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Lincoln Electric 8 manual

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Table of contents for the manual

  • Page 1

    RANGER ™ 8 OPERA TOR’S MANUAL For Machines with Code Numbers 10373, 10374, 10375, 10376, 10535, 10536, 10537,10538, or 10541,10886 IM510-E January, 2002 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- [...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

  • Page 6

    Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

  • Page 7

    vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications ................................................................................................A-1,A-2 Installation Instructions. ........................[...]

  • Page 8

    A-1 INST ALLA TION RANGER 8 A-1 * Based on a 10 min. period. TECHNICAL SPECIFICA TIONS - Rang er 8 (K1418-1) (K1418-2 CSA MEETS CANADIAN STD .) (K1419-1) (K1419-2 CSA MEETS CANADIAN STD .) (K2160-1 CSA MEETS CANADIAN STD .) INPUT - GASOLINE ENGINE RA TED OUTPUT - WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.2 in. 42.3 in. 529 lbs. (240kg.) K1418-1,[...]

  • Page 9

    A-2 INST ALLA TION RANGER 8 A-2 AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE A B OUTPUT AMPS OUTPUT VOLTS AC (RMS) 0 50 100 150 200 250 0 10 20 30 40 50 60 70 80 DC STICK / TIG (CC) OUTPUT OUTPUT AMPS OUTPUT VOLTS DC (RMS) A 210 OUTPUT RANGE B 50 OUTPUT RANGE A B 0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 CV OUTPUT RA[...]

  • Page 10

    A-3 INST ALLA TION RANGER 8 A-3 INST ALLA TION INSTR UCTIONS Safety Precautions Machine Gr ounding 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.). To prevent dangerous elec[...]

  • Page 11

    A-4 INST ALLA TION RANGER 8 A-4 Some of the factors to be considered are as follows: 1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments. 2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework. Pre-Operation Service READ the engine oper[...]

  • Page 12

    A-5 INST ALLA TION RANGER 8 A-5 Angle of Operation 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 [...]

  • Page 13

    A-6 INST ALLA TION RANGER 8 A-6 Connection of the LN-7 to the Ranger 8 • Shut the welder off. • Connect the LN-7 and the K240 contactor kit per instructions on the connection diagram S17742 (can be found in the back of this manual). • Place the “RANGE” switch to the “WIRE FEED” position and the “POLARITY” switch to the desired pol[...]

  • Page 14

    A-7 INST ALLA TION RANGER 8 A-7 115 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 Table[...]

  • Page 15

    A-8 INST ALLA TION RANGER 8 A-8 TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER 8. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electrical control. reg[...]

  • Page 16

    A-9 INST ALLA TION RANGER 8 A-9 Standby Power Connections The Ranger 8 is suitable for temporary, standby, or emergency power using the engine manufacturer ’ s recommended maintenance schedule. The Ranger 8 can be permanently installed as a standby power unit for 230V-3 wire, single phase 35 ampere service. (Connections must be made by a licensed[...]

  • Page 17

    A-10 INST ALLA TION RANGER 8 A-10 Connection of Ranger 8 to premises wiring must be done by a licensed electrician and must com- ply with the National Electrical Code and all other applicable electrical codes. 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 230 VOLT 115 VOLT 115 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVER[...]

  • Page 18

    B-1 OPERA TION RANGER 8 B-1 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. DESIGN FEA TURES AC/DC STICK WELDING (Constant Current) • AC 40 - 225 Amps • DC 40 - 210 Amps • 100% Duty Cycle on All S[...]

  • Page 19

    HONDA 20 H.P. GX620 .3 Gallons/Hour (1.3 Liters/Hour) .7 Gallons/Hour (2.7 Liters/Hour) 1.6 Gallons/Hour (6.0 Liters/Hour) 1.7 Gallons/Hour (6.3 Liters/Hour) 1.2 Gallons/Hour (4.6 Liters/Hour) 1.5 Gallons/Hour (5.7 Liters/Hour) B-2 OPERA TION B-2 W elder Controls - Function and Operation ENGINE “ ON-OFF ” Switch When placed in the “ ON ” po[...]

  • Page 20

    B-3 OPERA TION B-3 Starting/Shutdown Instructions Starting the Engine Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’ s Manual. 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 foll[...]

  • Page 21

    B-4 OPERA TION B-4 W elding Process Stick (Constant Current) Welding Connect welding cables to the "TO WORK ” and "ELECTRODE ” studs. Start the engine. Set the "Polarity ” switch to the desired polarity. Set the “ RANGE ” switch to a setting that is equal to or slightly greater than the desired welding current. (The “ RAN[...]

