Lincoln Electric RANGER 8 User Manual

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

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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.

RANGER™8

10535, 10536, 10537,10538, or

10541,10886

IM510-E

January, 2002

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

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• 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

SAFETY

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

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.

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

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.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.

___________________________________________________

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.

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

SAFETY

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.

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.

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.

5.b.

Do not weld in locations near chlorinated hydrocarbon 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 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.

vapors

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.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

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

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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

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 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.

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.

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.

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

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:

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

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

cu. in. (cu. cm.)

Capacities

Onan P216

(K1418-1) (K1418-2)

Kohler CH20

(K1419-1) (K1419-2)

Honda GX620

(K2160-1)

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners, Electrical

Ignition

16 HP @

3600 RPM

(Onan)

20 HP @

3600 RPM

(Kohler)

20 HP @

3600 RPM

(Honda)

High Idle 3700

Full Load 3500

Low Idle 2200

43(710)-Onan

38(624)-Kohler

37.5(614)-Honda

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

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)

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

SPECIFICATIONS

INSTALLATION

AC STICK / TIG (CC) OUTPUT

A 225 OUTPUT RANGE B 50 OUTPUT RANGE

A-2

OUTPUT VOLTS AC (RMS)

OUTPUT VOLTS DC (RMS)

50 100 150 200

OUTPUT AMPS

DC STICK / TIG (CC) OUTPUT

A 210 OUTPUT RANGE B 50 OUTPUT RANGE

50 100 150

OUTPUT AMPS

DC WIRE FEED (CV) OUTPUT

200 250 300

250

350

OUTPUT VOLTS DC (RMS)

100

150

OUTPUT AMPS

RANGER 8

CV OUTPUT RANGE

200

250 300

350

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.

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

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.

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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.

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.

RANGER 8

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.

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.

INSTALLATION

A-4

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.

Pre-Operation Service

CAUTION

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

WARNING

GASOLINE

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

fuel can cause fire or

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

0-50 Ft.

225 Amps

40% Duty Cycle

3 AWG

225 Amps

100% Duty Cycle

1 AWG

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.

RANGER 8

50-100 Ft.

100-150 Ft.

150-200 Ft.

200-250 Ft.

3 AWG

2 AWG

1 AWG

1/0 AWG

1 AWG

1/0 AWG

A-5

Angle of Operation

INSTALLATION

Location / Ventilation

A-5

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 is decreased at higher altitudes. Engine horsepower is reduced by 3.5% per 1000 feet for altitudes above 377 feet.

give increased power which

CAUTION

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 in the Ranger 8 base or weld to the Ranger 8 base.

drill holes

Connection of Lincoln Electric Wire Feeders

WARNING

Shut off welder before making any electrical connections.

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.)

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

Connection of the LN-7 to the Ranger 8

INSTALLATION

Welder Operation

A-6

• 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.

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 515R receptacles.

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.

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 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

A-7

GND

115 V

115 V*

230 V

*Current Sensing for Automatic Idle. (Receptacle viewed from front of Machine)

115 V Duplex Receptacles

The 115V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs.

INSTALLATION

A-7

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 230 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 230V operation only.

The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle (Refer to Tables I and II). Do not attempt to connect power receptacles in parallel.

TABLE I Maximum Current Draw from 115V Duplex Receptacles - No Welding

Load From K1418-1 and K1419-1 K1418-2, K1419-2 and K2160-1 115V/230V CSA Machines Dual Voltage Each Half of Total From Each Half of Total From Receptacle Each 115V Both 115V Each 115V Both 115V

Duplex Duplexes Duplex Duplexes

0 20* 70 15 60

1.1 KW 20* 60 15 60

3.4 KW 20* 40 15 40

5.7 KW 20* 20 15 20

8.0 KW 0 0 0 0

*NEMA 5-20P Plug required for 20Amp Draw

TABLE II Maximum Current Draw from 115V GFCI Duplex Receptacles - No Welding

Load From K1418-1 and K1419-1 K1418-2, K1419-2 and K2160-1 115V/230V CSA Machines Dual Voltage Each Half of Total From Each Half of Total From Receptacle Each 115V Both 115V Each 115V Both 115V

Duplex Duplexes Duplex Duplexes

0 15 40* 15 30**

1.1 KW 15 40* 15 30**

3.4 KW 15 40* 15 30**

5.7 KW 15 20* 15 20**

8.0 KW 0 0 0 0

*Maximum current draw from each 115V GFCI Duplex is 20 amps *Maximum current draw from each 115V GFCI Duplex is 15 amps

RANGER 8

A-8

ELECTRICAL DEVICE USE WITH THE RANGER 8.

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-

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

INSTALLATION

TABLE lll

itative elements to fail. Surge protection, transient protection, and additional loading is recommended for 100% fail-safe operation. DO NOT RUN

THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS.

maximum output torque, but they SHOULD BE SAFE from any frequency induced failures.

A-8

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 8

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER 8.

