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SVM107-B
July, 2002
TM
RANGER 8
For use with machine code numbers: 9972 thru 10886
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
ARC RAYS can burn.
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.
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.
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.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.
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.
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.
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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
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.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
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.
•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.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
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.
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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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iv
iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
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.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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.
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 met-
allique 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 defonc-
tionnement.
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.
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 soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX
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
RANGER 8
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Section A-1
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
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
RANGER 8
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A-2
A-2
INSTALLATION
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
Horsepower
Make/Model
Description
Speed (RPM)
Displacement
Capacities
cu. in. (cu. cm.)
Fuel:
9 Gal (34 L)
Lubricating Oil:
1.6 Qts (1.5 L)
Onan P220
(K1418-3)
20.5 HP @
3600 RPM
(Onan)
39.9(653)-Onan
2 cylinder
4 Cycle
High Idle 3700
Air-Cooled
Gasoline
Engine.
Fuel:
Kohler CH20
(K1419-3)
20 HP @
3600 RPM
(Kohler)
9 Gal (34 L)
Lubricating Oil:
2.0 Qts (1.9 L)
Full Load 3500
Low Idle 2200
38(624)-Kohler
Aluminum Alloy
with Cast Iron
Liners, Electrical
Ignition
Fuel:
Honda
20 HP @
3600 RPM
(Honda)
9 Gal (34 L)
Lubricating Oil:
1.9 Qts (1.8 L)
37.5(614)-Honda
GX620KI
(K2160-1)
RATED OUTPUT - WELDER
Welding Output *
AC Constant Current 225A / 25V / 100%
DC Constant Current 210A / 25V / 100%
DC Constant Voltage 200A / 20V / 100%
OUTPUT - GENERATOR
Auxiliary Power
8,000 Watts, 60 Hz AC
70 Amps @ 115V Single Receptacle (40 Amps at duplex outlets)
35 Amps @ 230V
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
30.3 in.
770 mm
19.2 in.
488 mm
42.3 in.
1074 mm
529 lbs. (240kg.) K1418-1,-2
511 lbs. (232kg.) K1419-1,-2 &
K2160-1
* Based on a 10 min. period.
RANGER 8
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A-3
A-3
INSTALLATION
AC STICK / TIG (CC) OUTPUT
SPECIFICATIONS
80
A 225 OUTPUT RANGE
B 50 OUTPUT RANGE
70
60
50
40
30
20
10
0
B
A
0
50
100
150
200
250
OUTPUT AMPS
DC STICK / TIG (CC) OUTPUT
80
70
60
50
40
30
A 210 OUTPUT RANGE
B 50 OUTPUT RANGE
20
10
0
A
B
0
200
OUTPUT AMPS
DC WIRE FEED (CV) OUTPUT
250
300
50
100 150
350
40
35
30
25
20
15
10
5
CV OUTPUT RANGE
0
0
200
50
100 150
250 300 350
OUTPUT AMPS
RANGER 8
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A-4
A-4
INSTALLATION
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 enti-
tled “Standby Power Connections”, as well as the arti-
cle on grounding in the latest U.S. National Electrical
Code and the local code.
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.
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
------------------------------------------------------------------------
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.
stud marked with the symbol
front of the welder.
is provided on the
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
Spark Arrester
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
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.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
CAUTION
Machine Grounding
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
Because this portable engine driven welder or genera-
tor creates it’s own power, it is not necessary to con-
nect it’s frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).
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.
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
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 dam-
age the welding equipment.
• be double insulated.
RANGER 8
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A-5
A-5
INSTALLATION
Some of the factors to be considered are as follows:
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 dis-
charged and does not have enough power to start the
engine, see the battery charging instructions in the
Battery section.
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.
Welding Output Cables
Pre-Operation Service
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces-
sary. Loose connections will result in overheating of
the output studs.
CAUTION
READ the engine operating and maintenance instruc-
tions supplied with this machine.
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.
WARNING
fuel can cause fire or
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
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
before starting engine.
------------------------------------------------------------------------
225 Amps
225 Amps
40% Duty Cycle 100% Duty Cycle
0-50 Ft.
3 AWG
3 AWG
2 AWG
1 AWG
1/0 AWG
1 AWG
1 AWG
1 AWG
1 AWG
1/0 AWG
Oil
50-100 Ft.
100-150 Ft.
150-200 Ft.
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.
200-250 Ft.
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)
Fuel
Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.
RANGER 8
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A-6
A-6
INSTALLATION
Angle of Operation
Location / Ventilation
The welder should be located to provide an unrestrict-
ed 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.
Internal combustion engines are designed to run in a
level condition which is where the optimum perfor-
mance 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 maintain-
ing the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.
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.
When operating at an angle, the effective fuel capaci-
ty will be slightly less than the specified 10 gallons.
High Altitude Operation
If the Ranger 8 will be consistently operated at alti-
tudes 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.
Connection of Lincoln Electric
Wire Feeders
WARNING
Shut off welder before making any electrical
connections.
CAUTION
Do not operate a Ranger 8 with a high altitude jet
installed at altitudes below 5000 ft. This will result
in the engine running too lean and result in higher
engine operating temperatures which can shorten
engine life.
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.
Contact your local Onan, Kohler or Honda Authorized
Dealer for high altitude jet kits that are available from
the engine manufacturer.
•
•
•
Position the welder “Polarity” switch to the desired
polarity, either DC (-) or DC (+).
WARNING
Position the “RANGE” switch to the “WIRE FEED”
position.
Muffler Relocation Shut off welder and allow
muffler to cool before touching muffler.
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.
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.)
•
•
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
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A-7
A-7
INSTALLATION
Connection of the LN-7 to the Ranger 8
Welder Operation
•
•
Shut the welder off.
Welder Output
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).
• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.
• Duty Cycle: 100% for both welding and auxiliary
power.
•
•
•
Place the “RANGE” switch to the “WIRE FEED”
position and the “POLARITY” switch to the
desired polarity.
Ranger 8
Place the “IDLER” switch in the “HIGH” idle
position. The engine idling device may not
function when welding in the “WIRE FEED” mode.
Constant Current
225 Amps AC @ 25 Volts
210 Amps DC @ 25 Volts
Constant Voltage
200 Amps DC @ 20 Volts
Adjust wire feed speed at the LN-7 and adjust the
welding voltage with the output “CONTROL” at
the welder.
Auxiliary Power
NOTE: If the output “CONTROL” is set below “3” the
K240 contactor may not pull in.
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.
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 equip-
ment, the bypass capacitor must be installed - order kit
T12246.
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.
INSTRUCTIONS
Additional Safety Precautions
115/230 Volt Dual Voltage Receptacle
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.
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 cir-
cuit (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.
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.
RANGER 8
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A-8
A-8
INSTALLATION
Motor Starting
GND
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.
115 V
230 V
115 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.
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.
RANGER 8
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A-9
A-9
INSTALLATION
TABLE lll
ELECTRICAL DEVICE USE WITH THE RANGER 8.
Type
Common Electrical Devices
Possible Concerns
Resistive
Heaters, toasters, incandescent
light bulbs, electric range, hot
pan, skillet, coffee maker.
NONE
Capacitive
TV sets, radios, microwaves,
appliances with electrical control.
Voltage spikes or high voltage
regulation can cause the capac-
itative elements to fail. Surge
protection, transient protection,
and additional loading is recom-
mended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE
TYPE LOADS.
Inductive
Single-phase induction motors,
drills, well pumps, grinders, small
refrigerators, weed and hedge
trimmers
These devices require large
current inrush for starting.
Some synchronous motors may
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,
complicated electrical equipment.
An inductive type line condition-
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 connect-
ed to the RANGER 8.
RANGER 8
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A-10
A-10
INSTALLATION
1. Install a double pole, double throw switch between
the power company meter and the premises
disconnect.
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 auxil-
iary power.
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.
TABLE I
SIMULTANEOUS WELDING AND POWER
Output Selector
Setting
Permissible Power
Watts (Unity Power
Factor)
Permissible Auxiliary
Current in Amperes
@ 115V *-or- @ 230V
Max. Stick or Wire
Feed Setting
None
2100
3800
0
0
9
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.)
175 Stick Setting
125 Stick Setting
18
32
16
90 Stick Setting
70 Stick Setting
50 Stick Setting
NO WELDING
5000
5600
6300
8000
42**
48**
54**
70**
21
24
27
35
4. Plug this cable into the 50 amp 115/230V
receptacle on the Ranger 8 case front.
* Each duplex receptacle is limited to 20 amps.
**Not to exceed 35A per 115VAC branch circuit when
splitting the 230 VAC output.
Standby Power Connections
The Ranger 8 is suitable for temporary, standby, or
emergency power using the engine manufacturer’s rec-
ommended maintenance schedule.
The Ranger 8 can be permanently installed as a stand-
by power unit for 230V-3 wire, single phase 35 ampere
service.
WARNING
(Connections must be made by a licensed electri-
cian 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.)
RANGER 8
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A-11
A-11
INSTALLATION
Figure A.1
CONNECTION OF RANGER 8 TO PREMISES WIRING
230 VOLT
GROUNDED CONDUCTOR
POWER
COMPANY
METER
230 Volt
115 VOLT
60 Hz.
3-Wire
Service
115 VOLT
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GROUND
35AMP
230 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
50 AMP, 115/230
VOLT PLUG
NEMA TYPE 14-50
230 VOLT
GND
N
50 AMP, 115/230 VOLT
RECEPTACLE
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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
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A-12
A-12
NOTES
RANGER 8
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Section B-1
Section B-1
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
RANGER 8
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B-2
B-2
OPERATION
• K930-1 TIG Module Available.
GENERAL DESCRIPTION
The Ranger™8 is a twin-cylinder, gasoline driven, mul-
tiprocess arc welder and AC power generator. It is built
in a heavy gauge steel case for durability on the job
site.
• 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.
DESIGN FEATURES
• Electric Starting.
AC/DC STICK WELDING (Constant Current)
• Battery Charging Ammeter.
• Full 8 KVA Auxiliary Output Receptacle.
• Factory Installed Engine Hour Meter.
• 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
• Engine Protection Shuts Engine Down in the
Event of Low Oil Pressure.
• Built-in Feet for Easy Mounting to Truck Bed or
Trailer.
DC SEMIAUTOMATIC WIRE FEED WELDING
(Constant Voltage)
• All Copper Alternator Windings and High
Quality Insulation for Long-Life and
Dependability.
• CV Tap Setting for 60-200 Amps.
• 100% Duty Cycle.
• Excellent Performance with .068” (1.7mm)
NR®-211-MP Innershield® Electrode.
• Powder Painted Case and Base for Outstanding
Corrosion Protection.
•
Limited MIG Welding with L-50 & L-56 using blended
Argon Shielding Gas.
• Quiet muffler with reversible exhaust feature; either
right or left side of machine.
• 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).
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:
AC/DC TIG WELDING (Constant Current)
• AC & DC TIG Welding Can be Done at All Constant
Current Output Range Settings.
• Air Cooled, Twin-Cylinder.
• Cast Aluminum Alloy Crankcase with Integral Cast
Iron Cylinder Liners.
AUXILIARY POWER
• 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.
• 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
* These trademarks are the property of their respec-
tive manufacturers.
• Bottom Mounted 9 Gallon Fuel Tank with a
Convenient Top Fill and Fuel Gauge.
• Polarity Switch for Selecting DC+, DC-, or AC
Welding Output.
RANGER 8
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B-3
B-3
OPERATION
Ranger 8 Approximate Fuel Consumption
ONAN
KOHLER
HONDA
20.5 H.P. P220
20 H.P. COMMAND
20 H.P. GX620KI
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
.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)
.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)
.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)
8000 Watts
“
Control” Switch
Welder Controls - Function and Operation
Explanation of Symbols that Appear on this Equipment
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.
Low Idle
OFF
ON
High Idle
ENGINE “ON-OFF” Switch
“IDLER” 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.
The idler switch has two positions, “HIGH” and
“AUTO”.
When in “HIGH” (
continuously at high idle.
) position, the engine will run
ENGINE “START” Push-Button Switch
When in “AUTO” (
operates as follows:
/
) idle position, the idler
Energizes engine starter motor.
“Polarity” Switch
•
Welding
CAUTION
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.
Never change the “Polarity” switch setting while
welding. This will damage the switch.
After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.
“
Range” Switch
Process
Maximum Current
on Each Setting
•
Auxiliary Power
STICK/TIG - CC
6 Range Settings
50, 70, 90
125, 175, 210 DC/225 AC
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.
