fusibles.

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

Mar. ‘93

v

Thank You

v

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!

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.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

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.

CAUTION

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

		TABLE OF CONTENTS				vi
			Page
		Installation.......................................................................................................................	Section A
		Technical Specifications ................................................................................................	A-1,A-2
		Installation Instructions.........................................................................................................	A-3
		Safety Precautions ........................................................................................................	A-3
		Machine Grounding.......................................................................................................	A-3
		Spark Arrester ...............................................................................................................	A-3
		Trailers ..........................................................................................................................	A-3
		Pre-Operation Engine Service..............................................................................................	A-4
		Oil..................................................................................................................................	A-4
		Fuel ...............................................................................................................................	A-4
		Battery Connections......................................................................................................	A-4
		Welding Cable Connections..........................................................................................	A-4
		Angle of Operation ........................................................................................................	A-5
		High Altitude Operation .................................................................................................	A-5
		Location and Ventilation................................................................................................	A-5
		Welding Cable Connections..........................................................................................	A-5
		Connection of Wire Feeders .........................................................................................	A-5
		Connection of Tig Module .............................................................................................	A-6
		Additional Safety Precautions .......................................................................................	A-6
		Auxiliary Power Receptacles, and Plugs ......................................................................	A-6,A-7
		Motor Starting.......................................................................................................................	A-7
		Electrical Device Used with the Ranger 8 ............................................................................	A-8
		Auxiliary Power While Welding............................................................................................	A-9
		Premises Wiring .................................................................................................................	A-10
		Operation.........................................................................................................................	Section B
		General Description..............................................................................................................	B-1
		Design Features ...................................................................................................................	B-1
		Other Features .....................................................................................................................	B-1
		Engine Options.....................................................................................................................	B-1
		Fuel Consumption ................................................................................................................	B-2
		Controls and Settings ...........................................................................................................	B-2
		Welder / Generator Controls...................................................................................	B-2,B-3
		Engine Operation .................................................................................................................	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
		DC Wire Feed Welding Processes(CV) .......................................................................	B-4
		Summary of Welding Processes ..................................................................................	B-5
		Accessories .....................................................................................................	Section C
		General Options / Accessories..............................................................................	C-1
		Recommended Equipment/ Accessories...............................................................	C-2
		Maintenance ....................................................................................................	Section D
		Safety Precautions ................................................................................................	D-1
		Routine Engine Maintenance ................................................................................	D-1
		Engine Adjustments...............................................................................................	D-2
		Slip Rings ..............................................................................................................	D-2
		Battery Maintenance .......................................................................................	D-2
		Engine Maintenance Parts..............................................................................	D-2
		Troubleshooting ..............................................................................................	Section E
		Safety Precautions.................................................................................................	E-1
		How to Use Troubleshooting Guide.......................................................................	E-1
		Troubleshooting Guide...................................................................................	E-2, E-3
		Wiring Diagrams & Dimension Print..............................................................	Section F
		Parts List ..................................................................................................................	P229

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS - Ranger 8 (K1418-1) (K1418-2 CSA MEETS CANADIAN STD.) (K1419-1) (K1419-2 CSA MEETS CANADIAN STD.)

(K2160-1 CSA MEETS CANADIAN STD.)

			INPUT - GASOLINE ENGINE
Make/Model	Description		Horsepower	Speed (RPM)	Displacement	Capacities
					cu. in. (cu. cm.)
Onan P216			16 HP @			Fuel:
(K1418-1)			3600 RPM			9 Gal (34 L)
(K1418-2)	2 cylinder		(Onan)	High Idle 3700	43(710)-Onan	Lubricating Oil:
						1.8 Qts (1.7 L)
	4 Cycle
	Air-Cooled
Kohler CH20						Fuel:
	Gasoline		20 HP @
(K1419-1)	Engine.		3600 RPM	Full Load 3500		9 Gal (34 L)
(K1419-2)	Aluminum Alloy		(Kohler)		38(624)-Kohler	Lubricating Oil:
	with Cast Iron					2.0 Qts (1.9 L)
	Liners, Electrical			Low Idle 2200		Fuel:
Honda GX620	Ignition		20 HP @
					37.5(614)-Honda	9 Gal (34 L)
(K2160-1)			3600 RPM
						Lubricating Oil:
			(Honda)
						1.9 Qts (1.8 L)

RATED OUTPUT - WELDER

Welding Output *

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

OUTPUT - GENERATOR

Auxiliary Power

8,000 Watts, 60 Hz AC

70 Amps @ 115V

35 Amps @ 230V

PHYSICAL DIMENSIONS

HEIGHT	WIDTH	DEPTH	WEIGHT
30.3 in.	19.2 in.	42.3 in.	529 lbs. (240kg.) K1418-1,-2
770 mm	488 mm	1074 mm	511 lbs. (232kg.) K1419-1,-2 &
			K2160-1

* Based on a 10 min. period.

RANGER 8

A-2	INSTALLATION	A-2

SPECIFICATIONS

OUTPUT VOLTS AC (RMS)

OUTPUT VOLTS DC (RMS)

OUTPUT VOLTS DC (RMS)

80	AC STICK / TIG (CC) OUTPUT
			A	225 OUTPUT RANGE
70
			B	50 OUTPUT RANGE
60
50
40
30
20	B
10				A
0	50	100		150	200	250
0
		OUTPUT AMPS
80	DC STICK / TIG (CC) OUTPUT
		A	210 OUTPUT RANGE
70
		B	50 OUTPUT RANGE
60

50

40

30

20
10	B		A
0
0	50	100	150	200	250	300	350
		OUTPUT AMPS

DC WIRE FEED (CV) OUTPUT

40

35

30

25

20

15

10				CV OUTPUT RANGE
5
0	50	100	150	200	250	300	350
0

OUTPUT AMPS

RANGER 8

A-3	INSTALLATION	A-3

INSTALLATION INSTRUCTIONS

Safety Precautions

WARNING

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.