RANGER 8

A-9

INSTALLATION

Auxilliary Power While Welding

It must be noted that the above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are permitted by following Table III. The permissible currents shown assume that current is being drawn from either the 115V or 230V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxiliary power.

TABLE III

SIMULTANEOUS WELDING AND POWER

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Max. Stick or Wire

Feed Setting None 0 0

175 Stick Setting 2100 18 9

125 Stick Setting 3800 32 16

90 Stick Setting 5000 42 21

70 Stick Setting 5600 48 24

50 Stick Setting 6300 54 27

NO WELDING 8000 70 35

Factor) @ 115V -or- @ 230V

A-9

2. Take necessary steps to assure load is limited to

the capacity of the Ranger 8 by installing a 35 amp 230V double pole circuit breaker. Maximum rated load for the 230V auxiliary is 35 amperes. Loading above 35 amperes will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment.

3. Install a 50 amp 115/230V plug (NEMA type 14-50)

to the Double Pole Circuit Breaker using No. 8, 4 conductor cable of the desired length. (The 50 amp 115/230V plug is available in the optional plug kit.)

4. Plug this cable into the 50 amp 115/230V

receptacle on the Ranger 8 case front.

Standby Power Connections

The Ranger 8 is suitable for temporary, standby, or emergency power using the engine manufacturer’s recommended maintenance schedule.

The Ranger 8 can be permanently installed as a standby power unit for 230V-3 wire, single phase 35 ampere service.

(Connections must be made by a licensed electrician who can determine how the 115/230V power can be adapted to the particular installation and comply with all applicable electrical codes.) The

WARNING

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 disconnect.

Switch rating must be the same or greater than the customer’s premises disconnect and service overcurrent protection.

RANGER 8

A-10

230 Volt

60 Hz. 3-Wire

Service

POWER

COMPANY

METER

230 VOLT

115 VOLT

LOAD

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 8 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

230 VOLT

GROUNDED CONDUCTOR

35AMP

230 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, 115/230

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 115/230 VOLT

RECEPTACLE

INSTALLATION

Figure 1

CONNECTION OF RANGER 8 TO PREMISES WIRING

A-10

WARNING

Connection of Ranger 8 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes.

RANGER 8

B-1

OPERATION

GENERAL DESCRIPTION

The Ranger™8 is a twin-cylinder, gasoline driven, multiprocess arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site.

DESIGN FEATURES

AC/DC STICK WELDING (Constant Current)

• AC 40 - 225 Amps

• DC 40 - 210 Amps

• 100% Duty Cycle on All Settings

• Output Selector with 6 Ranges

• Output Control for Fine Current Adjustment

• Use with a broad range of AC & DC Electrodes Including Fleetweld® 5P

DC SEMIAUTOMATIC WIRE FEED WELDING (Constant Voltage)

• CV Tap Setting for 60-200 Amps.

• 100% Duty Cycle.

• Excellent Performance with .068” (1.7mm) NR®-211-MP Innershield® Electrode.

•

Limited MIG Welding with L-50 & L-56 using blended

Argon Shielding Gas.

• The Recommended Wire Feeder is the LN-25, but Can Also be Used with the LN-7 Wire Feeder. (LN-7 and LN-25 without Contactor Requires the K240 Contactor Kit).

B-1

• K930-1 TIG Module Available.

• Remote Control Receptacle Kit Available.

•

Electronic Engine Idler. Engine Automatically Goes to Low Idle in 10 to 14 Seconds after Welding or Use

of Auxiliary Power. Includes High Idle Switch.

• Electric Starting.

• Battery Charging Ammeter.

• Full 8 KVA Auxiliary Output Receptacle.

• Factory Installed Engine Hour Meter.

• Engine Protection Shuts Engine Down in the

Event of Low Oil Pressure.

• Built-in Feet for Easy Mounting to Truck Bed or Trailer.

• All Copper Alternator Windings and High Quality Insulation for Long-Life and Dependability.

• Powder Painted Case and Base for Outstanding Corrosion Protection.

• Quiet muffler with reversible exhaust feature; either right or left side of machine.

ENGINE OPTIONS

AC/DC TIG WELDING (Constant Current)

• AC & DC TIG Welding Can be Done at All Constant Current Output Range Settings.

AUXILIARY POWER

• 8000 Watt AC 115/230 Volt 60 Hz. Generator.

• Operates AC Power Tools.

• Powers Battery Chargers.

• Powers a 1.5 HP Motor (If Started Under No Load).

• Lights Eighty 100 Watt Incandescent Bulbs.

• Can be Used for Standby Power.

OTHER FEATURES

• Bottom Mounted 9 Gallon Fuel Tank with a

Convenient Top Fill and Fuel Gauge.

• Polarity Switch for Selecting DC+, DC-, or AC

Welding Output.

Three Engines are available for the Ranger 8 Welders; the Onan P216 Performer®*, the Kohler 20 HP Command®* and the Honda GX620. All three engines have the following features:

• Air Cooled, Twin-Cylinder.

• Cast Aluminum Alloy Crankcase with Integral Cast

Iron Cylinder Liners.