WIRE FEED - CV
1 Range Setting
200
CAUTION
Never change the “RANGE” Switch setting while
welding. This will damage the switch.
RANGER 8
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B-4
B-4
OPERATION
Starting/Shutdown Instructions
Stopping the Engine
Starting 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.
WARNING
• Do not touch electrically live parts
of electrode with skin or wet
clothing.
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.
• Keep flammable material away.
Break-in Period
• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.
It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi-
mately 50 running hours)).
• Keep your head out of the fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
Be sure all Pre-Operation Maintenance has been per-
formed. Also, read the Engine Owner’s Manual.
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
Remove all loads connected to the AC power recepta-
cles. To start the engine, set the “Idler Control” switch
in the Automatic (
/
) position.
Use the choke control as follows:
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 informa-
tion.
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.
Kohler
CH20S
Onan
P220
Honda
GX620KI
Honda Engine - Always pull the choke control out
when starting the engine; cold. Place the “Engine”
switch in the “ON” position.
5 HRS
25 HRS
First Month
or 20 HRS
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.
RANGER 8
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B-5
B-5
OPERATION
Welding Process
Stick (Constant Current) Welding
Wire Feed Welding Processes
(Constant Voltage)
® electrode recommended for use
The only Innershield
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.
with the Ranger 8 is NR®-211-MP. The electrode sizes
and welding ranges that can be used with the Ranger
8 are shown in the following table:
Diameter
(in.)
Wire Speed
Approximate
Range In./Min.
Current Range
.035
.045
.068
80 - 110
70 - 130
40 - 90
75A to 120A
120A to 170A
125A to 210A
The Ranger 8 can be used with a broad range of AC
and DC stick electrodes. See “Welding Tips 1” includ-
ed with the Ranger 8 for electrodes within the rating of
this unit and recommended welding currents of each.
The Ranger 8 is recommended for limited “MIG” weld-
ing (GMAW - gas metal arc welding). The recom-
mended electrodes are .030” and .035” L-50 and L-56.
They must be used with a blended shielding gas such
as C25 (75% Argon - 25% CO2). The welding ranges
TIG (Constant Current) Welding
that can be used with the Ranger 8 are shown in the
following table:
The K930-[ ] TIG Module installed on a Ranger 8 pro-
vides 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.
Diameter
(in.)
Wire Speed
Range In./Min.
Approximate
Current Range
.030
.035
80 - 110
70 - 130
75A to 120A
120A to 170A
When using the Ranger 8 for AC TIG welding of alu-
minum, the following settings and electrodes are
recommended:
SETTINGS FOR PURE TUNGSTEN
TUNGSTEN
DIAMETER (in.)
RANGE SWITCH
SETTINGS
APPROXIMATE
CURRENT RANGE
1/8
3/32
1/16
70, 90, or 125
50, 70, or 90
80 - 150 Amps
45 - 130 Amps
40 - 80 Amps
50, or
70
SETTINGS FOR 1% THORIATED TUNGSTEN
TUNGSTEN
DIAMETER (in.)
RANGE SWITCH
SETTINGS
APPROXIMATE
CURRENT RANGE
1/8
3/32
1/16
70, 90, 125, or 175
80 - 225 Amps
50 - 180 Amps
45 - 120 Amps
50, 70,
50,
90, or 125
70, or 90
The K930-[ ] TIG Module should be used with the
Ranger 8 on high idle to maintain satisfactory opera-
tion. 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
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B-6
B-6
OPERATION
Summary of Welding Processes
CONTROL
CABLE
USED
ELECTRODE
WHEN NOT
WELDING
IDLE
MODE
TO START
WELDING
PROCESS
STICK
No
AUTO
Hot
Touch electrode to work.
Welding starts immediately
and engine goes to high
idle.
TIG/K7930-1/K938-1,
K936-( ) /K892-1
(WITH AMPTROL)
Yes
No
HIGH
Cold
Cold
Press Amptrol, contactor
closes, welding
starts immediately.
WIRE FEED, LN-25 WITH
INTERNAL CONTACTOR
AUTO
Press gun trigger, LN-25
contactor closes. Welding
starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”.
WIRE FEED, LN-7 WITH
K240 CONTACTOR KIT
Yes
HIGH
Cold
Press gun trigger,
contactor closes. Welding
starts immediately.
RANGER 8
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Section C-1
Section C-1
TABLE OF CONTENTS
-ACCESSORIES-
Accessories
Optional Equipment....................................................................................................................C-2
Recommended Equipment.........................................................................................................C-3
Stick....... ..............................................................................................................................C-3
TIG........................................................................................................................................C-3
Wirefeed ...............................................................................................................................C-3
RANGER 8
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C-2
C-2
ACCESSORIES
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).
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:
K704 Accessory Kit - Includes 35 ft (10.7m) 2/0 AWG elec-
trode 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.
K957-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack
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.
K889-2 & -3 Two-Wheel Undercarriage - For moving
by hand. Overall Width 29 in (.74m) Both have pneu-
matic tires. Puncture proof tires included with K889-3.
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.
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.
K894-1 Spark Arrester Kit - Includes a heavy gauge steel,
approved spark arrester and clamp for easy mounting to muf-
fler exhaust pipe.
K933-1 Four Wheel Undercarriage - For Hand
Moving. Rear pneumatic tires, front molded wheels.
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 limit-
ed to the 20 Amps. Two kits are required.
K934-1 Cylinder Brackets - For use with K933-1. for
transporting either one LPG fuel cylinder or one weld-
ing gas cylinder.
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR-
RIAGE - For moving by hand at construction sites.
Heavy duty puncture resistant pneumatic tires.
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 K936-3 control
cable is required if remote control is used. If remote control is
not used the K936-4 control cable is required.
K1770-1 UNDERCARRIAGE (FACTORY) - For mov-
ing by hand on a smooth surface. One or two gas cylin-
ders 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.
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)
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.
K939-1 Docking Kit - For mounting the K930-2 TIG Module
unit on top of the Ranger 8.
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.
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.)
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
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C-3
C-3
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
WIRE FEED
K449 LN-25 - Includes internal contactor for across the
arc operation (no control cable). Provides “cold” elec-
trode until gun trigger is pressed. Includes gas sole-
noid. 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
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C-4
C-4
NOTES
RANGER 8
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Section D-1
Section D-1
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
RANGER 8
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D-2
D-2
MAINTENANCE
CAUTION
WARNING
Make certain that the oil filler cap is securely tight-
ened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when
necessary and replace them when the mainte-
nance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
• OIL - Maintenance schedule for changing the oil and
oil filter after break-in:
Kohler
CH20S
Onan
P220
Honda
GX620KI
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.
6 Months or
100 HRS
Oil
100 HRS 50 HRS
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
1 Year or
200 HRS
Oil Filter 200 HRS 100 HRS
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
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.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust outside.
NOTE: Engine life will be reduced if the oil and oil fil-
ter are not changed according to the manufacturer’s
recommendation.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
and complete draining.
------------------------------------------------------------------------
See additional warning information
throughout this operator’s manual and
the Engine manual as well.
------------------------------------------------------------
• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the flex-
ible 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.
Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, cloth-
ing, and tools away from gears, fans, and all other mov-
ing parts when starting, operating, or repairing the
equipment.
• 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:
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.
•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
RANGER 8
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D-3
D-3
MAINTENANCE
•
Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling
the foam pre-filter is every 25 hours and replace-
ment of the air cleaner filter every 100 hours. More
frequent servicing is required with dusty operating
conditions. Refer to the maintenance section of the
Engine Owner’s Manual for more information.
Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil con-
tainer to be sure it includes the letters SG or SH.
SAE 10W-30 is recommended for general, all-tempera-
ture use, -5 F to 104 F (-20 C to 40 C). For the Onan
engine, it is recommended that SAE 30 oil be used
above 82 F (27 C).
•
•
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.
See Engine Owner’s Manual for more specific informa-
tion on oil viscosity recommendations.
Blow out the machine with low pressure air peri-
odically. In particularly dirty locations, this may be
required once a week.
Wash your hands with soap and water after handling
used oil.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.
• 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.
Do not throw it in the trash, pour it on the ground or
down a drain.
OIL FILTER CHANGE
1. Drain the engine oil.
• Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.
• Clean the filter mounting base, and coat the gasket of
the new oil filter with clean engine oil.
• Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil filter
socket tool to tighten the filter an additional 1/2 to 7/8
turn.
• Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.
• Start the engine and check for oil filter leaks.
• Stop the engine, and check the oil level. If necessary,
add oil to the upper limit mark on the dipstick.
RANGER 8
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D-4
D-4
MAINTENANCE
Engine Adjustments
WARNING
GASES FROM BATTERY can explode.
OVERSPEED IS HAZARDOUS
• 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.
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.
• CONNECTING A BATTERY CHARGER - Remove bat-
tery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When rein-
stalling, connect negative cable last. Keep well venti-
lated.
• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.
BATTERY ACID CAN BURN EYES AND SKIN.
• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
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.
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.
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.
CAUTION
Do not attempt to polish slip rings while engine is
running.
Hardware
Both English and Metric fasteners are used in this
welder.
WARNING
Engine Maintenance Parts
ONAN P220
KOHLER CH20S
HONDA GX620KI
ONAN 122-0737
FRAM PH4967
KOHLER 1205001
FRAM PH3614*
HONDA 15400-PR3-004
(HONDA CODE 3179553)
FRAM PH6811
Oil Filter
Air Filter
Element
ONAN 187-6068
KOHLER 4708303
FRAM CA79
HONDA 17211-ZJ1-000
(HONDA CODE 4209672)
Air Filter
Pre-Cleaner
KOHLER 2408302
HONDA 17218-ZJ1-000
(HONDA CODE 4209706)
N/A
Fuel Filter
ONAN 187-6119
KOHLER 2505002
FRAM G1
HONDA 16910-ZE8-005
(HONDA CODE 2106235)
Spark Plugs
(Resistor
Type)
ONAN 187-6161
CHAMPION N9YC
(.025” GAP)
CHAMPION RC12YC
(.030” GAP)
NKG BPR6ES
Nippondenso W20EPR-U
.O3O in., (76mm) gap
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.
RANGER 8
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D-5
D-5
MAINTENANCE
FIGURE D.1 - MAJOR COMPONENT LOCATIONS
1. OUTPUT TERMINALS (LOCATION)
2. ENGINE CONTROLS
3. AUXILIARY POWER RECEPTACLES
4. OUTPUT CONTROL PANEL
5. OUTPUT BRIDGE/CHOKE/REACTOR
6. FUEL TANK FILL
7. GASOLINE ENGINE
8. ROTOR/STATOR ASSEMBLY
9. BATTERY
10. MACHINE BASE
11. P.C. BOARD COVER
7
6
5
8
9
4
10
3
11
1
2
RANGER 8
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D-6
D-6
NOTES
RANGER 8
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................Section E
Battery, Starter, Engine, Excitation, Rotor,
Stator, and Idler Solenoid...................................................................................................E-2
Rotor Field Feedback and Auxiliary Power...........................................................................E-3
Weld Winding, Reactor, and Range Switch...........................................................................E-4
Output Bridge, Choke, Polarity Switch, and Output Terminals.............................................E-5
RANGE
SWITCH
AC
ELECTRODE
TERMINAL
POLARITY
SWITCH
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
WORK
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
PRINTED
CIRCUT
BOARD
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
FIELD
BRIDGE
FIGURE E.1 – RANGER 8 BLOCK LOGIC DIAGRAM
RANGER 8
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID
RANGE
SWITCH
AC
ELECTRODE
TERMINAL
POLARITY
SWITCH
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
WORK
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
PRINTED
CIRCUT
BOARD
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
FIELD
BRIDGE
winding and the field feedback winding. The field
feedback winding provides rotor current during
machine operation. The output of the RANGER 8 is
dependent on two criteria: the engine RPM and the
amount of current in the rotor winding.
BATTERY, STARTER, ENGINE,
ROTOR, STATOR, AND IDLER
SOLENOID
The 12VDC battery powers the starter motor. When
the engine is started and running, the battery circuit
voltage is fed, through the printed circuit board, to the
rotating field coil in the rotor via a brush and slip ring
configuration. This excitation (“flashing”) voltage mag-
netizes the rotor lamination. The rotor is mechanically
coupled to the engine. This rotating magnet induces a
voltage in the stationary windings of the main alterna-
tor (stator). Three separate and isolated windings are
incorporated in the stator lamination assembly. Each
winding set has a different number of turns producing
different magnitudes of AC output voltages. The three
windings are the weld winding, the auxiliary power
The flywheel alternator, located on the engine, supplies
“charging” current for the battery circuit. The battery
circuit provides power for the printed circuit board and
also for the idler solenoid. The idler solenoid is
mechanically connected to the engine throttle linkage.