  • Page 22

    B-5 OPERA TION B-5 RANGER 8 Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. TIG/K7930-1/K938-1, Yes HIGH Cold Press Amptrol, contactor K936-( ) /K892-1 closes, welding (WITH AMPTROL) start[...]

  • Page 23

    C-1 A CCESSORIES C-1 RANGER 8 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order: K957-1 Trailer K958-1 Ball Hitch K958-2 Lune[...]

  • Page 24

    C-2 A CCESSORIES C-2 RANGER 8 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 (r[...]

  • Page 25

    Honda GX620 6 Months or 100 HRS 1 Year or 200 HRS D-1 MAINTENANCE D-1 RANGER 8 SAFETY PRECA UTIONS 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 whe[...]

  • Page 26

    HONDA GX620 HONDA 15400-PR3-004 (HONDA CODE 3179553) FRAM PH6811 HONDA 17211-ZJ1-000 (HONDA CODE 4209672) HONDA 17218-ZJ1-000 (HONDA CODE 4209706) HONDA 16910-ZE8-005 (HONDA CODE 2106235) NKG BPR6ES Nippondenso W20EPR-U .O3O in., (76mm) gap D-2 MAINTENANCE D-2 Engine Adjustments OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this [...]

  • Page 27

    E-1 TR OUBLESHOO TING E-1 RANGER 8 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION This Troubleshooting Guide is provided to help you locate and repair poss[...]

  • Page 28

    E-2 TR OUBLESHOO TING E-2 RANGER 8 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PROBLEMS (S[...]

  • Page 29

    E-3 TR OUBLESHOO TING E-3 RANGER 8 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PROBLEMS (S[...]

  • Page 30

    F-1 DIA GRAMS F-1 RANGER 8 12 VOLT STARTER AM1 + - IDLER SOLENOID CR1 209 213 215 BATTERY S3 TO SPARK PLUGS IGNITION CONTROL 216A 212 212 (CAVITY #1) (NOTE CAVITY NUMBERS) LOCATING TAB 216 TERMINAL BLOCK CONNECTION + - AC AC B+ OIL PRESSURE SWITCH REGULATOR FLYWHEEL ALTERNATOR STARTER SOLENOID 209 208A 208B 208 (CAVITY #3) 216A CAPACITOR ELECTRICAL[...]

  • Page 31

    F-2 DIA GRAMS F-2 RANGER 8 12 VOLT STARTER IDLER SOLENOID CR1 209 213 215 BATTERY TO SPARK PLUGS IGNITION CONTROL 216A 212 (CAVITY #1) (NOTE CAVITY NUMBERS) LOCATING TAB TERMINAL BLOCK CONNECTION + - AC AC B+ OIL PRESSURE SWITCH REGULATOR FLYWHEEL ALTERNATOR STARTER SOLENOID 209 208 (CAVITY #3) CAPACITOR ELECTRICAL SYMBOLS PER E1537 TERMINAL BLOCK [...]

  • Page 32

    F-3 DIA GRAMS F-3 RANGER 8 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. [...]

  • Page 33

    F-4 DIA GRAMS F-4 RANGER 8 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. [...]

  • Page 34

    F-5 DIA GRAMS F-5 RANGER 8 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. [...]

  • Page 35

    F-6 DIA GRAMS F-6 RANGER 8 CONNECTION OF RANGER 8 T O LN-7 & K240 CONT A CT OR KIT 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.B. 3 conductor #16 power cord physically suitable for[...]

  • Page 36

    F-7 DIA GRAMS F-7 RANGER 8 L OF SHAFT 9.29 21.21 9.31 2.75 17.00 26.59 19.11 30.28 9.09 9.09 UNDERCARRIAGE MOUNTING HOLES 42.25 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 11.31 21.95 FOR OIL FILTER REMOVAL 30.00 8.80 30.00 42.00 C M17215-2 1-30-98E[...]

  • Page 37

    F-8 DIA GRAMS F-8 RANGER 8 8.80 42.25 10.33 9.09 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 21.21 30.28 9.29 9.31 30.00 UNDERCARRIAGE MOUNTING HOLES L 9.09 26.59 2.75 17.00 C OF SHAFT FOR OIL FILTER REMOVAL 42.00 30.00 22.15 M17215-3 1-30-98E[...]

  • Page 38

    NO TES RANGER 8[...]

  • Page 39

    Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay. Place your order now using the coupon below. The hardbound book con[...]

  • Page 40

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

  • Page 41

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

  • Page 42

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]