• Electric Start with Solid State Battery Charging Module.

• Solid State Breakerless Ignition.

• Spin on Oil Filter.

• Low Oil Pressure Shutdown Protection.

In addition to the above, the Kohler Command Engine has overhead valves and hydraulic valve lifters.

* These trademarks are the property of their respective manufacturers.

RANGER 8

B-2

OPERATION

Ranger 8 Approximate Fuel Consumption

B-2

ONAN P216

16 H.P. PERFORMER

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 8000 Watts

.4 Gallons/Hour

(1.5 Liters/Hour)

.9 Gallons/Hour

(3.5 Liters/Hour)

1.5 Gallons/Hour (5.8 Liters/Hour)

1.7 Gallons/Hour (6.5 Liters/Hour)

1.4 Gallons/Hour (5.3 Liters/Hour)

1.7 Gallons/Hour (6.5 Liters/Hour)

Welder Controls - Function and Operation

Explanation of Symbols that Appear on this Equipment

OFF

Low Idle

High Idle

ENGINE “ON-OFF” Switch

When placed in the “ON” position, this switch energizes the engine ignition circuit. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine.

ENGINE “START” Push-Button Switch

Energizes engine starter motor.

“Polarity” Switch

CAUTION

Never change the “Polarity” switch setting while welding. This will damage the switch.

KOHLER

20 H.P. COMMAND

.4 Gallons/Hour

(1.5 Liters/Hour)

.9 Gallons/Hour

(3.5 Liters/Hour)

1.3 Gallons/Hour (5.0 Liters/Hour)

1.4 Gallons/Hour (5.3 Liters/Hour)

1.2 Gallons/Hour (4.5 Liters/Hour)

1.4 Gallons/Hour (5.3 Liters/Hour)

HONDA

20 H.P. GX620

.3 Gallons/Hour

(1.3 Liters/Hour)

.7 Gallons/Hour

(2.7 Liters/Hour)

1.6 Gallons/Hour (6.0 Liters/Hour)

1.7 Gallons/Hour (6.3 Liters/Hour)

1.2 Gallons/Hour (4.6 Liters/Hour)

1.5 Gallons/Hour (5.7 Liters/Hour)

“ Control” Switch

Provides a fine welding current adjustment within the Range Switch settings in the STICK/TIG mode and welding voltage control with the Range switch set in the wire feed mode.

“IDLER” Switch

The idler switch has two positions, “HIGH” and “AUTO”.

When in “HIGH” ( ) position, the engine will run continuously at high idle. When in “AUTO” ( / ) idle position, the idler operates as follows:

• Welding

When the electrode touches the work, the welding arc is initiated and the engine accelerates to full speed.

“ Range” Switch

Process Maximum Current

STICK/TIG - CC 50, 70, 90 6 Range Settings 125, 175, 210 DC/225 AC

WIRE FEED - CV 1 Range Setting 200

on Each Setting

CAUTION

Never change the “RANGE” Switch setting while welding. This will damage the switch.

RANGER 8

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-3

OPERATION

B-3

Starting/Shutdown Instructions

Starting the Engine

WARNING

• 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.

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 8 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 (approximately 50 running hours)).

Be sure all Pre-Operation Maintenance has been performed. Also, read the Engine Owner’s Manual.

Remove all loads connected to the AC power receptacles. To start the engine, set the “Idler Control” switch in the Automatic ( / ) position.

Use the choke control as follows:

Onan Engine - If the engine is cold, pull the choke control out. Do not use the choke if the engine is warm or hot.

Kohler Engine - Always pull the choke control out when starting the engine; cold, warm or hot. Place the “Engine” switch in the “ON” position.

Honda Engine - Always pull the choke control out when starting the engine; cold. Place the “Engine” switch in the “ON” position.

Push the “START” button and crank the engine until it starts. Release the button as soon as the engine starts. Do not push the “START” button while the engine is running because this will cause damage to the ring gear and/or starter motor. After the engine has started, slowly return the choke control to the full “in” position (choke open).

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:

Kohler

CH20S

5 HRS

The oil filter is to be changed at the second oil change. Refer to the Engine Owner’s Manual for more information.

Onan P216

25 HRS

Honda

GX620

First Month

or 20 HRS

After running at high engine speed for 10-14 seconds, the engine will go to low idle.

RANGER 8

B-4

OPERATION

B-4

Welding Process

Stick (Constant Current) Welding

Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity” switch to the desired polarity. Set the “RANGE” switch to a setting that is equal to or slightly greater than the desired welding current. (The “RANGE” dial marking indicates the maximum for that range). Fine adjustment of the welding current is made by adjusting the output “CONTROL” or remote control. For best arc stability, use settings

5 through 10.

The Ranger 8 can be used with a broad range of AC and DC stick electrodes. See “Welding Tips 1” included with the Ranger 8 for electrodes within the rating of this unit and recommended welding currents of each.