If no current is being drawn from the RANGER 8, the
printed circuit board activates the idler solenoid, which
then brings the engine to a low idle state. When out-
put current is sensed, either weld or auxiliary, the print-
ed circuit board deactivates the idler solenoid, and the
engine returns to high RPM.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
RANGER 8
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER
RANGE
SWITCH
AC
ELECTRODE
TERMINAL
POLARITY
SWITCH
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
WORK
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
PRINTED
CIRCUT
BOARD
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
FIELD
BRIDGE
ROTOR FIELD FEEDBACK AND
AUXILIARY POWER
When full field voltage is applied to the rotor and the
engine is running at high speed (3700 RPM), a 230 AC
voltage is developed in the stator auxiliary winding.
This winding is tapped to provide 115 VAC. The two
voltages, (115 VAC and 230 VAC), are connected to
the appropriate receptacles and offer 8000 watts (total)
of AC power.
The AC voltage developed in the field winding is fed to
the full wave field bridge. The DC output of the bridge
is filtered by the field capacitor and controlled by the
printed circuit board according to the output control
setting. This filtered and controlled voltage is fed to
the rotor winding via the brush and slip ring configura-
tion. As the feedback voltage is increased or de-
creased, the outputs of the weld and auxiliary windings
are increased or decreased.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
RANGER 8
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH
RANGE
SWITCH
AC
ELECTRODE
TERMINAL
POLARITY
SWITCH
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
WORK
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
PRINTED
CIRCUT
BOARD
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
FIELD
BRIDGE
WELD WINDING, REACTOR, AND
RANGE SWITCH
The stator weld winding is connected to the reactor
and range switch. The inductance in the reactor offers
an impedance to current flow. The reactor coil is
tapped at various points. As the range switch is ro-
tated, different amounts of reactor coil are brought into
the current path. As more turns of reactor are brought
into the circuit, the more impedance there is to current
flow. Simply stated, the more reactor in the circuit, the
lower the welding current.
If a constant voltage is desired for wire feeding, then
the reactor is bypassed and the range switch is con-
nected to a tap on the stator weld winding to provide
a lower but “stiffer” output voltage.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
RANGER 8
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS
RANGE
SWITCH
AC
ELECTRODE
TERMINAL
POLARITY
SWITCH
CHOKE
OUTPUT
BRIDGE
AC
REACTOR
WORK
TERMINAL
STATOR
ROTOR
STATOR
MECHANICAL
ROTATION
ROTOR
SLIP
RINGS
STARTER
ENGINE
FLYWHEEL
ALTERNATOR
IDLER
SOLENOID
PRINTED
CIRCUT
BOARD
BATTERY
FIELD
CAPACITOR
115 & 230VAC
RECEPTACLES
OUTPUT
CONTROL
FIELD
BRIDGE
OUTPUT BRIDGE, CHOKE,
POLARITY SWITCH, AND OUTPUT
TERMINALS
The AC voltage developed in the stator weld winding
is delivered, through the reactor and range switch, to
the output bridge and polarity switch. Depending
upon the setting of the polarity switch, either AC volt-
age or DC voltage is delivered to the output terminals.
If AC output is selected, then the current path is from
the stator weld winding through the reactor, range
switch and polarity switch to the output terminals. If a
DC output is called for then the current path is through
the Output Bridge, where the AC voltage is rectified to
a DC voltage, and then to the choke, where the DC
output is filtered. The filtered DC current path is
through the Polarity Switch and on to the Output
Terminals.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
RANGER 8
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E-6
E-6
NOTES
RANGER 8
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Section F-1
Section F-1
TABLE OF CONTENTS
TROUBLE SHOOTING & REPAIR SECTION
Troubleshooting & Repair Section.................................................................................Section F
How to Use Troubleshooting Guide ......................................................................................F-2
PC Board Troubleshooting Procedures.................................................................................F-3
Troubleshooting Guide.................................................................................................F4 - F-13
Test Procedures
Rotor Voltage Test.........................................................................................................F-15
Rotor Resistance Test ...................................................................................................F-17
Auxiliary and Field Winding Test ...................................................................................F-21
Output Rectifier Bridge Test..........................................................................................F-25
Charging Circuit Test.....................................................................................................F-27
Engine Throttle Adjustment Test ...................................................................................F-29
Oscilloscope Waveforms.....................................................................................................F-33
Normal Open Circuit Voltage Waveform (115 VAC Supply)..........................................F-33
Typical DC Weld Output Waveform (CV Mode) – Machine Loaded..............................F-34
Typical DC Weld Output Waveform (CC Mode) – Machine Loaded .............................F-35
Typical AC Weld Output Waveform – Machine Loaded................................................F-36
Abnormal Open Circuit Weld Voltage Waveform (CV Mode, one diode open).............F-37
Abnormal Open Circuit DC Weld Voltage Waveform....................................................F-38
Normal Open Circuit Weld Voltage Waveform (CV Mode)............................................F-39
Normal Open Circuit DC Weld Voltage Waveform........................................................F-40
Normal Open Circuit AC Weld Voltage Waveform........................................................F-41
Replacement Procedures ....................................................................................................F-43
Brush Removal and Replacement ................................................................................F-43
Field Capacitor and Rectifier Bridge Removal and Replacement ................................F-47
Printed Circuit Board Removal and Replacement........................................................F-51
Output Rectifier Bridge Removal and Replacement.....................................................F-55
Engine Rotor Removal and Replacement (Kit S20788) ................................................F-59
Retest After Repair ..............................................................................................................F-64
RANGER 8
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only 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.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc-
tions. Simply follow the three-step procedure
listed below.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub-
ject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMP-
TOMS). This column describes possible symp-
toms that the machine may exhibit. Find the list-
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into three main categories: Output Problems,
Engine Problems, and Welding Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec-
trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con-
ducted without removing the case wrap-around
cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353 (WELD).
RANGER 8
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
equipment frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
Workstations
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical 1. Contact your local Lincoln 1. Contact The Lincoln Electric
Damage is Evident.
Authorized
Facility.
Field
Service
Service Dept. 1-800-833-9353
(WELD).
No weld output and no auxiliary 1. Check the brushes for wear and 1. Perform the Rotor Voltage Test.
power. Engine runs normally.
proper contact to the rotor slip
rings.
2. Check for the presence of
12VDC (at the pc board) from
lead #216 to frame ground. This
is the “flashing” voltage and is
present only when the Start,
Run, Stop switch S3 is in the
“Start” position. If the 12 VDC is
missing check the leads,
switches and connections asso-
ciated with the lead #216. See
Wiring Diagram.
Check for the presence of 12
VDC (at the pc board) from lead
#224 to frame ground. This is
the supply voltage to the board
and is present when the engine
is running and the S3 switch is
in the “Run” position. If the
12VDC is missing check the
leads, switches and connec-
tions associated with the lead
#224. See Wiring Diagram.
3. If Rotor Voltage Test is normal,
then
preform
the
Rotor
Resistance Test.
4. If the Rotor Voltage Test is NOT
normal, perform the Auxiliary
and Field Winding Voltage Test.
Then check the Field Diode
Bridge (D2) and the Field
Capacitor (C1). Replace if nec-
essary. If the Field Bridge and
Field Capacitor are good, then
the Printed Circuit Board may
be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No weld output, the auxiliary 1. Check the open circuit voltage 1. Disconnect lead W1 from the
power (230-115VAC) is operating
normally. Engine runs normally.
(OCV) at the welder output ter-
minals, engine at high idle (3650
RPM). Normal maximum is 73
to 80VAC. Normal DC maxi-
mum is 67 to 72VDC. If the
OCV is OK then proceed to
Step #2. If the OCV is not pre-
sent at the welder output termi-
nals, contact your local Lincoln
Output Bridge (D1) and check
for the presence of 80VAC from
lead W1 to lead W2 on the main
stator winding. See wiring dia-
gram. If the AC voltage is NOT
present, the winding in the sta-
tor may be faulty. Check the
winding for continuity and test
to be sure it is NOT grounded to
the stator iron. Replace if nec-
essary. If the correct AC volt-
age is present, proceed to step
#2.
Authorized
Facility.
Field
Service
2. Check the welding cables,
clamps and electrode holder for
loose or broken connections.
2. Check the Reactor, Range
Switch (S1) and associated
wires for loose or faulty connec-
tions. Check the reactor wind-
ing for continuity and test to be
sure it is NOT grounded to the
reactor iron.
3. Check the Choke (L1), Polarity
Switch (S2) and associated
wires for loose or faulty connec-
tions. Check the choke winding
for continuity and test to be
sure it is NOT grounded to the
choke iron.
4. Check the weld output termi-
nals and associated wires for
loose or faulty connections.
5. Perform the Output Bridge Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No auxiliary power, welding output 1. If machine is equipped with cir- 1. Check the auxiliary power
is normal. Engine runs normally.
cuit breakers, check circuit
breakers CB1 thru CB5. Reset
if tripped.
receptacles and associated
wires for loose or faulty connec-
tions.
2. Make sure the Output Control 2. Perform the Auxiliary and Field
(R1) is set at the maximum
position.
Winding Voltage Test.
3. If machine is equipped with cir-
cuit breakers, check for faulty
breakers and loose or faulty
connections on associated
wiring.
3. Check for loose or faulty plug(s)
at the power receptacle(s).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine has low welding output 1. The brushes may be worn. 1. If the engine HIGH IDLE RPM is
and low auxiliary output.
Contact your local Lincoln
Authorized Service Facility.
low, then perform The Throttle
Adjustment Test.
2. The engine RPM may be low.
2. Perform the Rotor Voltage Test.
3. If the rotor voltage is low the
Field Capacitor (C1) or the Field
Bridge (D2) may be faulty. Test
and replace if necessary.
4. Check the Output Control
Potentiometer. Normal resis-
tance is 10,000 ohms. Also
check associated wiring for
loose or faulty connections.
5. The Rotor may be faulty.
Perform the Rotor Resistance
Test.
6. The Printed Circuit Board may
be faulty. Replace.
7. If the engine HIGH IDLE RPM is
OK, then the engine may have
lost horsepower and be in need
of major repair.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
No DC welding output. AC welding 1. Make sure the Polarity Switch is 1. Perform the Output Bridge Test.
output and auxiliary power is nor-
mal.
in the proper position and is
“seated” correctly.
2. Check the Choke (L1), the
Polarity Switch (S2) and associ-
ated wires for loose or faulty
connections. Check the choke
winding for continuity and test
to be sure it is NOT grounded
the choke iron.
2. Make sure the electrode and
polarity are correct for the
process being used.
No AC welding output. DC welding 1. Make sure the Polarity Switch is 1. Check the operation of the
output and auxiliary power is nor-
mal.
in the proper position and is
“seated” correctly.
Polarity Switch (S2). Also check
the associated wires for loose
or faulty connections.
Wiring Diagram.
See
2. Make sure the electrode is cor-
rect for the process being used.
2. Check for continuity from lead
“S2” to lead “E” located in the
main stator. See Wiring Dia-
gram.
3. Make sure the welding cables
are not coiled or too long.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-9
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No constant voltage (CV) welding 1. Make sure the Range Switch 1. Check the operation of the
output. Constant current (CC) and
the auxiliary power are operating
normally.
(S1) is in the proper position
(CV) and “seated” correctly.
Range Switch (S1) and check
the associated wires for loose
or faulty connections. See
Wiring Diagram.
2. Make sure the wire feeder is
connected correctly.
2. Check for continuity from lead
C1 to lead W1 located in the
main stator. See Wiring Dia-
gram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-10
F-10
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
ENGINE PROBLEMS
Engine will not idle down to low
speed. Machine has normal weld
output and auxiliary power.
1. Make sure the Idler Switch (S4) 1. With the Idler Switch (S4) in the
is in the “Auto” position.
“Auto” position, check for the
presence of 12VDC at leads
#213 to #215 located at the
Idler Solenoid. If 12VDC is pre-
sent and the Idler Solenoid is
not activating, then the solenoid
may be faulty or there is a
mechanical restriction prevent-
ing it from functioning.
2. Make sure there is NOT an
external load on the weld termi-
nals nor the auxiliary power
receptacles.
2. If there is NOT 12VDC at leads
#213 to #215, then test for
12VDC from lead #213 to
ground (lead #5). See Wiring
Diagram. If 12VDC is present,
then check lead #215 for conti-
nuity (zero ohms) from the Idler
Solenoid to the Printed Circuit
Board plug 3J1. If lead #215 is
OK, then the Printed Circuit
Board may be faulty. Replace.
