Lincoln Electric SVM107-B User Manual
SVM107-B
July, 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.
SERVICE MANUAL
For use with machine code numbers: 9972 thru 10886
RANGER 8
TM
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
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SAFETY
i i
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 weld-
ing 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.
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
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SAFETY
ii 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
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SAFETY
iii iii
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.
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.
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SAFETY
iv 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” CSAStandard
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
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v v
RANGER 8
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual................................................................................................................................P-229
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TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1 Section A-1
RANGER 8
Installation
Technical Specifications .............................................................................................................A-2
AC Stick/TIG (cc) Output ............................................................................................................A-3
DC Stick/TIG (cc) Output............................................................................................................A-3
DC Wirefeed (cv) Output.............................................................................................................A-3
Installation Instructions ...............................................................................................................A-4
Safety Precautions......................................................................................................................A-4
Machine Grounding ....................................................................................................................A-4
Spark Arrestor.............................................................................................................................A-4
Trailers .........................................................................................................................................A-4
Pre-Operation Service ................................................................................................................A-5
Oil ... ...............................................................................................................................A-5
Fuel .................................................................................................................................A-5
Battery Connections.......................................................................................................A-5
Welding Output Cables...............................................................................................................A-5
Cable Lengths.............................................................................................................................A-5
Angle of Operation......................................................................................................................A-6
High Altitude Operation ..............................................................................................................A-6
Location/Ventilation ....................................................................................................................A-6
Connection of Wire Feeders ................................................................................................A-6/A-7
Additional Safety Precautions.....................................................................................................A-7
Welder Operation ........................................................................................................................A-7
Auxiliary Power ...........................................................................................................................A-7
115V Duplex Receptacles...........................................................................................................A-8
Motor Starting.............................................................................................................................A-8
Electrical Devices used w/Ranger 8 ...........................................................................................A-9
Auxiliary Power While Welding .................................................................................................A-10
Stand-by Power Connections...................................................................................................A-10
Connection of Ranger 8 to Premises Wiring ............................................................................A-11
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INSTALLATION
A-2 A-2
RANGER 8
* Based on a 10 min. period.
TECHNICAL SPECIFICATIONS - Ranger 8 (K1418-3 CSA MEETS CANADIAN STD.)
(K1419-3 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 Single Receptacle (40 Amps at duplex outlets)
35 Amps @ 230V
PHYSICAL DIMENSIONS
Make/Model
Onan P220
(K1418-3)
Kohler CH20
(K1419-3)
Honda
GX620KI
(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.)
39.9(653)-Onan
38(624)-Kohler
37.5(614)-Honda
Capacities
Fuel:
9 Gal (34 L)
Lubricating Oil:
1.6 Qts (1.5 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
20.5 HP @
3600 RPM
(Onan)
20 HP @
3600 RPM
(Kohler)
20 HP @
3600 RPM
(Honda)
INSTALLATION
A-3 A-3
RANGER 8
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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
INSTALLATION
A-4 A-4
RANGER 8
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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
INSTALLATION
A-5 A-5
RANGER 8
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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 P220 - 1.6 Quarts (1.5 Liters)
Kohler CH20S - 2.0 Quarts (1.9 Liters)
Honda GX620KI-1.9 Quarts (1.6 Liters)
INSTALLATION
A-6 A-6
RANGER 8
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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
INSTALLATION
A-7 A-7
RANGER 8
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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 1 15/230
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 NEMA14-50R receptacle and two 20 amp 115 volt
NEMA 5-20R 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 40 amps
of 230 volt power to a two wire circuit, up to 40 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 column.
Ranger 8
Constant Current 225 Amps AC @ 25 Volts
210 Amps DC @ 25 Volts
Constant Voltage 200 Amps DC @ 20 Volts
CAUTION
INSTALLATION
A-8 A-8
RANGER 8
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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.
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.
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.
GND
115 V
115 V*
230 V
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
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INSTALLATION
A-9 A-9
RANGER 8
TABLE lll
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-
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.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required,
and liabilities still exist. DO
NOT USE THESE DEVICES
WITH A RANGER 8
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER 8.