TIG (Constant Current) Welding

The K930-[ ] TIG Module installed on a Ranger 8 provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding processes. The TIG Module allows full range output control. Afterflow time is adjustable from 0 to 55 seconds.

current

Wire Feed Welding Processes (Constant Voltage)

The only Innershield with the Ranger 8 is NR

electrode recommended for use

-211-MP. The electrode sizes and welding ranges that can be used with the Ranger 8 are shown in the following table:

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

The Ranger 8 is recommended 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% CO

). The welding ranges

that can be used with the Ranger 8 are shown in the following table:

Diameter Wire Speed Approximate

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

.030 80 - 110 75A to 120A .035 70 - 130 120A to 170A

When using the Ranger 8 for AC TIG welding of aluminum, the following settings and electrodes are recommended:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 70, 90, or 125 80 - 150 Amps 3/32 50, 70, or 90 45 - 130 Amps 1/16 50, or 70 40 - 80 Amps

SETTINGS FOR 1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 70, 90, 125, or 175 80 - 225 Amps 3/32 50, 70, 90, or 125 50 - 180 Amps 1/16 50, 70, or 90 45 - 120 Amps

The K930-[ ] TIG Module should be used with the Ranger 8 on high idle to maintain satisfactory operation. It can be used in the AUTO position but the delay going to flow idle after welding is ceased will be increased if the AFTERFLOW CONTROL is set above 10 seconds.

RANGER 8

B-5

CONTROL ELECTRODE

CABLE IDLE WHEN NOT TO START

PROCESS USED MODE WELDING WELDING

STICK No AUTO Hot Touch electrode to work.

TIG/K7930-1/K938-1, Yes HIGH Cold Press Amptrol, contactor K936-( ) /K892-1 closes, welding (WITH AMPTROL) starts immediately.

WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25 INTERNAL CONTACTOR contactor closes. Welding

OPERATION

Summary of Welding Processes

Welding starts immediately and engine goes to high idle.

starts immediately and engine goes to high idle. NOTE: Output Control must be set above “3”.

B-5

WIRE FEED, LN-7 WITH Yes HIGH Cold Press gun trigger, K240 CONTACTOR KIT contactor closes. Welding

starts immediately.

RANGER 8

C-1

ACCESSORIES

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

C-1

K802-N Power Plug Kit - Provides four 115V plugs

rated at 20 amps each and one dual voltage, full KVA plug rated at 115/230V, 50 amps. (For K1418-2 or K1419-2 CSA machines and machines with GFCI receptacles, use K802-R).

K704 Accessory Kit - Includes 35 ft (10.7m) 2/0 AWG electrode cable, 30 ft. (9.1m) 2/0 AWG work cable, headshield with No. 12 filter, GC300 work clamp and Cooltong® 300 electrode holder. Cables are rated at 300 amps, 100% duty cycle.

K892-1 Remote Control Receptacle Kit - Includes a 6-pin MS-type (Amphenol) receptacle and a local-remote toggle switch that mounts in the case front. Required when using a K930-2 Tig Module with an optional Amptrol or when using a Remote Control.

K1631-1 Puncture Proof Wheel Kit - For converting K889-2 to puncture proof pneumatic tires.

K893-1 Caster for Undercarriage - Mounts to the front of the K889-2 to allow easy movement on smooth surfaces. Includes 6” diameter hard rubber wheel and convenient toe-on, toe-off locking brake.

K933-1 Four Wheel Undercarriage - For Hand Moving. Rear pneumatic tires, front molded wheels.

K934-1 Cylinder Brackets transporting either one LPG fuel cylinder or one welding gas cylinder.

K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCARRIAGE - For moving by hand at construction

sites. Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY) - For moving by hand on a smooth surface. One or two gas cylinders can be mounted on the rear of the undercarriage with the installation of K1745-1 Cylinder Holder(s). Heavy duty puncture resistant pneumatic tires and front caster.

For use with K933-1.

for

K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CONTROL - Portable control provides same dial range as the

output control on the welder. Has a convenient 6 pin plug for easy connection to the welder.

K894-1 Spark Arrester Kit - Includes a heavy gauge steel, approved spark arrester and clamp for easy mounting to muffler exhaust pipe.

K896-1 GFCI Receptacle Kit - Includes two UL approved 115V ground fault circuit interrupter duplex type receptacles with covers and installation instructions. Replaces the two factory installed 115V duplex receptacles. Each receptacle of each GFCI duplex is rated at 15 amps, but the maximum total current from each GFCI duplex is limited to 20 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 for easy carrying, complete with a handle. High frequency bypass is built in. The K938-1 Contactor Kit must be field installed in the TIG Module when used with a Ranger 8. Additionally, the K9363 control cable is required if remote control is used. If remote control is not used the K936-4 control cable is required.

K1745-1 SINGLE GAS CYLINDER HOLDER

For use on K1770-1 Undercarriage. One or two may be installed on an undercarriage.

K1788-1 ROLL CAGE - Gives added damage protection.

K886-1 Canvas Cover -To protect the Ranger 8 when

not in use. Made from attractive red canvas material which is flame retardant, mildew resistant, and water repellent.