3. If there is NOT 12VDC from lead
#213 to ground (lead #5), then
check the Idler Switch (S4) for
proper operation and as-
sociated wires for loose or
faulty connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-11
F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
Engine will not go to high idle when 1. Make sure the welding cables 1. Check for broken or faulty con-
attempting to weld. Welding out-
put is normal when Idler Switch is
in “HIGH” position. Automatic idle
function works properly when the
auxiliary power is loaded.
and connections are tight.
nections in the sensing leads
(#254 and #254A). Make sure
their connections are tight at
the Electrode Output Terminal
and also at the Polarity Switch.
See Wiring Diagram.
2. Make sure the leads are looped
three times through the current
sensor on the Printed Circuit
Board.
Engine will not go to high idle when 1. MaKe sure the welding cables 1. Check for broken or faulty con-
attempting to weld or when the
auxiliary power is loaded. Welding
output and auxiliary power output
is normal when Idler Switch is in
the “HIGH” position.
and connections are tight.
nections in the sensing leads.
(#254 and #254A). Make sure
their connections are tight at
the Electrode Terminal and also
at the Polarity Switch. See
wiring diagram.
2. Automatic idler may not func-
tion if the auxiliary power is
loaded to less than 150 Watts.
2. Check lead #3, making sure it is
looped through the current sen-
sor on the Printed Circuit Board.
3. The Printed Circuit Board may
be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-12
F-12
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
ENGINE PROBLEMS
Engine will not crank or cranks very 1. Check for loose or faulty battery 1. If the battery is replaced or
slow.
cable connections.
tests good, then the charging
circuit may be faulty. Perform
the Charging Circuit Test.
2. The battery may be faulty.
3. Check the ammeter to see if the
battery is charging. If not, the
charging circuit may be defec-
tive.
2. The starter motor or starter
solenoid may be faulty.
3. The Engine may be hard to
crank due to a mechanical fail-
ure in the engine.
The Engine shuts off.
1. The Engine may be low on or 1. The oil pressure switch may be
out of fuel. faulty. Replace if necessary.
2. The Oil level may be low. 2. The fuel shut off solenoid may
Check and fill to proper level.
be faulty (Kohler Engines only).
3. The fuel filter may be clogged.
Engine does not develop full 1. The fuel filter may be clogged. 1. Due to wear, the engine may be
power.
Replace if necessary.
in need of repair.
2. The air filter may be clogged.
Replace if necessary.
3. The spark plug(s) may be faulty.
Replace if necessary.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-13
F-13
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is “cold.” Engine 1. Check for loose or faulty con- 1. Check for the correct open cir-
runs normally (3700 RPM no load).
Auxiliary power is functioning nor-
mally.
nections at the weld output ter-
minals and welding cable con-
nections.
cuit voltage (OCV) at the welder
output terminals (80VAC Max.
72VDC Max.). If the correct
voltage is present at the output
terminals, then check for loose
connections on the heavy cur-
rent carrying leads inside the
2. The welding cable may be too
long or coiled, causing an
excessive voltage drop.
RANGER 8.
Diagram.
See Wiring
2. If the OCV is low at the welder
output terminals, then Perform
The Engine Throttle Adjustment
Test.
3. Perform the Output Rectifier
Bridge Test.
4. Check for shorted or grounded
windings in the reactor and also
in the main stator. See Wiring
Diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353 (WELD).
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F-14
F-14
NOTES
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F-15
F-15
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct DC voltage is being applied to the rotor at maximum
engine speed (3700 RPM). This information will aid the technician in determining if the gen-
erator field is operating properly.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
This procedure takes approximately 30 minutes to perform.
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F-16
F-16
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST (continued)
FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST
Brushes
Slip Rings
Lead 200A
Lead 219
+
-
TEST PROCEDURE
1. With the 5/16” nut driver, remove the 6
9. Connect the negative meter probe to the
other brush (lead 219).
sheet metal screws from the case top.
2. Remove the rubber gasket (cover seal)
from the lift bail.
10. Start the engine and run it at high idle
(3650 RPM). Set the output control to the
MAXIMUM position (position 10).]
3. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
11. Check the voltage reading on the volt-
meter. It should read between 37 and 46
VDC.
4. Remove the case top, then reinstall the
fuel cap.
12. If the voltage reading is low or not pre-
sent, the generator field is not functioning
properly. Perform the Rotor Resistance
Test. The Field Diode Bridge (D2), the
Field Capacitor (C1), and/or the Printed
Circuit Board may be faulty.
5. With the 5/16” nut driver, remove the 5
screws holding the right case side.
6. Remove the right case side by lifting up
and out.
7. Set the volt/ohmmeter to the DC volts
position.
13. If the voltage reading is normal, the field
circuit is functioning properly. Install the
right case side with the 5 sheet metal
screws with the 5/16” nut driver. Remove
the fuel cap; install the case top and tight-
en the 6 sheet metal screws with the
5/16” nut driver. Install the rubber gasket
over the lift bail and install the fuel cap.
8. Connect the positive meter probe to the
brush nearest the rotor lamination (lead
200A). See Figure F.1 for location.
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F-17
F-17
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
This procedure takes approximately 30 minutes to perform.
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F-18
F-18
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE TEST (continued)
FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS
+
-
Lead 200A
Lead 219
TEST PROCEDURE
1. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
9. Isolate the rotor electrically by removing
the generator brush leads. Refer to
Figure F.2 as you perform the remaining
steps.
2. Remove the rubber gasket (cover seal)
from the lift bail.
10. Remove lead 219 from the negative
brush.
3. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
11. Remove lead 200A from the positive
brush.
4. Remove the case top, then replace the
fuel cap.
12. Measure the resistance across the rotor
slip rings.
5. With the 5/16” nut driver, remove the 5
screws holding the right case side.
A. Set the ohmmeter on the low scale
(X1).
6. Remove the right case side by lifting up
and out.
B. Place one meter probe on one of the
rotor slip rings. Place the other probe
on the other slip ring.
7. Conduct the test with the gasoline engine
OFF.
C. Check the resistance across the slip
rings. It should read between 4 and 5
ohms.
8. Remove the spark plug wires to prevent
accidental engine kickback or starting.
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F-19
F-19
TROUBLESHOOTING & REPAIR
13. Measure the resistance to ground.
A. Set the ohmmeter on the high scale
(X100,000).
B. Place one probe on either of the slip
rings. Place the other probe on any
good, unpainted ground. The
machine ground stud works well.
C. Check the resistance. It should read
very high, at least 0.5 megohm
(500,000 ohms).
If the test does not meet the resistance
specifications, then the rotor may be
faulty. Replace the rotor.
If the test does meet the resistance
specifications, then the rotor is okay.
14. Connect lead 200A to the positive
brush, which is the one nearest the rotor
lamination. Connect lead 219 to the
negative brush.
15. Reinstall the case side, case top, fuel
cap, lift bail gasket and spark plug wires.
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F-20
F-20
NOTES
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F-21
F-21
TROUBLESHOOTING & REPAIR
AUXILIARY AND FIELD WINDING TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct AC voltages are being generated from the stator
windings.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
This procedure takes approximately 30 minutes to perform.
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F-22
F-22
TROUBLESHOOTING & REPAIR
AUXILIARY AND FIELD WINDING TEST (continued)
FIGURE F.3 – LOCATION OF LEADS #3 AND #5
Machine
Case
Front
115V
Receptacle
Lead #3
Lead #5
TEST PROCEDURE
To test the 115 VAC winding:
To test the 230 VAC winding:
1. Remove the fuel cap and lift bail rubber
gasket. With the 5/16” nut driver, remove
the case top and left side; then reinstall the
fuel cap.
1. Remove the fuel cap and lift bail rubber
gasket. With the 5/16” nut driver, remove
the case top and left side; then reinstall
the fuel cap.
2. Connect the volt/ohmmeter probes to
leads #3 and #5 where they connect to the
115 VAC receptacle. See Figure F.3.
2. Connect the volt/ohmmeter probes to
leads #6 and #3 where they connect to the
230 VAC receptacle.
3. Start the engine and run it at high idle (3650
RPM).
NOTE: It is easier to insert the probes direct-
ly into the receptacle to perform this test.
However, the probes may not reach in far
enough to make or keep a good connection.
In this case, before you start the gasoline
engine, insert two test probes into the recep-
tacle. Hold the test probes firmly in place to
measure voltage (Step 5).
4. Set the output control to the maximum
position (position 10).
5. Check the AC voltage reading. It should be
approximately 125 VAC.
3. Start the engine and run it at high idle (3650
RPM)
4. Set the output control to the maximum
position (position 10).
5. Check the AC voltage reading. It should be
approximately 240 VAC.
RANGER 8
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F-23
F-23
TROUBLESHOOTING & REPAIR
AUXILIARY AND FIELD WINDING TEST (continued)
FIGURE F.4 - LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER
201
201A
7
_
AC
200
200A
200B
+
9
AC
7
201
201A
200
200A
200B
9
Field
Bridge
Rectifier
Retaining
Tab
Cable Tie
Capacitor
To test the field winding:
1. Remove the fuel cap and lift bail rubber
gasket. With the 5/16” nut driver, remove
the case top and left side; then reinstall
the fuel cap.
If the voltage readings are within specifica-
tions, then the windings are good and func-
tioning properly.
6. Reinstall the case side, case top, fuel cap,
and lift bail gasket.
2. Connect the volt/ohmmeter probes to leads
#7 and #9 where they connect to the Field
Bridge Rectifier. See Figure F.4.
3. Start the engine and run it at high idle (3650
RPM).
4. Set the output control to the maximum
position (position 10).
5. Check the AC voltage reading. It should be
between 36 and 43 VAC.
If any one or more of the readings are missing
or not within specifications, then check for
loose or broken wires between the test points
and the stator windings. See the Wiring
Diagram. Make sure the windings are NOT
grounded internally to the stator iron. If the
leads are intact, then the stator may be faulty.
Replace the stator.
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F-24
F-24
NOTES
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F-25
F-25
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if there are faulty diodes in the Output Rectifier Bridge.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
7/16” wrench or 7/16” socket wrench and 6” socket extension
Wiring Diagram
This procedure takes approximately 60 minutes to perform.
RANGER 8
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F-26
F-26
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE TEST (continued)
FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER LEADS
Ohmmeter Probes
Pigtail
+
Diode
-
Output rectifier
Bridge Assembly
Machine Front
TEST PROCEDURE
1. Remove the spark plug wires to prevent
accidental engine kickback or starting.
10. With the 7/16” wrench or socket wrench
and 6” extension, remove the nuts and
washers holding the diode bridge pigtails
and the heavy current-carrying leads to
the studs located in the middle of the rec-
tifier assembly. Note their locations and
the order of fasteners for reassembly.
2. WIth the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
11. Electrically isolate the diode pigtails by
bending them back into “free air.”
5. Remove the case top, then replace the
12. With an ohmmeter or diode tester, check
each of the four diodes from their pigtails
to their respective heat sinks. See Figure
F.5.
fuel cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
13. Reverse the tester leads and check the
diodes again. Diodes should have a low
resistance in one polarity and a very high
resistance in the opposite polarity.
7. Remove the right case side by lifting up and
out.
8. Conduct the test with the gasoline engine
OFF.
14. Replace any “shorted” or “open” diode as
the tests indicate.
9. Locate the Output Rectifier Bridge behind
the machine case front.
15. Reconnect the diode pigtails and heavy
leads to their respective studs.
16. Reinstall the case side, case top, fuel cap,
lift bail gasket and spark plug wires.
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F-27
F-27
TROUBLESHOOTING & REPAIR
CHARGING CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the Flywheel Alternator, Regulator, and associated circuitry are
functioning properly.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
This procedure takes approximately 20 minutes to perform.
RANGER 8
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F-28
F-28
TROUBLESHOOTING & REPAIR
CHARGING CIRCUIT TEST (continued)
FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR
Engine
Ground
Lead
(Green)
Voltage
Regulator
AC Lead
DC Lead
AC Lead
TEST PROCEDURE
1. Start the engine and run it at high idle
(3650 RPM).
5. If the DC voltage reading is incorrect or not
present, the voltage regulator may be
faulty. Replace the entire voltage regulator
module.
2. Set the voltmeter for AC volts and place
one meter probe on each of the two out-
side leads that attach to the engine voltage
regulator. See Figure F.6 for location.
Check for 42-52 VAC at the voltage regula-
tor.