INSTALLATION
A-10 A-10
RANGER 8
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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
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.
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.
WARNING
Auxiliary Power While Welding
Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
115V or 230V supply (not both at the same time). Also,
the “Output Control” is set at “10” for maximum auxiliary power.
TABLE I
SIMULTANEOUS WELDING AND POWER
Output Selector Permissible Power Permissible Auxiliary
Setting Watts (Unity Power Current in Amperes
Factor) @ 115V
*-or- @ 230V
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
* Each duplex receptacle is limited to 20 amps.
**Not to exceed 35A per 115VAC branch circuit when
splitting the 230 VAC output.
INSTALLATION
A-11 A-11
RANGER 8
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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.
230 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
230 VOLT
115 VOLT
115 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
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
Figure A.1
CONNECTION OF RANGER 8 TO PREMISES WIRING
WARNING
NOTES
A-12 A-12
RANGER 8
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Section B-1 Section B-1
RANGER 8
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
General Description ....................................................................................................................B-2
Other Features ............................................................................................................................B-2
Engine Options ...........................................................................................................................B-2
Approximate Fuel Consumption.................................................................................................B-3
Controls and Settings ................................................................................................................B-3
Engine Operation ........................................................................................................................B-4
Before Starting the Engine ..................................................................................................B-4
Starting the Engine ..............................................................................................................B-4
Stopping the Engine ............................................................................................................B-4
Break-in Period ....................................................................................................................B-4
Welding Process .........................................................................................................................B-5
Summary of Welding Processes.................................................................................................B-6
OPERATION
B-2 B-2
RANGER 8
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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).
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.
• 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 KVAAuxiliary 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
Three Engines are available for the Ranger 8 Welders;
the Onan P220, the Kohler 20 HP Command®* and the
Honda GX620KI. 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.
• Overhead Valves & Hydraulic Valve Lifters.
* These trademarks are the property of their respec-
tive manufacturers.
OPERATION
B-3 B-3
RANGER 8
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HONDA
20 H.P. GX620KI
.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)
Welder Controls - Function and Operation
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
Never change the “Polarity” switch setting while
welding. This will damage the switch.
“ Range” Switch
Never change the “RANGE” Switch setting while
welding. This will damage the switch.
“ 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.
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.
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
ONAN
20.5 H.P. P220
.6 Gallons/Hour
(2.3 Liters/Hour)
.8 Gallons/Hour
(3.0 Liters/Hour)
1.5 Gallons/Hour
(5.8 Liters/Hour)
1.6 Gallons/Hour
(6.1 Liters/Hour)
1.2 Gallons/Hour
(4.5Liters/Hour)
1.6Gallons/Hour
(6.1Liters/Hour)
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)
Ranger 8 Approximate Fuel Consumption
ON
OFF
Explanation of Symbols that Appear on this Equipment
Low Idle
High Idle
CAUTION
STICK/TIG - CC 50, 70, 90
6 Range Settings 125, 175, 210 DC/225 AC
WIRE FEED - CV
1 Range Setting 200
Process Maximum Current
on Each Setting
CAUTION
OPERATION
B-4 B-4
RANGER 8
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Starting/Shutdown Instructions
Starting the Engine
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).
After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.
Stopping the Engine
Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.
Stop the engine by placing the “Engine” switch in the
“OFF” position.
A fuel shut off valve is not required on the Ranger 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)).
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:
The oil filter is to be changed at the second oil change.
Refer to the Engine Owner’s Manual for more information.
• Do not touch electrically live parts
of electrode with skin or wet
clothing.
• Keep flammable material away.
• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.
• Keep your head out of the fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WARNING
Honda
GX620KI
First Month
or 20 HRS
Kohler
CH20S
5 HRS
Onan
P220
25 HRS
OPERATION
B-5 B-5
RANGER 8
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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
current
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.
When using the Ranger 8 for AC TIG welding of aluminum, the following settings and electrodes are
recommended:
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.