K802-R Power Plug Kit - Provides four 115V plugs rated at 15 amps each and one dual voltage, full KVA plug rated at 115/230V, 50 amps.

RANGER 8

K936-3 Remote Control Cable - Control cable for connect-

ing the K930-2 TIG Module to a Ranger 8 equipped with a K892-1 Remote Kit. 9-Socket to a grounded 115 V plug and a 6 pin MS-connector. (Contains circuits 2, 4, 31, 32, 75, 76, 77 and ground)

K939-1 Docking Kit - For mounting the K930-2 TIG Module unit on top of the Ranger 8.

K1816-1 FULL KVA ADAPTER KIT - Plugs into the 120/240V NEMA 14-50R receptacle on the casefront (which accepts 4-prong plugs) and converts it to a NEMA 6-50R receptacle, (which accepts 3-prong plugs.)

C-2

ACCESSORIES

RECOMMENDED EQUIPMENT

STICK

K704 Accessory Kit which includes:

• Electrode Holder & Cable

• Work Clamp & Cable

• Headshield

K892-1 Remote Control Receptacle Kit and K857 Remote Control Kit are optional for remote current control.

TIG

Magnum™ TIG Torch Magnum Parts Kit and Argon Gas K930-2 TIG Module (requires K938-1 Contactor Kit) K939-3 Control Cable (see Optional Equipment)

Optional:

• K939-1 Docking Kit

• K963 Hand Amptrol®

• K870 Foot Amptrol

• K892-1 Remote Control Receptacle Kit

• K915-1 Adapter Cable

C-2

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. K892-1 Remote control Receptacle Kit and K444-1 Remote voltage Control Kit are required for voltage control at the feeder.

LN7-K240 Contactor Kit is required.

Magnum Gun is required for gas-shielded welding. Innershield Gun is required for gasless welding.

RANGER 8

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

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 maintenance 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.

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

Read the Safety Precautions in the front of this manual and the engine instruction manual before working on this machine.

CAUTION

Make certain that the oil filler cap is securely tightened 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:

Kohler

CH20S

Oil

Oil Filter

The above schedule is for normal operating conditions. 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.

• Air Cleaner - With normal operating conditions, the

maintenance schedule for cleaning and re-oiling the foam pre-filter is every 25 hours and replacement 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.

100 HRS

200 HRS

Onan

P216

50 HRS

100 HRS

Honda GX620

6 Months or

100 HRS

1 Year or 200 HRS

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, clothing, 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.

RANGER 8

• Blow out the machine with low pressure air periodically. 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 handle from maximum to minimum setting twice each morning before starting to weld.

D-2

MAINTENANCE

D-2

Engine Adjustments

OVERSPEED IS HAZARDOUS

WARNING

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.

CAUTION

Do not attempt to polish slip rings while engine is running.

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 battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

• 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.

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.

Engine Maintenance Parts

ONAN P216 KOHLER CH20S

ONAN 122-0645 KOHLER 1205001

Oil Filter FRAM PH3614 FRAM PH3614*

Air Filter ONAN 140-2628-01 KOHLER 4708303 Element FRAM CA140PL FRAM CA79

Air Filter ONAN 140-1496 KOHLER 2408302 Pre-Cleaner

Fuel Filter ONAN 149-2005 KOHLER 2505002

FRAM G1 FRAM G1

Spark Plugs ONAN 167-0263 CHAMPION RC12YC (Resistor CHAMPION RS14YC (.030” GAP)

Type) (.025” GAP)

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

RANGER 8

HONDA GX620

HONDA 15400-PR3-004

(HONDA CODE 3179553)

FRAM PH6811

HONDA 17211-ZJ1-000

(HONDA CODE 4209672)

HONDA 17218-ZJ1-000

(HONDA CODE 4209706)

HONDA 16910-ZE8-005

(HONDA CODE 2106235)

NKG BPR6ES

Nippondenso W20EPR-U

.O3O in., (76mm) gap

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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.

__________________________________________________________________________

E-1

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 (SYMPTOMS)”. 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.

CAUTION

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.

RANGER 8

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF MISADJUSTMENTS(S)

E-2

RECOMMENDED

COURSE OF ACTION

No welder or output power.

Engine will not idle down to low speed.

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.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

Engine will not go to high idle when attempting to weld.

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.

CAUTION

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.

RANGER 8

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF MISADJUSTMENTS(S)

E-3

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.

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.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

Engine does not develop full power.

Engine is hard to start.

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.

CAUTION

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.