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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.

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

Machine Grounding

Because this portable engine driven welder or generator creates it’s own power, it is not necessary to connect 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 equipment 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.

When this welder is mounted on a truck or trailer, it’s frame must be securely connected to the metal 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 entitled “Standby Power Connections”, as well as the article on grounding in the latest U.S. 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 insulated joints, or to the metal framework of a building which has been effectively grounded. The U.S. 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.

CAUTION

An incorrect arrester may lead to damage to the engine or adversely affect performance.

Trailers

The recommended trailer for use with this equipment for in plant and yard towing by a vehicle is Lincoln’s K768-2. Consult applicable federal, state, and local laws regarding specific requirements for use on public highways.

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.

RANGER 8

A-4	INSTALLATION	A-4

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.

Pre-Operation Service

CAUTION

READ the engine operating and maintenance instructions supplied with this machine.

WARNING

GASOLINE fuel can cause fire or explosion.-

• Stop engine while fueling.

•Do not smoke when fueling.

•Do not overfill tank.

•Keep sparks and flame away from tank.

•Wipe up spilled fuel and allow fumes to clear

before starting engine.

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

Oil

The Ranger 8 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.

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Onan P218 - 1.8 Quarts (1.7 Liters)

Kohler CH20S - 2.0 Quarts (1.9 Liters)

Honda GX620-1.9 Quarts (1.6 Liters)

Fuel

Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling.

Battery Connections

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.

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 connections 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.

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

					225 Amps			225 Amps
					40% Duty Cycle			100% Duty Cycle
					3 AWG			1 AWG
		0-50 Ft.
		50-100 Ft.			3 AWG			1 AWG
		100-150 Ft.			2 AWG			1 AWG
		150-200 Ft.			1 AWG			1 AWG
		200-250 Ft.			1/0 AWG			1/0 AWG

RANGER 8

A-5	INSTALLATION	A-5

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 10 gallons.

High Altitude Operation

If the Ranger 8 will be consistently 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.

CAUTION

Do not operate a Ranger 8 with a high altitude jet installed at altitudes below 5000 ft. This will result in the engine running too lean and result in higher engine operating temperatures which can shorten engine life.

Contact your local Onan, Kohler or Honda Authorized Dealer for high altitude jet kits that are available from the engine manufacturer.

WARNING

Muffler Relocation Shut off welder and allow muffler to cool before touching muffler.

The Ranger 8 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 8 without the cover in place will result in a higher noise level and no increase in machine output.)

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 outside area.

WARNING

• Damage to the fuel tank may cause fire or explosion. Do not drill holes in the Ranger 8 base or weld to the

Ranger 8 base.

Connection of Lincoln Electric

Wire Feeders

WARNING

Shut off welder before making any electrical connections.

Wire Feed (Constant voltage)

Connection of the LN-25 to the Ranger 8

•Shut the welder off.

•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.

•Position the welder “Polarity” switch to the desired polarity, either DC (-) or DC (+).

•Position the “RANGE” switch to the “WIRE FEED” position.

•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.

•Place the idler switch in the “AUTO” position.

•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.

RANGER 8

A-6	INSTALLATION	A-6

Connection of the LN-7 to the Ranger 8

•Shut the welder off.

•Connect the LN-7 and the K240 contactor kit per instructions on the connection diagram S17742 (can be found in the back of this manual).

•Place the “RANGE” switch to the “WIRE FEED” position and the “POLARITY” switch to the desired polarity.

•Place the “IDLER” switch in the “HIGH” idle position. The engine idling device may not function when welding in the “WIRE FEED” mode.

•Adjust wire feed speed at the LN-7 and adjust the welding voltage with the output “CONTROL” at the welder.

NOTE: If the output “CONTROL” is set below “3” the K240 contactor may not pull in.

Connection of K930-[ ] TIG Module to the Ranger 8.

The TIG Module is an accessory that provides high frequency 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 8 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 moving parts and assures proper cooling air flow.

Read and understand all Safety Precautions before operating 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: 100% for both welding and auxiliary power.

Ranger 8

Constant Current 225 Amps AC @ 25 Volts 210 Amps DC @ 25 Volts

Constant Voltage 200 Amps DC @ 20 Volts

Auxiliary Power

The Ranger 8 can provide up to 8,000 watts of 115/230 volts AC, single phase 60Hz power for continuous use. The front of the machine includes three receptacles for connecting the AC power plugs; one 50 amp 115/230 volt NEMA 14-50R receptacle and two 20 amp 115 volt NEMA 5-20R receptacles.The CSA machine has one 50 amp 115/230 volt NEMA 14-50R receptacle and two 15 amp 115 volt NEMA 5- 15R receptacles.

CAUTION

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 auxiliary power.

115/230 Volt Dual Voltage Receptacle

The 115/230 volt receptacle can supply up to 35 amps of 230 volt power to a two wire circuit, up to 35 amps of 115 volts power from each side of a three wire circuit (up to 70 amps total). Do not connect the 115 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 colunm.

RANGER 8