Wire Feed Welding Processes
(Constant Voltage)
The only Innershield
®
electrode recommended for use
with the Ranger 8 is NR®-21 1-MP. The electrode sizes
and welding ranges that can be used with the Ranger
8 are shown in the following table:
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
2
). The welding ranges
that can be used with the Ranger 8 are shown in the
following table:
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
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.035 80 - 110 75A to 120A
.045 70 - 130 120Ato 170A
.068 40 - 90 125A to 210A
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.030 80 - 110 75A to 120A
.035 70 - 130 120Ato 170A
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
OPERATION
B-6 B-6
RANGER 8
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Summary of Welding Processes
CONTROL ELECTRODE
CABLE IDLE WHEN NOT TO START
PROCESS USED MODE WELDING WELDING
STICK No AUTO Hot Touch electrode to work.
Welding starts immediately
and engine goes to high
idle.
TIG/K7930-1/K938-1, Y es 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
starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”.
WIRE FEED, LN-7 WITH Yes HIGH Cold Press gun trigger,
K240 CONTACTOR KIT contactor closes. Welding
starts immediately.
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TABLE OF CONTENTS
-ACCESSORIES-
Accessories
Optional Equipment....................................................................................................................C-2
Recommended Equipment.........................................................................................................C-3
Stick....... ..............................................................................................................................C-3
TIG........................................................................................................................................C-3
Wirefeed ...............................................................................................................................C-3
Section C-1 Section C-1
RANGER 8
ACCESSORIES
C-2 C-2
RANGER 8
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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.
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 -
For use with K933-1.
for
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 mov-
ing 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.
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.
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.
K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CON-
TROL - Portable control provides same dial range as the out-
put 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.
K1690-1 GFCI RECEPTACLE KIT -
Includes one UL
approved 120V ground fault circuit interrupter duplex type
receptacle with cover and installation instructions.
Replaces the factory installed 120V duplex receptacle.
Each receptacle of the GFCI Duplex is rated at 20 Amps,
the maximum total current from the GFCI Duplex is limited to the 20 Amps. Two kits are required.
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 K9381 Contactor Kit must be field installed in the TIG Module
when used with a Ranger 8. Additionally, the K936-3 control
cable is required if remote control is used. If remote control is
not used the K936-4 control cable is required.
K936-3 Remote Control Cable - Control cable for connecting 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 case front (which
accepts 4-prong plugs) and converts it to a NEMA 6-50R
receptacle, (which accepts 3-prong plugs.)
ACCESSORIES
C-3 C-3
RANGER 8
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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
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.
NOTES
C-4 C-4
RANGER 8
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Section D-1 Section D-1
RANGER 8
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Routine Maintenance..................................................................................................................D-2
Engine Maintenance.............................................................................................................D-2
Change the Oil ...............................................................................................................D-2
Engine Oil Refill Capacities............................................................................................D-2
Change the Oil Filter ......................................................................................................D-3
Engine Adjustments .............................................................................................................D-4
Slip Rings .............................................................................................................................D-4
Engine Maintenance Parts ...................................................................................................D-4
Major Component Locations ...............................................................................................D-5
MAINTENANCE
D-2 D-2
RANGER 8
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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.
------------------------------------------------------------
WARNING
Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, 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.
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:
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 fil-
ter are not changed according to the manufacturer’s
recommendation.
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
and complete draining.
• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in
and twist the drain valve counterclockwise. Pull the
valve out and drain the oil into a suitable container.
• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.
• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
•1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler
•1.5 US qt. (1.2 Imp qt., 1.4 liter)-Onan P220 OHV
•1.59 US qt.{1.3 Imp qt., 1.5 litre}-Honda LX620KI
With oil filter replacement:
•2.0 US qt. (1.7 Imp qt., 1.9 liter) -Kohler
•1.65 US qt. (1.4 Imp qt., 1.6 liter)-Onan P220 OHV
•1.90 US qt. {1.58 Imp qt.., 1.8 litre} Honda GX620KI
Honda
GX620KI
6 Months or
100 HRS
1 Year or
200 HRS
CAUTION
Oil
Oil Filter
Kohler
CH20S
100 HRS
200 HRS
Onan
P220
50 HRS
100 HRS
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