RANGER 8

F-1

DIAGRAMS

F-1

CCW

OUTPUT

254

GROUND SCREW

CONTROL

75A

76A

77A

254

254A

CHOKE

AT BLOWER BAFFLE

PCB1

TURNS 3

SENSOR

CURRENT

254A

WORK

75 5E 76

ELECTRODE

GND-E

GND-G

215 224

216

201A

219

200B

REACTOR

GND-C

9 3

STATOR

GND-D

4 3

2 1

GND-E

77A

76A

75A

200B

GND-D

ENGINE FOOT

200

FIELD C1

CAPACITOR

200A

115 V

GND-G

219

201

ENGINE

CROSS

ROTOR

201A

115V/230V

SUPPORT

SLIP RING NEAREST LAMINATION

115 V

GND-C

SILVER

COLORED

(WHITE WIRES)

TERMINALS

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

2 3

CONNECTOR PIN NUMBERS:

7-19-96G

M18331

215

213

IDLER

BUTTON

216

213

216A

SOLENOID

HOUR

224B

IN "AUTO"

POSITION

"S4" SHOWN

METER

224

224A

212

209

AM1

208

K1418-1 Code 10373 & 10535 RANGER 8 ONAN - Wiring Diagram

208A

"S3" SHOWN IN

RUN POSITION

START

208B

212

224C

BATTERY

12 VOLT

208

GND-H

SWITCH

OIL PRESSURE

224A

TERMINAL BLOCK

216A

(SEE CONN.)

STARTER

REGULATOR

PLUGS

SPARK

STARTER

CR1

SOLENOID

B-

ACB+

IGNITION

CONTROL

209

CAPACITOR

FLYWHEEL ALTERNATOR

WELDER LEAD END

(NOTE CAVITY NUMBERS)

ENGINE COMPONENTS

224A&C (CAVITY #4)

LOCATING TAB

208 (CAVITY #3)

RANGER 8

224C (CAVITY #2)

CONNECTION

TERMINAL BLOCK

212 (CAVITY #1)

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..

F-2

WORK

START

BUTTON

216

213

77 75 5E 76

215 224

216

ELECTRODE

GND-E

GND-G

213

IDLER

"S4" SHOWN

201A

219

200B

REACTOR

GND-C

215

SOLENOID

HOUR

224B

IN "AUTO"

POSITION

STATOR

METER

PCB1

75A

OUTPUT

CONTROL

CHOKE

76A

77A

TURNS 3

254

SENSOR

CURRENT

254A

CCW

254

254A

GROUND SCREW

AT BLOWER BAFFLE

209

(LPG VERSION ONLY)

GROUND LEAD

SHUT OFF SOLENOID

AM1

208

K1418-2 Code 10374 & 10536 RANGER 8 ONAN (CSA VERSION) - Wiring Diagram

208A

208B

212

DIAGRAMS

4 3

77A

76A

75A

GND-E

GND-D

224

224A

212

224C

GND-D

BATTERY

12 VOLT

208

200B

224A

CB5

115V

CB3

15A

GND-G

CB1

35A

GND-H

TERMINAL BLOCK

200

FIELD C1

CAPACITOR

200A

219

15A

ENGINE

FOOT

SWITCH

OIL PRESSURE

(SEE CONN.)

201

ENGINE

CROSS

216A

SPARK

ROTOR

201A

15A

CB6

115V/230V

GND-C

SUPPORT

STARTER

SOLENOID

B-

ACB+

REGULATOR

PLUGS

IGNITION

SLIP RING NEAREST LAMINATION

115V

CB4

15A

35A

CB2

(WHITE WIRES)

TERMINALS

SILVER

COLORED

209

CR1

FLYWHEEL ALTERNATOR

CONTROL

M18332

7-19-96G

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

2 3

CONNECTOR PIN NUMBERS:

224C (CAVITY #2)

224A&C (CAVITY #4)

WELDER LEAD END

(NOTE CAVITY NUMBERS)

CONNECTION

TERMINAL BLOCK

F-2

"S3" SHOWN IN

RUN POSITION

LOCATING TAB

ONLY)

SOLENOID

SHUT OFF

(LPG VERSION

CAPACITOR

ENGINE COMPONENTS

208 (CAVITY #3)

212 (CAVITY #1)

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..

RANGER 8

F-3

WORK

210

213

77 75

ELECTRODE

GND-E

GND-G

IDLER

IN "AUTO"

"S4" SHOWN

5E 76

215 224

201A

219

200B

REACTOR

2 W2

GND-C

SOLENOID

METER

HOUR

224A

224B

POSITION

STATOR

GND-D

215

224

PCB1

TURNS 3

254

SENSOR

CURRENT

254A

CCW

254

OUTPUT

CONTROL

75A

76A

77A

CHOKE

254A

GROUND SCREW

AT BLOWER BAFFLE

209A

211

AM1

K1419-1 Code 10375 & 10537 RANGER 8 KOHLER - Wiring Diagram

208A

IN "RUN"

POSITION

"S3" SHOWN

START

BUTTON

221

208B

DIAGRAMS

4 3

77A

76A

75A

GND-E

209

211

208

224A

GND-D

BATTERY

12 VOLT

209A

4 3 2 1

221

224C

TERMINAL BLOCK

B B

200B

115 V

GND-G

ENGINE

(SEE CONN.)

FIELD C1

FOOT

210

200

CAPACITOR

200A

219

201

GND-H

CR1

STARTER

SOLENOID

N.A.