6. If the DC voltage reading is correct, check
the associated wiring and circuitry. See
the Wiring Diagram.
3. If the AC voltage is low or not present, the
engine flywheel alternator may be faulty.
This is an engine problem; consult your
local engine repair facility.
4. If the voltage reading is correct, then check
the output of the voltage regulator to deter-
mine the charging voltage for the battery.
Run the engine at high idle (3650 RPM).
Set the voltmeter for DC volts and place
one meter probe on the middle lead and
one probe on the green ground wire con-
nected to the voltage regulator. See Figure
F.6 for location. Check for 13-15 VDC.
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F-29
F-29
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
If the machine output is low, this test will determine whether the gasoline engine is operating
at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjust-
ing the throttle to the correct RPM are given.
MATERIALS NEEDED
5/16” Nut driver
3/8” open end or box wrench
Strobe-tach, frequency counter, oscilloscope, or vibratach
Black or red marking pencil
This procedure takes approximately 35 minutes to perform.
RANGER 8
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F-30
F-30
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.7 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD
Blower Paddle
TEST PROCEDURE
This test can be conducted by any one of four
methods.
8. Connect the strobe-tach according the
manufacturer’s instructions.
Strobe-tach Method:
9. Reconnect the spark plug wires and start
the engine. Direct the strobe-tach light on
the blower paddle and synchronize it to
the rotating mark.
1. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
2. Remove the rubber gasket (cover seal) from
the lift bail.
10. With the machine at HIGH IDLE the tach
should read between 3650 and 3750 RPM.
3. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
With the machine at LOW IDLE the tach
should read between 2150 and 2250 RPM.
4. Remove the case top, then replace the
fuel cap.
5. Conduct this procedure with the gasoline
engine OFF.
6. Remove the spark plug wires to prevent
accidental engine kickback or starting.
7. With the black or red marking pencil, place
a mark on one of the blower paddles. See
Figure F.7 for location.
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F-31
F-31
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.8
FIGURE F.9
HIGH IDLE ADJUSTMENT NUT
LOW IDLE ADJUSTMENT NUT
Solenoid
3/8" Low Idle
Adjustment
Nut
Muffler
Housing
Throttle
linkage
Choke
Cable
Rod
3/8" High Idle
Adjustment Nut
11. If either of the readings is incorrect, adjust
the throttle as follows:
2. Start the engine and check the frequency
counter. At HIGH IDLE (3700 RPM), the
counter should read 60.8 to 62.5 Hz. At
LOW IDLE (2200 RPM), the counter
should read 35.8 to 37.5 Hz. Note that
these are median measurements; hertz
readings may vary slightly above or below.
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjust-
ment nut. Turn the nut clockwise to
increase HIGH IDLE speed. Adjust the
speed until the tach reads between 3650
and 3750 RPM.
3. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 3/8”
wrench to adjust the solenoid nut, which
changes the amount of throw in the throttle
lever arm. See Figure F.9 for location of the
adjustment nut. Adjust the nut until the
tach reads between 2150 and 2250 RPM.
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjust-
ment nut. Turn the nut clockwise to in-
crease HIGH IDLE speed.
Adjust the
speed until the frequency reads between
60.8 and 62.5 Hz.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLER
switch to AUTO and wait for the engine to
change to low idle speed. Use the 3/8”
wrench to adjust the solenoid nut, which
changes the amount of throw in the throttle
lever arm. See Figure F.9 for location of the
adjustment nut. Adjust the nut until the fre-
quency reads between 35.8 and 375.Hz.
Frequency Counter Method
1. Plug the frequency counter into one of the
115 VAC auxiliary receptacles.
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F-32
F-32
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
Oscilloscope Method:
Vibratach Method:
1. Connect the oscilloscope to the 115 VAC
receptacle, according to the manufactur-
er’s instructions. At 3700 RPM, the wave-
form should exhibit a period of 16.2 mil-
liseconds. At 2200 RPM, the waveform
should exhibit a period of 27.3 millisec-
onds. Refer to NORMAL OPEN CIRCUIT
VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE – NO LOAD in this section of
the manual.
1. Place the vibratach as close to the engine
as possible. With the machine case top
removed, the top of the air cleaner is the
best location.
2. Start the engine and observe the whip
handle of the vibratach. At HIGH IDLE
(3700 RPM), the whip handle should
exhibit maximum oscillation. At LOW IDLE
(2200 RPM), the whip handle should
exhibit minimum oscillation. Note that
these are median measurements; vibrat-
ach readings may vary slightly above or
below:
2. If either waveform periods is incorrect,
adjust the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjust-
ment nut. Adjust the speed until the period
is 16.2 milliseconds.
3. If either of the vibratach indications is
incorrect, adjust the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjust-
ment nut. Turn the nut clockwise to
increase HIGH IDLE speed. Adjust the
speed until the vibratach whip handle
exhibits maximum oscillation at 3650 to
3750 RPM.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLER
switch to AUTO and wait for the engine to
change to low idle speed. Use the 3/8”
wrench to adjust the solenoid nut, which
changes the amount of throw in the throttle
lever arm. See Figure F.9 for location of the
adjustment nut. Adjust the speed until the
period is 27.3 milliseconds.
Adjust LOW IDLE: First make sure that
there is no load on the machine. Set the
IDLER switch to AUTO and wait for the
engine to change to low idle speed. Use
the 3/8” wrench to adjust the solenoid nut,
which changes the amount of throw in the
throttle lever arm. See Figure F.9 for loca-
tion of the adjustment nut. Adjust the
speed until the vibratach whip handle
exhibits minimum oscillation at 2150 to
2250 RPM.
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F-33
F-33
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM
16.2 ms
CH1
0 volts
5 ms
50 volts
This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine 115 VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-34
F-34
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE)
MACHINE LOADED
CH1
0 volts
5 ms
20 volts
MACHINE LOADED TO 200 AMPS AT 20 VDC
This is the typical CV output voltage
generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time. The machine
was loaded with a resistance grid
bank.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-35
F-35
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
MACHINE LOADED
CH1
0 volts
5 ms
20 volts
MACHINE LOADED TO 200 AMPS AT 26 VDC
This is the typical DC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time. The machine
was loaded with a resistance grid
bank.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-36
F-36
TROUBLESHOOTING & REPAIR
TYPICAL AC WELD OUTPUT WAVEFORM
MACHINE LOADED
CH1
0 volts
5 ms
20 volts
MACHINE LOADED TO 225 AMPS AT 25 VDC
This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time. The machine
was loaded with a resistance grid
bank.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-37
F-37
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
ONE OUTPUT DIODE NOT FUNCTIONING
CH1
0 volts
5 ms
20 volts
This is NOT the typical CV output
voltage waveform. One output diode
is not functioning. Note the “gap” in
the waveform. One output diode was
disconnected to simulate an open or
nonfunctioning output diode. Each
vertical division represents 20 volts
and each horizontal division repre-
sents 5 milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-38
F-38
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
ONE OUTPUT DIODE NOT FUNCTIONING
CH1
0 volts
5 ms
50 volts
This is NOT the typical DC (+) output
voltage waveform. One output diode
is not functioning. Note the “gap” in
the waveform. One output diode was
disconnected to simulate an open or
nonfunctioning output diode. Each
vertical division represents 50 volts
and each horizontal division repre-
sents 5 milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-39
F-39
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
CH1
0 volts
5 ms
20 volts
This is the typical CV output voltage
generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
RANGER 8
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F-40
F-40
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
CH1
0 volts
5 ms
50 volts
This is the typical DC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
RANGER 8
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F-41
F-41
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
CH1
0 volts
5 ms
50 volts
This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-42
F-42
NOTES
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F-43
F-43
TROUBLESHOOTING & REPAIR
BRUSH REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained person-
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-
nician or 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in accessing the generator brushes for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
5/16” open end wrench
7/16” wrench
Slot head screw driver
Needle nose pliers
This procedure takes approximately 30 minutes to perform.
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F-44
F-44
TROUBLESHOOTING & REPAIR
BRUSH REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove the spark plug wires.
13. Snap the plastic retainer back onto the
brush holder. The brushes may need
some repositioning; wiggle them slightly to
help them seat properly on the slip rings.
2. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal)
from the lift bail.
14. To reinstall the brushes, depress the
spring-loaded brushes into the holder and
slip a suitable non-metallic, fairly stiff
retainer through the slots at the top and
bottom of the holder. A cable tie works
well; see Figure F.10. This will hold the
brushes up so that you can easily install
the holder.
4. Remove the fuel cap. The rubber gasket
for the fill tube with come off with the case
top.
5. Remove the case top, then reinstall the
fuel cap.
6. With the 5/16” nut driver, remove the 5
15. Slide the brush holder assembly back into
the bracket and, with the 5/16” open end
wrench, install the two screws that hold it
in place.
screws holding the right case side.
7. Remove the right case side by lifting up
and out.
8. With the needle nose pliers, gently remove
the blue and the red wires from the
brushes. See Figure F.10.
16. With the 7/16” wrench, install the brush
holder assembly bracket to the stator
frame.
9. With the 7/16” wrench, remove the brush
holder assembly bracket from the stator
frame.
17. Slowly remove the non-metallic retainer
from the brush holder and let the brushes
snap back against the slip rings.
10. With the 5/16” open end wrench, remove
the two screws that secure the brush hold-
er assembly to the bracket. Slide the
brush holder assembly out of the bracket.
18. With the needle nose pliers, connect the
red and the black wires to the appropriate
terminals on the brushes. The red wire is
inboard.
11. To change the brushes, use the slot head
screw driver to pop off the plastic retainer
on the back of the brush holder assembly.
19. Check the wire connections for clearance
and tightness.
20. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wires.
12. Remove the old brushes and insert the
new ones. One corner of the terminal clip
is beveled so that the brush can go in only
one way.
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F-45
F-45
TROUBLESHOOTING & REPAIR
BRUSH REMOVAL AND REPLACEMENT (continued)
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.
FIGURE F.10 - BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE
Cable
Tie
Brushes
7/16" Brush
Assembly
Bracket Bolts
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F-46
F-46
NOTES
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F-47
F-47
TROUBLESHOOTING & REPAIR
FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in accessing and removing the field capacitor
and rectifier bridge for maintenance or replacement of either component.
MATERIALS NEEDED
5/16” Nut driver
Jumper wire with alligator clips on each end for discharging the field capacitor
Slot head screw driver
Needle nose pliers
Wiring Diagram
This procedure takes approximately 30 minutes to perform.
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F-48
F-48
TROUBLESHOOTING & REPAIR
FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT (continued)
FIGURE F.11
RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR
201
201A
7
_
AC
200
200A
200B
+
9
AC
7
201
201A
200
200A
200B
9
Field
Bridge
Rectifier
Jumper
Retaining
Tab
Cable Tie
Capacitor
PROCEDURE
1. Remove the engine spark plug wires.
9. Both the capacitor and the rectifier bridge
are mounted in a molded plastic holder.
To remove it, pull out on the top of the
holder, then slide it upward.
2. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal) from
the lift bail.
10. Cut the cable tie, and then snap the
capacitor out of the assembly.
4 Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
11. Loosen the two screws on the top of the
capacitor. Lead 200 attaches to the posi-
tive (+) terminal. Lead 201 attaches to the
negative terminal (-) terminal.
5. Remove the case top, then reinstall the
fuel cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
12. To install the capacitor, reattach the leads
to their respective terminals [200 to posi-
tive (+); 201 to negative (-) ] and tighten
the screws. Snap the capacitor back into
the molded plastic holder and slide the
holder back into position in the panel.
Replace the cable tie.
7. Remove the right case side by lifting up and
out.
8. Discharge the field capacitor by connecting
the jumper wire clips on the black and the
red wire terminals on the top of the capac-
itor. See Figure F.11 for location. Leave the
clips on for at least 5 seconds, then
remove.
13. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wires.
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F-49
F-49
TROUBLESHOOTING & REPAIR
FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT (continued)
PROCEDURE - RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT
1. To remove the rectifier bridge, first you will
have to remove the field capacitor. Follow
Steps 1 - 10 above.
5. Slide the bridge back into the molded plas-
tic holder until the retainer clip snaps it
securely in place. Snap the capacitor back
into the holder and then slide the unit back
into position in the panel.
2. Depress the retainer clip on the molded
plastic holder and slide the rectifier bridge
out.
6. Check that the leads are not grounded and
for clearance and tightness.
3. With the needle nose pliers, gently remove
the 6 wires from the rectifier bridge.
7. Reinstall the case side, fuel cap, lift bail gas-
ket, and case top.
4. Replace the wires to their appropriate loca-
tions on the new rectifier bridge (See the
Wiring Diagram.):
Lead 200 and 200A are piggybacked on
the positive (+) terminal. Depending on the
bridge used, this corner may be beveled
and/or marked with a + sign.
Lead 201 and 201A are piggybacked on
the negative (-) terminal, which will always
be located diagonally across from the pos-
itive (+) terminal.
The two leads #7 and #9 are the AC side of
the bridge and attach to the other two cor-
ners. Either lead can go on either terminal.
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F-50
F-50
NOTES
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F-51
F-51
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL
AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this man-
ual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the printed circuit board for main-
tenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
1/4” Nut driver
Diagonal cutters
Wiring Diagram
This procedure takes approximately 20 minutes to perform.
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F-52
F-52
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT
(continued)
FIGURE F.12 - PRINTED CIRCUIT BOARD LOCATION
Current
Sensor
Current
Sensing Leads
In Line
Connectors
12 Pin
Molex Plug
5/16"
Screw (4)
PROCEDURE
9. Remove the 12-pin molex plug from the
Printed circuit board.
Before starting the following procedure, refer to
the topic “PC Board Troubleshooting
Procedures” at the beginning of this section.
10. Detach the two in-line connectors from the
current sensing leads (254 and 254A - see
the Wiring Diagram.). These leads attach
to the current sensor located on the print-
ed circuit board.
1. Remove the engine spark plug wires.
2. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal) from
the lift bail.
11. Remove lead #3 from the 115 VAC recep-
tacle. Thread the lead through the hole in
the current sensor in order to separate it
from the printed circuit board. It will prob-
ably be necessary to cut any cable ties
restraining the wiring. Use the diagonal
cutters.
4. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
5. Remove the case top, then reinstall the
fuel cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
7. Remove the right case side by lifting up and
out.
8. WIth the 5/16” nut driver, remove the printed
circuit board cover. See Figure F.12.
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F-53
F-53
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL
AND REPLACEMENT (continued)
CAUTION
Be sure to follow the recommended static-
free methods for handling printed circuit
boards. Failure to do so can result in perma-
nent damage to the equipment.
12. With the 1/4” nut driver, remove four
screws holding the printed circuit board.
13. Replace the old printed circuit board with
a new one.
14. Thread lead #3 back through the current
sensor on the printed circuit board and
reattach the lead to the 115 VAC recep-
tacle.
15. Connect current sensing leads 254 and
254A. See the Wiring Diagram for the
proper connections.
16. Connect the 12-pin molex plug.
17. Replace any cable ties that were cut dur-
ing the removal procedure.
18. With the 5/16” nut driver, install the
printed circuit board cover.
19. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wires.
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F-54
F-54
NOTES
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F-55
F-55
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output rectifier bridge for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
1/2” wrench
7/16” wrench
3/8” wrench
Slot head screw driver
Dow Corning 340
Wiring Diagram
This procedure takes approximately 60 minutes to perform.
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F-56
F-56
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT (continued)
FIGURE F.13 - OUTPUT RECTIFIER CONNECTIONS
To S1 Range Sw.
To S2 Polarty Sw.
#10
W1
+
Choke
Mounting Screws
with
Insulators
S2
-
To Polarity Switch
#8
Machine Front
PROCEDURE
1. Remove the engine spark plug wires.
For the remaining steps, refer to Figure F.13.
2. With the 5/16” nut driver, remove the 6 sheet
metal screws from the case top.
8. With the 1/2” wrench, remove the choke
lead and the #10 lead (Blue) from the recti-
fier positive heat sink.
3. Remove the rubber gasket (cover seal) from
the lift bail.
9. With the 1/2” wrench, remove the heavy
cable and the #8 lead (Blue) from the rectifi-
er negative heat sink.
4. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
10. WIth the 7/16” wrench, remove the W1 lead
and the heavy lead going to the S2 Polarity
switch.
5. Remove the case top, then reinstall the fuel
cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
11. With the 7/16” wrench, remove the S2 lead
and the heavy lead going to the S1 Range
switch.
7. Remove the right case side by lifting up and
out.
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F-57
F-57
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT (continued)
12. With the 3/8” wrench and slot head screw
17. With the 7/16” socket wrench, install the
W1 lead and the heavy lead going to the
S2 Polarity switch. Note the order of fas-
teners: flat washer at the bottom followed
by pigtails, heavy leads, flat washer, lock
washer, and nut.
driver, remove the four mounting screws
(two on each side). Note the placement of
the nylon insulators. These must be in
place when you reinstall the rectifier
bridge assembly in order to electrically
insulate the bridge from the choke lam-
ination assembly.
18. With the 1/2” socket wrench, install the
heavy cable and the #8 lead (Blue) to the
rectifier negative heat sink. Note the order
of fasteners: bolt and flat washer from the
bottom up through the heat sink; on top,
leads, flat washer, lock washer, and nut.
13. Remove the rectifier assembly by tilting it
up and lifting it toward the front of the
machine.
14. Reassembly: Refer to the Wiring Diagram
for proper connections to the positive and
negative sides of the rectifier assembly.
The two sides of the bridge are marked +
and -, respectively.
19. With the 1/2” socket wrench, install the
choke lead and the #10 lead (Blue) to the
rectifier positive heat sink. Note the order
of fasteners: bolt and flat washer from the
bottom up through the heat sink; on top,
leads, flat washer, lock washer, and nut.
NOTE: Use Dow Corning 340 on all aluminum
electrical connection surfaces.
20. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wire.
15. With the 3/8” wrench and slot head screw
driver, install the four mounting screws
(two on each side). Note the placement of
the nylon insulators. These must be in
place when you install the rectifier
bridge assembly in order to electrically
insulate the bridge from the choke lam-
ination assembly.
16. With the 7/16” socket wrench, install the
S2 lead and the heavy lead going to the S1
Range switch. Note the order of fasteners:
flat washer at the bottom followed by pig-
tails, heavy leads, flat washer, lock wash-
er, and nut.
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F-58
F-58
NOTES
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F-59
F-59
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the engine and/or rotor for main-
tenance or replacement of either component.
NOTE: The procedures described here are for a Kohler engine. The same basic procedures
apply to the Onan engine, although there may be a few slight wiring variations.
MATERIALS NEEDED
Lincoln Electric Rotor Removal Kit (S20788) - FOR ROTOR REMOVAL ONLY
1/4” nut driver
5/16” nut driver
Slot head screw driver
3/8” wrench
7/16” wrench
1/2” wrench
9/16” wrench
5/8” wrench
Locking pliers
Needle nose pliers
Diagonal cutters
Impact wrench
Torque wrench (ft lbs)
Feeler gauge (.017)
INSTRUCTIONS
For Engine and Rotor removal only, follow steps 1-25 under ENGINE AND ROTOR REMOVAL
PROCEDURE. For reassembly of engine and rotor go to REASSEMBLY PROCEDURE.
For rotor removal, follow the ENGINE AND ROTOR REMOVAL PROCEDURE and ROTOR
REMOVAL PROCEDURE.
This procedure takes approximately 3 hours to perform.
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F-60
F-60
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND
REPLACEMENT (continued)
FIGURE F.14 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL
5
3
1
6
8
7
1
2
9
1. STATOR COWLING COVER
2. BLOWER FAN
3. IDLE LINKAGE
4. BRUSH HOLDER BRACKET
5. ENGINE LIFT BAILS
4
6. STATOR/ENGINE MOUNTING BOLTS
7. ROTOR
8. ROTOR SHAFT BEARING
9. ROTOR THRU-BOLT
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F-61
F-61
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL
AND REPLACEMENT (continued)
ENGINE AND ROTOR
REMOVAL PROCEDURE
1. Refer to Figure F.14 for component loca-
tions.
15. With the 1/4” nut driver, disconnect the
engine choke cable from the engine. Mark
the location of the retainer for reassembly.
The other end can remain connected.
2. Remove the engine spark plug wires.
3. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
16. Disconnect the idle linkage by unsnapping
the plastic clip at the engine end of the
idler rod. Snap the clip back onto the rod
to avoid losing it; remove the rod for
reassembly.
4. Remove the rubber gasket (cover seal)
from the lift bail.
5. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
17. Disconnect the fuel line from the fuel tank.
Plug the hose and also plug the connec-
tion at the fuel tank to prevent the escape
of gasoline fumes.
6. Remove the case top, the reinstall the fuel
cap.
18. Cut the cable ties and remove leads 224C
and 210 from the oil pressure switch.
7. WIth the 5/16” nut driver, remove the 5
screws holding the right case side and the
5 screws holding the left case side.
19. With the 9/16” wrenches, remove the
ground lead from the right engine foot
mounting bolt.
8. Remove the case sides by lifting up and
out.
20. With the 7/16” wrench, remove the brush
holder bracket and leads #219 & 200A
from the stator frame.
9. WIth the 3/8” wrench, remove the battery
cover.
10. Disconnect the negative battery cable,
then the positive battery cable. BE SURE
TO DISCONNECT THE NEGATIVE BAT-
TERY CABLE FIRST. Remove the battery
and set it aside.
20A. (For Onan Engine only) with a 1/2”
wrench remove the muffler support bolt.
21. Support the engine with a chain hoist. Lift
bails are provided on the top of the engine
for this purpose.
11. With the diagonal cutters, cut the cable
ties around the leads from the starter sole-
noid and disconnect the leads. Remove
lead 209A from the harness bundle.
22. With the 9/16” wrench, remove the right
and left engine foot mounting bolts.
23. With the 9/16” wrench, remove the four
bolts that hold the stator to the engine.
There is one lock washer per bolt.
12. Disconnect the large black plug in front of
the fuel tank spout.
13. With the 3/8” wrench, remove the cowling
covers at the rear on the stator, both sides
of the machine.
24. With the chain hoist, unweight the engine
gently. Use a pry bar to carefully pry
between the engine and the stator frame in
order to unseat the bearing on the end of
the rotor shaft. Separate the engine and
rotor from the stator frame, supporting the
rotor by hand to prevent damage to the
rotor core.
14. WIth the 3/8” wrench, remove the two
screws that hold the vertical fan baffle in
place. Slide the baffle forward toward the
rectifier bridge heat sink assembly.
15. Hold the rotor shaft with locking pliers and
unscrew the blower fan. Turn the fan
counterclockwise. You do not need to
remove the fan from the machine, but be
sure it is completely unscrewed from the
rotor shaft.
25. Move the engine and rotor assembly to a
bench. The engine is off balance with the
rotor still attached; therefore, support the
end of the rotor with a wooden two-by-
four before unhooking the chain hoist.
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F-62
F-62
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND
REPLACEMENT (continued)
FIGURE F.15 - ENGINE AND ROTOR REMOVED FROM STATOR
2
1. THRU-BOLT
2. ROTOR
1
ROTOR REMOVAL PROCEDURE
1. To remove the rotor, double check that the
engine spark plug wires are disconnect-
ed. You will be turning the rotor during this
procedure, and this could accidentally cause
engine kickback.
4. Turning it counterclockwise, screw in the
left-hand thread rotor removal tool from the
kit into the rotor shaft. Support the rotor with
one hand and tighten the tool to approxi-
mately 50 ft lbs with the torque or impact
wrench.
2. With an impact wrench, remove the rotor
thru-bolt. See Figure F.15. If an impact
wrench is not available, use the 5/8” box
wrench. Hold the rotor with one hand and
shock the wrench with the mallet to loosen
the thru-bolt. The thru-bolt has a star wash-
er and lock washer, beveled to conform to
the rotor shaft. Pull out the thru-bolt.
5. If the rotor does not pop off, tighten the rotor
removal tool an additional 5 ft lbs. Hold the
rotor with one hand until the rotor pops off
the engine crankshaft.
HINT: If the rotor does not pop off, hit the end
of the rotor removal tool with a hammer.
6. Slide the rotor the rest of the way off the
crankshaft. Be careful not to lose the wash-
er that fits between the blower fan and the
rotor.
3. Install the appropriate long thru-bolt (two are
provided) supplied with Lincoln Electric
Rotor Removal Kit S20788. The slot head
must face out. Screw in the bolt with the slot
head screw driver until the bolt bottoms out
on the engine crankshaft, about 3/4”.
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F-63
F-63
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND
REPLACEMENT (KIT S20788) (continued)
REASSEMBLY PROCEDURE
NOTE: Lincoln Electric recommends that a new
bearing (Lincoln part #M9300-85) be installed
when you replace the rotor and blower assem-
bly.
8. Attach leads to the oil pressure switch refer
to wiring diagram. Replace any cut cable
ties.
