Lincoln RANGER 8 Operator's Manual

RANGER™8

OPERATOR’S MANUAL

For Machines with Code Numbers 10373, 10374, 10375, 10376,

10535, 10536, 10537,10538, or

10541,10886

IM510-E

January, 2002

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.

R

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

Copyright © 2002 Lincoln Global Inc.

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.

i

SAFETY

i

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 can­cer, 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

ii

SAFETY

ii

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.

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

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

6.h. Also see item 1.c.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Thank You

vv

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 Immediatel

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:

y

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

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

vi

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

RANGER 8

A-1

* Based on a 10 min. period.

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

RATED OUTPUT - WELDER

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

OUTPUT - GENERATOR

Welding Output *

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

Auxiliary Power

8,000 Watts, 60 Hz AC

70 Amps @ 115V

35 Amps @ 230V

PHYSICAL DIMENSIONS

Make/Model

Onan P216

(K1418-1)
(K1418-2)

Kohler CH20

(K1419-1)
(K1419-2)

Honda GX620

(K2160-1)

Description

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners, Electrical

Ignition

Speed (RPM)

High Idle 3700

Full Load 3500

Low Idle 2200

Displacement

cu. in. (cu. cm.)

43(710)-Onan

38(624)-Kohler

37.5(614)-Honda

Capacities

Fuel:

9 Gal (34 L)

Lubricating Oil:

1.8 Qts (1.7 L)
Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts (1.9 L)
Fuel:

9 Gal (34 L)

Lubricating Oil:

1.9 Qts (1.8 L)

Horsepower

16 HP @

3600 RPM

(Onan)

20 HP @

3600 RPM

(Kohler)

20 HP @

3600 RPM

(Honda)

A-2

INSTALLATION

RANGER 8

A-2

AC STICK / TIG (CC) OUTPUT

A 225 OUTPUT RANGE
B 50 OUTPUT RANGE

A

B

OUTPUT AMPS

OUTPUT VOLTS AC (RMS)

0

50 100 150 200

250

0

10

20

30

40

50

60

70

80

DC STICK / TIG (CC) OUTPUT

OUTPUT AMPS

OUTPUT VOLTS DC (RMS)

A 210 OUTPUT RANGE
B 50 OUTPUT RANGE

A

B

0

50 100 150

200 250 300

350

0

10

20

30

40

50

60

70

80

CV OUTPUT RANGE

0

50

100

150

200

250 300

OUTPUT AMPS

350

0

5

10

15

20

25

30

35

40

DC WIRE FEED (CV) OUTPUT

OUTPUT VOLTS DC (RMS)

SPECIFICATIONS

A-3

INSTALLATION

RANGER 8

A-3

INSTALLATION INSTRUCTIONS

Safety Precautions

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.

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.

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

CAUTION

A-4

INSTALLATION

RANGER 8

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

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

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.

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.

CAUTION

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.

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

WARNING

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

0-50 Ft.

50-100 Ft.

100-150 Ft.

150-200 Ft.

200-250 Ft.

225 Amps

40% Duty Cycle

3 AWG

3 AWG

2 AWG

1 AWG

1/0 AWG

225 Amps

100% Duty Cycle

1 AWG

1 AWG

1 AWG

1 AWG

1/0 AWG

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)

A-5

INSTALLATION

RANGER 8

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.

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.

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.

Connection of Lincoln Electric
Wire Feeders

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.

CAUTION

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.

WARNING

WARNING

A-6

INSTALLATION

RANGER 8

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.

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 5­15R receptacles.

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.

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

Constant Current 225 Amps AC @ 25 Volts

210 Amps DC @ 25 Volts

Constant Voltage 200 Amps DC @ 20 Volts

CAUTION