201A

115V/230V

CROSS

ENGINE

REGULATOR

MODULE

IGNITION

ROTOR

SLIP RING NEAREST LAMINATION

115 V

GND-C

SILVER

COLORED

(WHITE WIRES)

FUEL

SOLENOID

SHUTOFF

B-

FLYWHEEL ALTERNATOR

TERMINALS

SUPPORT

STARTER

AC ACB+

224C (CAVITY #4)

GENERATOR LEAD END

(NOTE CAVITY NUMBERS)

LOCATING TAB

211 (CAVITY #3)

2 3

CONNECTOR PIN NUMBERS:

208 (CAVITY #2)

CONNECTION

TERMINAL BLOCK

221 (CAVITY #1)

F-3

7-19-96G

M18333

ELECTRICAL SYMBOLS PER E1537

OIL

RANGER 8

SWITCH

PRESSURE

ENGINE COMPONENTS

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

LEAD COLOR CODE:

R = RED

B = BLACK

W = WHITE

U = BLUE

V = VIOLET

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

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..

F-4

210

WORK

213

ELECTRODE

GND-E

GND-G

IDLER

IN "AUTO"

"S4" SHOWN

77 75 5E 76

215 224

201A

219

200B

REACTOR

GND-C

SOLENOID

METER

HOUR

224A

224B

POSITION

STATOR

GND-D

215

224

PCB1

TURNS 3

254

SENSOR

CURRENT

254A

CCW

254

OUTPUT

CONTROL

75A

76A

77A

CHOKE

254A

GROUND SCREW

AT BLOWER BAFFLE

209A

211

AM1

START

BUTTON

208A

K1419-2 Code 10376 & 10538 RANGER 8 KOHLER (CSA) - Wiring Diagram

IN "RUN"

POSITION

"S3" SHOWN

208B

221

DIAGRAMS

4 3

77A

76A

75A

9 3

GND-E

209

211

208

224A

GND-D

BATTERY

12 VOLT

209A

4 3 2 1

221

224C

(SEE CONN.)

TERMINAL BLOCK

B B B

200B

200

FIELD C1

CAPACITOR

200A

219

CB5

15A

115V

CB3

15A

GND-G

CB1

35A

ENGINE

FOOT

GND-H

CR1

210

201

STARTER

SOLENOID

N.A.

201A

115V/230V

ENGINE

CROSS

SUPPORT

REGULATOR

IGNITION

ROTOR

SLIP RING NEAREST LAMINATION

15A

CB6

STARTER

AC ACB+

MODULE

115V

CB4

15A

35A

CB2

GND-C

SILVER COLORED

FUEL

SOLENOID

SHUTOFF

B-

FLYWHEEL ALTERNATOR

TERMINALS

GENERATOR LEAD END

(NOTE CAVITY NUMBERS)

CONNECTOR PIN NUMBERS:

(WHITE WIRES)

208 (CAVITY #2)

224C (CAVITY #4)

LOCATING TAB

211 (CAVITY #3)

1 2 3

CONNECTION

TERMINAL BLOCK

221 (CAVITY #1)

F-4

7-19-96G

M18334

ELECTRICAL SYMBOLS PER E1537

RANGER 8

OIL

PRESSURE

SWITCH

ENGINE COMPONENTS

LEAD COLOR CODE:

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

R = RED

B = BLACK

W = WHITE

U = BLUE

V = VIOLET

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

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..

F-5

DIAGRAMS

F-5

RA (CSA) - WIRING DIAGRAMK2160-1 Code 10886 NGER 8 HONDA

CCW

254

OUTPUT

CONTROL

GROUND SCREW

IN "RUN"

"S3" SHOWN

76A 75A

77A

254

254A

CHOKE

AT BLOWER BAFFLE

209A

AM1

208C

BUTTON

START

208A

POSITION

221

77 75 5E 76

215 224

201A

219

200B

12 7

REACTOR

WORK

ELECTRODE

GND-E

GND-G

PCB1

3 T URNS

SENSOR

CURRENT

254A

4 3

77A

76A

75A

200B

STATOR

GND-E

GND-D

GND-C

GND-D

BATTERY

12 VOLT

209

215

224

209A

211B

4 3

211

208

221

224C

SEE DETAIL

224A

210

211B

IN LINE

4 AMP

CB7

25A

IDLER

SOLENOID

213

METERHOUR

224A

213

224B

210

POSITION

IN "AUTO"

"S4" SHOWN

211

208B

DIODE

115V

CB3

211C

211A

CONNECTION

224E

225A

15A

GND-G

CB1

224D

221A

208D

STA RTER

CB5

35A

ENGINE

FIELD

15A

FOOT

SOLENOID

210A

200

CAPACITOR

200A

219

ENGINE

GND-H

CR1

B/Y

B/R

N.A.