9. Unplug the fuel tank connection and fuel
hose and connect them.
1. Clean the tapered engine crankshaft. Slide
the rotor onto the shaft.
10. Connect the idle linkage to the idler rod.
Snap the plastic clip back into place.
2. Insert the rotor thru-bolt, and with the
torque wrench tighten the bolt to 50 ft lbs.
11. Connect the engine choke cable at the
position marked during disassembly.
3. Support the engine/rotor assembly with the
chain hoist. Fit the rotor into the stator
frame, being careful not to damage the
rotor core against the stator. The bearing
will seat into its race about half way.
12. Screw the blower fan back onto the end of
the rotor shaft. Be sure the washer is in
place and hand tighten the fan only.
13. Reposition the vertical fan baffle and secure
it with the two screws.
4. Insert the four bolts and lock washers that
hold the engine to the stator. With the
9/16” wrench, draw the bolts up evenly in
order to seat the bearing properly. Tighten
to 22 ft-lb. moving diagonally from bolt to
bolt.
13A. (For Onan Engine only) Install the muffler
support hardware on the Onan engine.
14. Install the two cowling covers at the rear of
the stator.
5. Check the rotor-stator air gap with the .017
feeler gauge. The measurement is taken at
the blower end of the rotor before the fan is
reinstalled. Turn the rotor with a pair of
locking pliers as necessary so that the rotor
“iron” is up to take the measurement. (The
rotor has two flat sides, which are not mea-
sured for air gap.) Slide in the gauge. Then
rotate the shaft 180 degrees and measure
again. If the gauge does not clear, loosen
the four engine/stator bolts; retighten the
bolts and recheck the air gap. Repeat until
the proper .017 minimum air gap is
achieved.
15. Connect the black plug in front of the fuel
tank fill spout.
16. Connect the leads to the starter solenoid
and replace any cable ties cut during disas-
sembly.
17. Install the battery. Connect the positive
battery cable, then the negative battery
cable. BE SURE TO CONNECT THE POS-
ITIVE BATTERY CABLE FIRST.
18. Replace the battery cover.
19. Reinstall the case side, fuel cap, lift bail
gasket, and case top. Connect the spark
plug wires.
6. Fasten the ground lead to the right engine
mounting bolt and install both bolts.
20. Conduct the “Retest after Repair” proce-
dure, the following topic in this section of
the manual.
7. Install the brush holder bracket back into
the stator frame. Refer to the topic “Brush
Removal and Replacement” in this section
of the manual.
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F-64
F-64
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics.
OR
• If you repair or replace any electrical components.
ENGINE OUTPUT
Mode
Low Idle
No Load RPM
2150-2250
Load RPM
NA
High Idle
3700-3750
3100-3600
WELDER DC OUTPUT1
Output Control
Range Switch
Open Circuit
Volts
Load Volts
Load Amps
Maximum
Maximum
67 - 72
21 - 26.5
205 - 240
WELDER AC OUTPUT1
Output Control
Range Switch
Open Circuit
Volts
Load Volts
Load Amps
Maximum
Maximum
73 - 80
25 - 32
225 - 275
WELDER CV OUTPUT1
Output Control
Range Switch
Open Circuit
Volts
Load Volts
Load Amps
Maximum
Wire Feed CV
29 - 33
19 - 22
200 - 220
AUXILIARY POWER RECEPTACLE OUTPUT1
2
230 Volt Receptacle
115 Volt Receptacle
Open Circuit
Voltage
Load Volts
Load Amps
Open Circuit
Voltage
Load Volts
Load Amps
236 - 253
207 - 240
34 - 41.5
118 - 126.5
103.5 - 115
70 - 80
FIELD AMPS AND VOLTS
Slip Ring Volts
Field Amps
37 - 46 VDC
6.7 - 8.2 VDC
1 OUTPUT CONTROL switch set at MAXIMUM (position 10).
2 Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.
RANGER 8
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Section G-1
Section G-1
TABLE OF CONTENTS
DIAGRAMS SECTION
Diagrams Section............................................................................................................Section G
Dimension Print Ranger 8 (Onan) .........................................................................................G-2
Dimension Print Ranger 8 (Honda & Kohler) ........................................................................G-3
Connection Diagrams ...........................................................................................................G-4
Wiring Diagram Ranger 8 Onan Non CSA Model.................................................................G-5
Wiring Diagram Ranger 8 Onan CSA Model.........................................................................G-6
Wiring Diagram Ranger 8 Kohler Non CSA Model...............................................................G-7
Wiring Diagram Ranger 8 Kohler CSA Model.......................................................................G-8
Wiring Diagram Ranger 8 Honda CSA Model ......................................................................G-9
Idler/Control PC Board Schematic .....................................................................................G-10
Idler/Control PC Board Assembly.......................................................................................G-11
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G-2
G-2
DIAGRAMS
DIMENSION PRINT – RANGER 8 (ONAN)
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G-3
G-3
DIAGRAMS
DIMENSION PRINT – RANGER 8 (HONDA & KOHLER)
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G-4
G-4
DIAGRAMS
RANGER 8 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.
Keep guards in place.
Keep away from moving parts.
Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
6 PIN
AMPHENOL
OPTIONAL K444-1
REMOTE CONTROL
LN-25
WIRE FEEDER
ELECTRODE
TO WORK
WORK CLIP LEAD
TO WORK
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR
SWITCH TO THE WIRE FEED (CV) POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH
IN "OUTPUT CONTROL REMOTE" POSITION.
CRM 21883
M17486
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
TO LN-7
21
GND.
32
2
4
31
N.D.
CONNECT THE CONTROL CABLE
GROUND LEAD TO THE FRAME
K240 CONTACTOR KIT
115V (50/60HZ.)
N.B.
N.C.
TERMINAL MARKED
NEAR
(NOTE
:
600 AMP CAPACITY)
POWER
THE TERMINAL STRIP OR TO
SOURCE
AN UNPAINTED FRAME SCREW.
75
77 76
AUTO.
EQUIP.
POWER
N.F.
&
N.G.
N.J.
SOURCE
ELECTRODE CABLE TO LN-7
ELECTRODE
WORK
S17742
10-2-92
TO WORK
WELDER STANDARD OUTPUT TERMINALS
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.
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
power source to the CV position.
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.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 volt-
amperes.
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.
N.D. Leads #21 and GND do not appear on LN-7’s with codes
below 7026.
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 volt-
age 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.
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
RANGER 8
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G-5
G-5
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ONAN NON CSA MODEL
K1418-1 RANGER 8 ONAN - Wiring Diagram
CCW
R1
254
OUTPUT
CONTROL
"S3" SHOWN IN
RUN POSITION
GROUND SCREW
AT BLOWER BAFFLE
L1
CHOKE
+
-
209
208
+
10
AM1
76A
75A
77A
208A
S2
D1
254
254A
8
-
S3
254A
CURRENT
SENSOR
208B
S5
START
BUTTON
PCB1
5D
3
TURNS
254A
212
S1
WORK
5F
216
E
12
8
7
R1
R2
R3
R4
S2
C1
213
213
S4
R6
R5
J1
1
10
ELECTRODE
216A
6
S1
6
"S4" SHOWN
IN "AUTO"
POSITION
IDLER
SOLENOID
GND-G
GND-E
W2
W1
224B
REACTOR
+
C1
GND-C
GND-D
HOUR
215
STATOR
METER
224
5D
3
9
7
5E
224A
GND-E
P5
J5
1
2
3
4
5
3
1
212
75A
77A
+
-
B
2
224C
208
76A
12 VOLT
GND-D
3
4
BATTERY
7
ENGINE FOOT
224A
3A
9
3
200B
J2
115 V
GND-H
OIL PRESSURE
SWITCH
+
GND-G
TERMINAL BLOCK
(SEE CONN.)
D2
C1 FIELD
CAPACITOR
200
200A
+
-
5
6
219
5L
3A
5K
3B
TO
216A
ENGINE
CROSS
SUPPORT
SPARK
PLUGS
201
201A
J4
3B
115V/230V
STARTER
SOLENOID
REGULATOR
AC
STARTER
IGNITION
CONTROL
AC B+
5K
B-
ROTOR
CR1
J3
GND-C
115 V
209
CAPACITOR
5
FLYWHEEL ALTERNATOR
SILVER
SLIP RING NEAREST LAMINATION
5L
COLORED
ENGINE COMPONENTS
TERMINALS
(WHITE WIRES)
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
WELDER LEAD END
(NOTE CAVITY NUMBERS)
208 (CAVITY #3)
CONNECTOR PIN NUMBERS:
224A&C (CAVITY #4)
224C (CAVITY #2)
12
3
7
1
4
LOCATING TAB
212 (CAVITY #1)
2
3
6
2
1
J1
J5
TERMINAL BLOCK
CONNECTION
7-19-96G
M18331
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-6
G-6
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ONAN CSA MODEL
K1418-2 RANGER 8 ONAN (CSA VERSION) - Wiring Diagram
CCW
R1
254
"S3" SHOWN IN
RUN POSITION
OUTPUT
CONTROL
GROUND SCREW
L1
AT BLOWER BAFFLE
CHOKE
+
-
209
208
+
10
8
AM1
76A
75A
77A
208A
S2
D1
254
5G
5D
254A
-
S3
254A
CURRENT
SENSOR
208B
S5
START
BUTTON
SHUT OFF SOLENOID
GROUND LEAD
(LPG VERSION ONLY)
PCB1
3
TURNS
254A
WORK
212
S1
5F
216
E
12
8
7
R1
S2
C1
213
213
S4
R2
R3
R4
R6
J1
10
R5
ELECTRODE
1
6
5G
S1
6
"S4" SHOWN
IN "AUTO"
POSITION
IDLER
GND-G
GND-E
SOLENOID
W2
W1
224B
REACTOR
+
C1
GND-C
GND-D
HOUR
215
STATOR
METER
224
5D
3
9
7
5E
224A
GND-E
P5
J5
1
2
3
4
5
3
1
212
75A
77A
+
-
B
2
224C
208
76A
3
12 VOLT
GND-D
3
4
BATTERY
7
224A
9
200B
J2
115V
GND-H
3E
SHUT OFF
SOLENOID
CB3
15A
6
+
CB1
35A
GND-G
TERMINAL BLOCK
(SEE CONN.)
CB5
15A
(LPG VERSION
D2
C1 FIELD
CAPACITOR
ONLY)
3D
ENGINE
FOOT
200
OIL PRESSURE
SWITCH
3C
200A
+
-
12
5
219
5L
5K
TO
216A
ENGINE
CROSS
SUPPORT
SPARK
PLUGS
201
201A
J4
115V/230V
11
STARTER
REGULATOR
AC
CB6
15A
SOLENOID
STARTER
IGNITION
CONTROL
AC B+
GND-C
11
CB2
35A
B-
ROTOR
CR1
J3
115V
3D
209
5K
CB4
15A
3E
CAPACITOR
3A
5
FLYWHEEL ALTERNATOR
SLIP RING NEAREST LAMINATION
3A
SILVER
5L
3B
ENGINE COMPONENTS
COLORED
3B
TERMINALS
(WHITE WIRES)
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
WELDER LEAD END
(NOTE CAVITY NUMBERS)
CONNECTOR PIN NUMBERS:
12
208 (CAVITY #3)
7
3
4
224A&C (CAVITY #4)
LOCATING TAB
212 (CAVITY #1)
2
1
3
6
2
1
J1
J5
TERMINAL BLOCK
CONNECTION
224C (CAVITY #2)
7-19-96G
M18332
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-7
G-7
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - KOHLER NON CSA MODEL
K1419-1 RANGER 8 KOHLER - Wiring Diagram
CCW
R1
254
OUTPUT
CONTROL
"S3" SHOWN
IN "RUN"
POSITION
GROUND SCREW
AT BLOWER BAFFLE
L1
CHOKE
+
-
208A
209A
+
10
8
76A
75A
77A
S3
S2
AM1
S5
START
BUTTON
221
D1
254
254A
-
254A
CURRENT
SENSOR
208B
PCB1
5H
211
5D
3
TURNS
254A
WORK
S1
210
5F
E
12
8
7
213
R1
213
S4
S2
C1
R2
R3
R4
R6
J1
1
10
GND-E
R5
ELECTRODE
"S4" SHOWN
IN "AUTO"
POSITION
6
IDLER
SOLENOID
S1
6
GND-G
224B
2
W
+
224A
REACTOR
HOUR METER
5D
C1
GND-C
GND-D
215
STATOR
224
W1
5H
3
9
7
5E
GND-E
P5
J5
1
2
3
4
5
3
224A
209
208 211
75A
77A
12 VOLT
BATTERY
224C
221
209A
+
-
76A
B
B
GND-D
TERMINAL BLOCK
B
7
B
B
1
2
3
4
(SEE CONN.)
3A
9
3
200B
R
W
J2
115 V
R
V
+
GND-G
ENGINE
FOOT
U
D2
C1 FIELD
CAPACITOR
210
200
200A
+
-
GND-H
5
6
CR1
219
N.A.
OIL
PRESSURE
SWITCH
5L
3A
5K
3B
STARTER
SOLENOID
201
201A
J4
3B
ENGINE
CROSS
SUPPORT
115V/230V
IGNITION
MODULE
AC B+
REGULATOR
AC
STARTER
GND-C
B-
FUEL
ROTOR
J3
SHUTOFF
5K
115 V
SOLENOID
5
SILVER
COLORED
TERMINALS
FLYWHEEL ALTERNATOR
SLIP RING NEAREST LAMINATION
5L
ENGINE COMPONENTS
(WHITE WIRES)
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
GENERATOR LEAD END
(NOTE CAVITY NUMBERS)
LEAD COLOR CODE:
CONNECTOR PIN NUMBERS:
B = BLACK
R = RED
W = WHITE
U = BLUE
V = VIOLET
4
2
3
12
7
1
211 (CAVITY #3)
224C (CAVITY #4)
208 (CAVITY #2)
1
3
2
6
LOCATING TAB
J5
J1
221 (CAVITY #1)
TERMINAL BLOCK
CONNECTION
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
7-19-96G
M18333
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-8
G-8
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - KOHLER CSA MODEL
K1419-2 RANGER 8 KOHLER (CSA) - Wiring Diagram
CCW
R1
254
OUTPUT
CONTROL
"S3" SHOWN
IN "RUN"
POSITION
GROUND SCREW
AT BLOWER BAFFLE
L1
CHOKE
+
-
208A
209A
+
10
8
76A
75A
77A
S3
221
S2
AM1
S5
START
BUTTON
D1
254
254A
-
254A
CURRENT
SENSOR
208B
PCB1
5H
211
5D
3
TURNS
254A
WORK
S1
210
5F
E
12
8
7
213
R1
R2
213
S4
S2
C1
R6
J1
1
10
GND-E
R3
R4
R5
ELECTRODE
"S4" SHOWN
IN "AUTO"
POSITION
6
IDLER
SOLENOID
S1
GND-G
224B
2
W
+
224A
REACTOR
HOUR METER
5D
C1
GND-C
GND-D
215
STATOR
224
W1
5H
3
9
6
7
5E
GND-E
P5
J5
1
2
3
4
5
3
224A
209
208 211
3
75A
77A
12 VOLT
BATTERY
224C
221
209A
+
-
76A
B
B
GND-D
TERMINAL BLOCK
B
7
B
B
1
2
3
4
(SEE CONN.)
9
200B
R
W
J2
115V
3E
CB3
15A
R
V
6
+
CB1
35A
GND-G
ENGINE
FOOT
U
CB5
15A
D2
C1 FIELD
CAPACITOR
210
3D
200
3C
200A
+
-
GND-H
12
5
CR1
219
N.A.
OIL
PRESSURE
SWITCH
5L
5K
STARTER
SOLENOID
201
201A
ENGINE
CROSS
J4
115V/230V
11
IGNITION
MODULE
AC B+
REGULATOR
AC
SUPPORT
CB6
15A
STARTER
GND-C
11
CB2
35A
B-
FUEL
ROTOR
J3
115V
SHUTOFF
3D
SOLENOID
5K
CB4
15A
3E
3A
5
FLYWHEEL ALTERNATOR
SLIP RING NEAREST LAMINATION
3A
5L
ENGINE COMPONENTS
3B
SILVER COLORED
TERMINALS
(WHITE WIRES)
3B
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
GENERATOR LEAD END
(NOTE CAVITY NUMBERS)
CONNECTOR PIN NUMBERS:
LEAD COLOR CODE:
4
2
3
12
7
1
B = BLACK
R = RED
W = WHITE
U = BLUE
V = VIOLET
211 (CAVITY #3)
224C (CAVITY #4)
208 (CAVITY #2)
1
3
2
6
LOCATING TAB
J5
J1
221 (CAVITY #1)
TERMINAL BLOCK
CONNECTION
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
7-19-96G
M18334
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-9
G-9
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - HONDA CSA MODEL
K2160-1 RANGER 8 HONDA (CSA) - WIRING DIAGRAM
CCW
R1
254
"S3" SHOWN
IN "RUN"
POSITION
OUTPUT
CONTROL
GROUND SCREW
L1
AT BLOWER BAFFLE
CHOKE
+
-
208A
209A
+
10
8
76A 75A
77A
S3
S2
AM1
S5
START
221
D1
BUTTON
254
208C
254A
-
254A
CURRENT
208B
PCB1
SENSOR
5H
211
5D
3 TURNS
254A
CB7
25A
S1
210
WORK
5F
E
12
8
10
6
7
213
R1
R2
213
S4
S2
C1
R6
J1
1
GND-E
R3
R5
R4
ELECTRODE
"S4" SHOWN
IN "AUTO"
POSITION
IDLER
SOLENOID
S1
GND-G
224B
2
W2
+
224A
REACTOR
C1
HOUR METER
5D
GND-C
GND-D
215
STATOR
224
W1
5H
3
9
6
7
5E
GND-E
P5
J5
1
2
3
4
5
3
12 VOLT
224A
BATTERY
208 211
3
75A
76A
77A
211B
209A
224C
221
+
D9
4 AMP
IN LINE
209
GND-D
7
2
4
1
3
SEE DETAIL
211B
9
200B
210
DIODE
NO
CONNECTION
J2
115V
-
3E
224E
211A
211C
CB3
15A
225A
6
+
CB1
35A
GND-G
224D
221A
B/R
208D
STARTER
SOLENOID
ENGINE
FOOT
CB5
15A
210A
D2
FIELD
C1
3D
OIL
CAPACITOR
N.A.
CR1
200
PRESSURE
SWITCH
3C
200A
+
-
GND-H
12
5
B/Y
219
5L
5K
IGNITION
MODULE
ENGINE
CROSS
SUPPORT
FUEL
SHUTOFF
SOLENOID
201
201A
W/U
J4
115V/230V
11
W
5
212
5P
GY
CB6
15A
GY
GND-C
11
CB2
3E 35A
ROTOR
J3
115V
3D
20 AMP
CHARGE COIL
5K
CB4
15A
1
2
3
4
6
STARTER
3A
5
SLIP RING NEAREST LAMINATION
3A
5L
3B
SILVER COLORED
TERMINALS
3B
RECTIFIER/REGULATOR
MODULE
(WHITE WIRES)
B
HONDA ENGINE COMPONENTS
GENERATOR LEAD END
(NOTE CAVITY NUMBERS)
CONNECTOR PIN NUMBERS:
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
4
2
3
12
7
1
211 (CAVITY #3)
LEAD COLOR CODE:
224C (CAVITY #4)
208 (CAVITY #2)
1
2
3
6
B = BLACK OR GRAY
R = RED OR PINK
W = WHITE
LOCATING TAB
J5
J1
221 (CAVITY #1)
TERMINAL BLOCK
CONNECTION
U = BLUE
GY = GRAY
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL SYMBOLS PER E1537
A
M19988
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-10
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - IDLER/CONTROL PC BOARD
6 4 1 8 2
+10V
R74
D13
+12V
J1
J1
12
7
10.0K
4
9
R13
#216
#224
J1
3A
600V
13.7K
R73
6
3 TURNS
#18 WIRE
47.5K
C3
.047
10.0K
R62
+ DIODES
TO
IDLE
R72
+10V
+10V
C1
.05
600V
TP1
130V
38J
SWITCH
+10V
C15
0.1
50V
+
t
100V
10.0K
D1
.13
60V
6
R17
1
R71
10.0K
R14
33.2K
- DIODES
MOLEX
133K
case
J1
10K
HOLE IN
SENSOR
J1
12
10K
R70
D
TO
SOLENOID
3
SNUBBER
X2
Q4
#215
16
10.0K
1
15A
20
SET
RESET
V
DD
60V
C16
5W
2
3
4
5
6
7
15
14
13
12
11
J1
R69
MONO IN
OSC INH
#200B
+FIELD
0.1
10K
R16
X4
11
R4
10.0K
R68
50V
IN
1
G
DZ8
27V
5W
390
5W
S
D9
DZ2
15V
FLASH
OUT
OUT
1
2
DECODE
3A
D15
+12V
10.0K
1W
600V
R5
R58
D
C
B
case
TP-A
R67
20
8
BY-PASS
R19
26.7K
10.0K
5W
D3
10
11
CLOCK INH
VSS
X1 -C
+10V
10.0K
C29
0.1
50V
15A
8
332
9
13
A
R3
6
7
C27
100
50V
475
200V
DZ7
20V
5W
4536B
10
R63
68.1
X1 -A
1
D4
1N4936
+
t
D16
1N4007
1
C4
56
5W
.5
8
X5
300V
500mA
Q6
18
R64
68.1
COM
3.32K
15V
REF
COM
TL431
6
C2
100
15V
475
475
J1
COM
R65
OVERCURRENT
COM PROTECTION
5
-FIELD
3.32K
COM
.1
7W
TP-D
1.00K
TP-B
J1
R39
R40
681K
+10V
2
C30
820p
50V
5E
+10V
1.00K
GND
Q5
195mA
60V
D10
3A
600V
case
COM
G
9
8
COM
COM
X1 -D
+10V
14
10K
D
+10V
10K
S18104-3
HEAT SINK
R53
R54
4.75K
Q1
D14
DZ5
27V
1W
D12
33A
22.1K
REMOTE INPUT
5
6
200V
IRFP250
HYSTERESIS
SWITCH
0.1
S
J1
J1
C28
1N4936
DZ4
15V
1W
7
50V
R6
R43
475
X3 -B
1
77
76
39.2K
120
2.5W
C21
COM
DZ3
15V
1W
10
40V
600mA
Q3
R34
.0047
C14
0.1
50V
8
R49
475
3
1400V
D7
C23
4.75K
X3 -C
case
9
R46
52.3K
COM
6.81K
R7
R8
R50
475
8
CURRENT AMP.
R32
1
COM
10K
4.75K
4.75K
X3 -A
R33
2
J1
10
C9
681K
D8
100K
15.0K
C22
.0047
C13
0.1
50V
#201A
50V
1.8
0.1
COM
1400V
20V
5
case
C26
12
X1 -B
2
COM
COM
J1
14
R31
26.7K
4
R9
R44
475
X3 -D
7
75
13
C8
.0047
1400V
DZ6
10V
5W
120
2.5W
OVERCURRENT
PROTECTION
C7
18
15V
D11
1N4936
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
+10V
R51
475
case
22.1K
C24
R-
74
C- 30
2.94K
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
COM
16
D-
LABELS
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
COM
C11
COM
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
C19
C12
NOTES :
C10
3
1
X2
3
4
16
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
COMPLETE BOARD, THIS DIAGRAM MAY
S15128-11
X1
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
FRAME CONNECTION
FILENAME: M16482_3G
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
X4
X3
EARTH GROUND CONNECTION
LM2901
12
LM224
4536B
8
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
8-2-96E
Ch’ge.Sht.No.
11-22-96
9-25-92A
EQUIP.
TYPE
G8000/RANGER 8 IDLER/FIELD CONTROL
11
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
7-18-97E
12-4-97K
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
SCHEMATIC
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
4-16-93H
2-18-94M
7-14-2000D
COM
SHT.
I.E.B.
10/13/92
CHK.
SUP’S’D’G.
M16482
DR.
DATE
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-11
G-11
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - IDLER/CONTROL
PART NO.
ITEM
REQ’D
IDENTIFICATION
1.02
+.04
-
4.00
X X
X
R48
R66
R61
R65
A
TP
-
3.80
Q4
X
XX
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
X
X
X
X
X
X
X
X
R58
R5
C4
R4
R21
C3
X1
x
x
x
x
x
x
x
D9
X4
Q1
D3
C11
R41
C15
R62
D10
J1
X2
X3
TP-B
R8
D13
R6
R7
.20
0
R9
L8484-3
+.04
-
6.00
3.20
5.80
.20
0
UNLESS OTHERWISE SPECIFIED:
CAPACITORS=MFD/VOLTS
7-14-2000D
RESISTORS=OHMS (1/4 WATT)
INDUCTANCE=HENRYS
8484-3
L
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
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SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three col-
umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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