IGNITION

OIL

SWITCH

PRESSURE

201

CROSS

SUPPORT

FUEL

SHUTOFF

MODULE

W/U

208 (CAVITY #2)

224C (CAVITY #4)

ROTOR

(NOTE CAVITY NUMBERS)

GENERATOR LEAD END

SLIP RING NEAREST LAMINATION

CONNECTOR PIN NUMBERS:

211 (CAVITY #3)

201A

CB6

15A

115V

15A

CB4

CB2

35A

115V/230V

SOLENOID

GND-C

TERMINALS

(WHITE WIRES)

SILVER COLORED

212

STA RTER

6 5

MODULE

2 1

RECTIFIER/R EGULATOR

CONNECTION

TERMINAL BLOCK

LOCATING TAB

221 (CAVITY #1)

HONDA ENGINE COMPONENTS

20 AMP

CHARGE COIL

GY = GRAY

U = BLUE

R = RED OR PINK

B = BLACK OR GRAY

W = WHITE

LEAD COLOR CODE:

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

M19988

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

RANGER 8

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..

F-6

M17486

ELECTRODE CABLE

LN-25

WIRE FEEDER

REMOTE CONTROL

TO WORK

ELECTRODE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

TO WORK

WORK CLIP LEAD

TO WORK

6 PIN AMPHENOL

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.

RANGER 8 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM

CRM 21883

OPTIONAL K444-1

N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO THE WIRE FEED (CV) POSITION.

WARNING

Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.

Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment.

DIAGRAMS

F-6

CONNECTION OF RANGER 8 TO LN-7 & K240 CONTACTOR KIT

CONNECTION OF LN-7 & K240 CONTACTOR KIT WITH 115 VOLT AC AUXILIARY POWER AND CV OUTPUT

CONTROL CABLE

N.D.

ONNECT THE CONTROL CABLE

ROUND LEAD TO THE FRAME ERMINAL MARKED NEAR HE TERMINAL STRIP OR TO N UNPAINTED FRAME SCREW.

N.F. & N.G.

ER STANDARD OUTPUT TERMINALS

WARNING: Turn the power off when making connections.

N.A. Use power source polarity switch to set for desired elec-

trode polarity. Position the output selector switch on the

N.J.

power source to the CV position.

N.B. 3 conductor #16 power cord physically suitable for the

installation and plug rated at 115 volts 15 amperes AC.

N.C. Plug into 115 volt AC receptacle on welder control panel or

other 115 volt AC supply rated at a minimum of 500 voltamperes.

N.D. Leads #21 and GND do not appear on LN-7’s with codes

below 7026.

N.E. Welding cables must be of proper capacity for the current

and duty cycle of immediate and future applications.

N.F. If LN-7 is equipped with a meter kit, extend lead #21 using

#14 or larger insulated wire physically suitable for the

N.C.

WORK

POWER SOURCE

ELECTRODE

GND. 32 2 4 31

N.B.

AUTO.

EQUIP.

installation. An S16586-”length” remote voltage sensing work lead may be ordered for this purpose. Connect it directly to the work piece independent of the welding work cable. For convenience, this extended #21 lead should be taped to the welding work lead.

N.G. Tape up bolted connection where lead #21 is extended.

N.H. Idler switch on power source must be in high idle position.

N.J. If an optional remote output control is used, connect it to

this terminal strip or 6 pin Amphenol receptacle. NOTE: Terminal strip or 6 pin Amphenol receptacle not available on all power sources.

CAUTION: Any speed up of the engine RPM by changing the

governor setting or over-riding the throttle linkage will cause an increase in the AC auxiliary voltage. If this voltage goes above 140 volts, the LN-7 control circuit will be damaged. The engine governor setting is pre-set at the factory - do not adjust above RPM specifications listed in engine welder operating manual.

RANGER 8

POWER SOURCE

TO LN-7

K240 CONTACTOR KIT 115V (50/60HZ.) (NOTE : 600 AMP CAPACITY)

ELECTRODE CABLE TO LN-7

TO WORK

S17742 10-2-92

F-7

DIAGRAMS

42.00

F-7

M17215-2

1-30-98E

CENTER OF GRAVITY WITH OIL IN

ENGINE AND FULL FUEL TANK.

21.95

21.21

11.31

30.008.80 30.00

42.25

UNDERCARRIAGE MOUNTING HOLES

OF SHAFT

9.29

9.31

30.28

26.59

2.75

RANGER 8

FOR OIL FILTER

REMOVAL

9.099.09

19.11

17.00

F-8

CENTER OF GRAVITY WITH OIL IN

ENGINE AND FULL FUEL TANK.

22.15

21.21

DIAGRAMS

30.00

8.80

42.00

42.25

F-8

M17215-3

1-30-98E

UNDERCARRIAGE MOUNTING HOLES

OF SHAFT

9.299.31

10.33

30.28

26.59

9.09

2.75

RANGER 8

17.00

FOR OIL FILTER

REMOVAL

NOTES

RANGER 8

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(JFLF-515)

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WARNING

Spanish

AVISO DE

PRECAUCION

● 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 mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● 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 molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● 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.

● 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 öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● 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.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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.

• World's Leader in Welding and Cutting Products •

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric RANGER 8 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual