Lincoln Electric RANGER IM604-B User's Manual
Contents
1. wol WL Ld TOHINOO SNANL Nani L 9 zao GION310S YvYvvvv er 9 i 4401NHS voz 9 9 9 AN9 En f ov __ VLOZ veo LHOddnsS 0 AOEZIASLL SSONO Wolvinods NOILINOI vr A gt Ge e YILYYLS YN lo S imp T a vec 1004 X ANIONS 90N9 g zr M 4 NNOO 33S S 519018 TWNINYAL a AHBLIVS Lez 8 602 KC S Mi 9 as Hs COON 912 re Y3LIW HNOH 8 vrez NOILISOd 5 aNo GION310S arec FP o1nv NI 1D INMOHS 79 d 3 0N9 J ELZ vs 36 vez qe 289 gt d HS agoz S3NIHOVW 3WOS 0802 4 1 NO 3 V3ddV LON 5308 NOLINE LYVLS WV ss VES 2 02 3144v8 LV T Yy NMOHS ES VSD 1 NYNO AINO 12601 3802 9418 sjaued eunsojoue y JO euo uo y juo 10 S SIUL 3 LON RANGER 8 LPG LINCOLN E 23 WELDER STANDARD OUTPUT TERMINALS CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED hNEAR2. LE 23 DIMENSION PRINT EE 24 PARTS LISTS i P229 Series 254 4 P255 C 1 GENERAL DESCRIPTION The 8 LPG is a twin cylinder LPG fuel engine driven multiprocess arc welder and AC power genera tor It is built in a heavy gauge steel case for durability on the job site DESIGN FEATURES AC DC STICK WELDING Constant Current AC 40 225 Amps DC 40 210 Amps 100 Duty Cycle on All Settings Output Selector with 6 Ranges Output Control for Fine Current Adjustment Use with a broad range of AC amp DC Electrodes Including Fleetweld 5P DC SEMIAUTOMATIC WIRE FEED WELDING Constant Voltage CV Tap Setting for 60 200 Amps 100 Duty Cycle Excellent Performance with 068 1 7mm NRG 211 MP Innershield Electrode Limited MIG Welding with L 50 amp 1 56 using blended Argon Shielding Gas The Recommended Wire Feeder is the LN 25 but Can Also be Used with the LN 7 Wire Feeder LN 7 and LN 25 without Contactor Requires the K240 Contactor Kit AC DC TIG WELDING Constant Current AC amp DC TIG Welding Can be Done at All Constant Current Output Range Settings AUXILIARY POWER 8000 Watt AC 115 230 Volt 60 Hz Generator Operates AC Power Tools Powers Battery Chargers Powers a 1 5 HP Motor If Started Under No Load Lights Eighty 100 Watt Incandescent Bulbs Can be Used for Standby Power OTHER FEATURES Po
3. TO WORK 10 2 92 WARNING Turn the power off when making connections N A N B N C N D N E N F Use power source polarity switch to set for desired electrode polarity Position the output selector switch on the power source to the CV position 3 conductor 16 power cord physically suitable for the instal lation and plug rated at 115 volts 15 amperes AC Plug into 115 volt AC receptacle on welder control panel or other 115 volt AC supply rated at a minimum of 500 volt amperes Leads 21 and GND do not appear on LN 7 s with codes below 7026 Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications If LN 7 is equipped with a meter kit extend lead 21 using 14 or larger insulated wire physically suitable for the installa tion An S16586 length remote voltage sensing work lead N G N H N J may be ordered for this purpose Connect it directly to the work piece independent of the welding work cable For conve nience this extended 21 lead should be taped to the welding work lead Tape up bolted connection where lead 21 is extended Idler switch on power source must be in high idle position If an optional remote output control is used connect it to this terminal strip or 6 pin Amphenol receptacle NOTE Terminal strip or 6 pin Amphenol receptacle not available on all power sources CAUTION Any speed up of t
4. Have qualified personnel do maintenance and troubleshooting work Turn the engine off before working inside the machine e Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete e If guards are missing from a machine obtain replacements from a Lincoln Distributor See Machine Parts List Read the Safety Precautions in the front of this manu al and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair keep hands hair clothing and tools away from gears fans and all other moving parts when starting operating or repair ing the equipment Routine Maintenance 1 Atthe end of each day s use make certain that the valve on the LPG fuel supply cylinder is closed Check the crankcase oil level add oil if needed CAUTION 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 2 OIL Maintenance schedule for changing the oil and oil filter after break in Kohler CH20S 200 hr The above schedule is for normal operating condi 17 More frequent oil changes are required with dusty high temperature and other severe operating condi tions Refer to the maintenance sec
5. ply cylinder Always de pressurize the LPG supply hose at the end of each days use Close the valve on the LPG supply cylinder while the engine is running at high idle The engine will continue to run for about 30 sec onds and then stop After the engine stops place the engine ON OFF switch in the OFF position Break in Period It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in period approxi mately 50 running hours IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN The engine manufacturer s recommendation for the running time until the first oil change is 5 hours The oil filter is to be changed at the second oil change Refer to the Engine Owner s Manual for more information Welding Process Stick Constant Current Welding Connect welding cables to the TO WORK and ELECTRODE studs Start the engine Set the Polarity switch to the desired polarity Set the RANGE switch to a setting that is equal to or slightly greater than the desired welding current The RANGE dial marking indicates the maximum current for that range Fine adjustment of the welding current 12 is made by adjusting the output CONTRO
6. Remote Control Receptacle Kit K892 1 Includes a 6 pin MS type Amphenol receptacle and a local remote toggle switch that mounts in the case front Requires a Remote Control Option Remote Control K857 Consists of a control box with 25 ft 7 5m of four conductor cable Permits remote adjustment of output voltage Requires Remote Control Receptacle Kit to be mounted in machine Spark Arrester Kit K894 1 Includes a heavy gauge steel approved spark arrester and clamp for easy mounting to muffler exhaust pipe GFCI Receptacle Kit K896 1 Includes two UL approved 115V ground fault circuit interrupter duplex type receptacles with covers and installation instruc tions Replaces the two factory installed 115V duplex receptacles Each receptacle of each GFCI duplex is rated at 15 amps but the maximum total current from each duplex is limited to 20 amps TIG Module K930 1 Provides high frequency and shielding gas control for AC and DC GTAW TIG welding applications Compact case is designed for easy carrying complete with 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 For use of optional Amptrol the K892 1 Remote Control Receptacle Kit must be installed in the Ranger 8 The K939 1 Docking Kit is available for mounting the TIG Module on top of the Ranger 8 The K936 3 control cable is required if remote control is used
7. 23 Keep your head out of the fumes DA Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owner s Manual 2 Use ventilation or exhaust to remove fumes from breathing zone Remove all loads connected to the AC power recepta cles To start the engine set the Idler Control switch in the Automatic Ge position Open the fuel valve on the supply cylinder Always pull the choke control out when starting the engine cold warm or hot Place the Engine switch in the ON position Push the START button and crank the engine until it starts Release the button as soon as the engine starts Do not push the START button while the engine is running because this will cause damage to the ring gear and or starter motor After the engine has started slowly return the choke control to the full position Choke Open RANGER 8 LPG LINCOLN 12 After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine NOTE Backfiring may occur if engine is not allowed to cool at low idle before stop ping Stop the engine by placing the Engine switch in the OFF position Close the fuel valve on the LPG sup
8. 8 10 High Frequency Generator for TIG Welding Applications 10 OPERATING INSTRUCTIONS iii 10 15 Additional Safety Precautions nennen 10 Welder Operation 10 Welder 10 Ranger 8 Typical Fuel 10 Welder Controls Function and 11 Start Shutdown Instructions 2 11 Breakin Lm 12 WeldingPrOCess cionem mardi 12 Stick Constant Current 12 TIG Constant Current Weldmg sese 12 Wire Feed Welding Processes Constant 13 Summary of Welding Process 13 EE 13 Standby Power Connection 14 Connecting Ranger 8 to Premises 15 Electrical Device use with Ranger 8 LPG 16 MAINITENANGE erh ee te 17 Safety TE 17 elle 17 Engine AGUS OMS 17 SIP RINGS 18 Battery tessuti E 18 18 Engine Maintenance Parts ss 18 TROUBLESHOOTING AR Re eege ebe 19 20 Wirng DIagramr EET 21 22 Connection
9. 9900 Watts 60 Hz AC Ranger 8 REISE DC Constant Current 30 3 x 19 2 x 43 8 LPG K1616 1 Welder with 210A 25V 100 70 Amps 8 009 watts of 115V 770 x 488 x 1113 mm Kohler Auxiliary Power DC Constant Voltage 200A 20V 100 35 Amps 511 Ibs 233 kg 230V O C V 80V Engine Product Operating Name Description Horsepower Speeds Displacement Capacities Ranger 8 2 Cylinder 20 HP Full Load 38 1 cu in Fuel Kohler CH20S 4 Cycle 3600 RPM 3500 RPM 624 cc LPG cyl Command w LP Air Cooled LPG Engine High Idle Lubricating Oil Aluminum Alloy with 3700 RPM 2 0 Qts 1 9 L Cast Iron Liners Electronic Ignition Low Idle Auto Electronic Idler 2200 RPM Overhead Valves RANGER 8 LPG LINCOLN 5 3 SPECIFICATIONS AC STICK TIG CC OUTPUT 225 OUTPUT RANGE 50 OUTPUT RANGE lt o l gt 2 n 2 o 100 150 200 250 OUTPUT AMPS DC STICK TIG CC OUTPUT 210 OUTPUT RANGE 50 OUTPUT RANGE D o o gt 2 n 2 o 0 50 100 150 200 250 300 350 5 DC WIRE FEED CV OUTPUT D o LE o gt 2 CV OUTPUT RANGE o 0 50 100 150 200 250 300 350 OUTPUT AMPS RANGER 8 LPG LINCOLN 4 OPTIONAL EQUIPMENT Field Installed Four Wheel Undercarriage K933 1 Allows move ment of the Ranger 8 by hand without lifting Easily assembles to the Ranger 8 Includes two rugged hard
10. THE TERMINAL STRIP OR TO i POWER AN UNPAINTED FRAME SCREW i 0 CONNECTION DIAGRAMS 23 RANGER 8 LN 25 ACROSS THE ARC CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts 6 PIN ET AMPHENOL G ELECTRODE TO WORK SWITCH TO THE WIRE FEED CV POSITION x SS MOVING PARTS can injure Keep guards in place Keep away from moving parts Only qualified personnel should install use or service this equipment OPTIONAL K444 1 REMOTE CONTROL LN 25 WIRE FEEDER Le CLIP LEAD 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 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 amp K240 CONTACTOR KIT CONNECTION OF LN 7 amp K240 CONTACTOR K CONTROL CABLE T WITH 115 VOLT AUXILIARY POWER AND CV OUTPUT TO LN 7 K240 CONTACTOR KIT amp N G N J RK ELECTRODE 115V 50 60HZ NOTE 600 AMP CAPACITY POWER i gt ELECTRODE CABLE TO LN 7 517742
11. TRHORERMEI HS TFS ET REL BE SUCR Rr de EL ES AMENER 0 FAIS zeit ele EFSA BEHE VT Aal veel d illai aul Gud AAL Gail ag ls Ca L LINCOLN 5 World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
12. WIRE FEED CV 1 Range Setting 200 CAUTION Never change the RANGE Switch setting while welding This will damage the switch Control Provides a fine welding current adjustment within the Range Switch settings in the STICK TIG mode and welding voltage control with the Range switch set in the wire feed mode IDLER Switch The idler switch has two positions HIGH and AUTO When in HIGH position the engine will run continuously at high idle When in AUTO operates as follows 140 gt idle position the idler 11 a Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds b Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle Starting Shutdown Instructions Starting the Engine A WARNING Do not touch electrically live parts of electrode with skin or wet clothing Keep flammable material away Insulate yourself from work and ground Wear eye ear and body protection
13. back to the cooling air inlet A WARNING 23 Operate welder in open well ventilated area or vent the engine exhaust fumes outdoors Connection of Lincoln Electric Wire Feeders A WARNING Shut off welder before making any electrical connections Wire Feed Constant voltage Connection of the LN 25 to the Ranger 8 a Shut the welder off b 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 c Position the welder Polarity switch to the desired polarity either DC or DC d Position the RANGE switch to the WIRE FEED position e 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 f Place the idler switch in the AUTO position g 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 LPG LINCOLN 10 Connection of the LN 7 to the Ranger 8 a Shut the welder off b 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 c Place the RANG
14. in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lir
15. in parallel Maximum Current Draw No Welding Load from K1616 1 Ranger 8 LPG 115 230V Each 115V Duplex Total from Both 115V Duplexes Dual Voltage Receptacle ___20 p 20 Load from 115 230V Dual Voltage Receptacle Maximum current draw from each 115V GFCI Duplex receptacle is 20 amps 115 230 Volt Dual Voltage Receptacle The 115 230 volt receptacle can supply up to 35 amps of 230 volt power to a two wire circuit or up to 35 amps of 115 volt power from each side of a three wire circuit up to 70 amps total Do Not connect the 115 volt circuits in parallel Current sensing for the auto matic idle feature is only in one leg of the three wire circuit as shown below GND 230V Current Sensing for Automatic Idle Receptacle viewed from front of machine Motor Starting Most 1 5 HP motors can be started if there is no load on the motor or other load connected to the machine 14 since the full load current rating of a 1 5 HP motor is approximately 20 amperes 10 amperes for 230 volt motors Larger motors through 2 hp can be run pro vided the receptacle rating as previously stated is not exceeded This may necessitate 230V operation only Auxiliary Power While Welding It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are permitted by following Table l The permissible currents shown assume that current is being drawn from ei
16. is hands For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only I IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 52 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders CHECK ONE Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only Credit Card Y USE THIS FORM TO ORDER Order from sooks OR FRE
17. of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS 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 standards 4 b Use suitable clothing made from d
18. statement appears where the information must be followed to avoid minor personal injury or damage to this equipment RANGER 8 LPG LINCOLN 8 TABLE OF CONTENTS Page SAFETY PRECAUTIONS eere er tete apte de ex DRM TE ner tt i iv INTRODUCTORY INFORMATION GENERAL DESCRIPTION dte e une 1 DESIGN FEATURES ieu aeu 1 SPECIFICATIONS M 2 3 OPTIONAL EQUIPMENT patrare aa rex xu ru mper 4 RECOMMENDED EQUIPMENT xeu n Renegade dune 5 INSTALLATION INSTRUCTIONS 6 Safety 6 Machine Gro tidilig 6 me DEINER 6 JUICIO 7 8 SCENE 7 M M MES 7 gp UP 8 Battery Corn ctiOh Rex deg risa 8 Welding Eelere EE 8 gn EE 9 High Altitude Operations 9 Murtler Blelocatilon cese iiit rna rona tende A 9 Location Ventilation cuocere ette ertt Revue ade KE Ee de x dnt Noua 9 Connection of Lincoln Electric Wire Feeders 9 10 Connection of the LN 25 to the Ranger 8 9 Connection of the LN 7 to the Ranger
19. 0 125 or 175 225 Amps 3 32 50 70 90 or 125 50 180 Amps 1 16 50 45 120 Amps 70 or 90 RANGER 8 LPG LINCOLN 13 13 It is recommended that the Ranger 8 be used HIGH The Ranger 8 is recommended for limited weld idle when using the TIG Module It can be used in the AUTO position but the delay going to low idle after welding is ceased will be increased if the AFTER FLOW CONTROL is set above 10 seconds Wire Feed Welding Processes Constant Voltage The only Innershield electrode recommended for use with the Ranger 8 is NR 211 MP The electrode sizes and welding ranges that can be used with the Ranger 8 are shown in the following table Diameter Wire Speed Range In Min Approximate Current Range 75A to 120A 80 110 045 045 70 130 120A to 170A 068 40 90 125A to 210A 80 110 70 130 120A to 170A 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 The welding ranges that can be used with the Ranger 8 are shown in the following table Wire Speed Approximate Current Range Diameter in Range In Min 75A to 120A Summary of Welding Processes PROCESS STICK TIG K930 1 K938 1 K936 J K892 1 WITH AMPTROL WIRE FEED LN 25 WITH INTERNAL CONTACTOR WIRE FEED LN 7 WITH K240 CONTACTOR KIT Au
20. COLN N N DIAGRAMS 22 Jequunu SAM juowyedoq 29119 eui eidelt s paised si opoo e 104 5 y enueui siy Aq jou y S 122 gt ONILV9O1 ri ALIAVO CS SYSEWNN ALIAVO M QV313801VH3N39 6v00cIN V NOILO3NNOO 30018 TWNINYAL Z 802 d ALIAVO LIZ o on o ojo D a SYSEWNN Nid HOLO3NNOO uvas WOds NMOHS SLIN3NOdINOO LNO 4 3SVO 12913 Yad SIOEWAS 1VOlIH LO3 T3 ALLIHM M 101A A HO ama n AVH9 HO MOVIE 8 73009 JHL SdOLS TVNINZL SIHL ONIGNNOYDS NOLLVNIIAV 1 LSSYVAN dS m IC N 6 Kul ooe qii 12 8002 1 16 3 a BP Sis deeg 77 ve 43407109 ae 6 3LIHM STVNINYAL oes YOLVNHILIV TH33HMA 4 SIN3NOdINOO ANIDNA
21. D AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te a l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU e za 24758 else e MAS AH PARAH 387E Turn power off bef
22. 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 RANGER 8 LPG LINCOLN 7 Pre Operation Service CAUTION READ the engine operating and maintenance instruc tions supplied with this machine A WARNING LPG fuel can cause fire or explosion All leak testing must be done in a well ventilated area free from all potential ignition sources e Keep sparks and flame away from machine and LPG supply cylinder Do not expose the LPG supply cylinder to temper atures exceeding 120 F 49 C Do not weld on or near the LPG supply cylinder Do not smoke or allow any potential ignition sources near the LPG supply cylinder Always be certain that the LPG supply cylinder is NOT in the welding circuit Do not allow either welding cable to come in contact with the supply cylinder Replace the fuel supply hose if there is excessive abrasion cracks or wear or if the hose is cut Fuel A lift truck type coupler is provided on the supplied fuel line for easy hand attachment to a lift truck type LPG fuel cylinder The fuel cylinder must meet D O T Specification 4E 240 The valve on the fuel cylinder must be installed on the outlet marked LIQUID The engine will not develop full power if connected to the vapor outlet CAUTION Be cert
23. Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk
24. E switch to the WIRE FEED position and the POLARITY switch to the desired polarity d Place the IDLER switch in the HIGH idle position The engine idling device may not function when welding in the WIRE FEED mode e Adjust wire feed speed at the LN 7 and adjust the welding voltage with the output CONTROL at the welder NOTE If the output CONTROL is set below 3 the K240 contactor may not pull in Connection of TIG Module K930 1 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 If any other high frequency accessory is used with the Ranger 8 a bypass capacitor Order Kit 12246 must be installed in the Ranger 8 10 OPERATING INSTRUCTIONS Additional Safety Precautions Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Do not tamper with the carburetor settings or the fuel hose from the regulator to the carburetor The engine has been pre set for optimum performance Changes in the carburetor settings or fuel hose length can result in reduced performance and excessive carbon monoxide emmisions Read and understand all Safet
25. E INFORMATIVE CATALOGS li Welding School ED 80 New Lessons in Arc Welding Seminar Information Procedure Handbook Twelfth ED 45 How to Read Shop Drawings Educational Video Information ED 93 epes H BOOK DIVISION Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Tiles _______ Price Code Quantity Cost Incentive Management 5 00 IM Name Address Telephone Signature as it appears on Charge Card 0 t 1500 PH _ 3 4580 HA 1 Edition luames F Lincoln Arc Welding Foundation Book Information JFLF 515 EE A New Approach to Industrial Economics 5 00 The American Century of John C Lincoln 5 00 AC Welding Preheat Calculator 300 wC8 Pipe Welding Charis 5 nef 2 BUET ea Shipping Goss CEET WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez n
26. ECTRIC 5 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 e Use open well ventilated areas or vent exhaust outside O AR combustion of LPG fuel does pro duce carbon monoxide Although the level of CO emission is lower than gasoline combustion the exhaust from the Ranger 8 LPG can kill MOVING PARTS can injure Do not operate with doors open guards off NY Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Machine Grounding Because this portable engine driven welder or gener ator 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 electric shock other equip ment to which this engine driven welder supplies power must a be grounded to the frame of the welder using a grounded type plug or b be double insulated When this welder is mounted on a truck or trailer it s frame must be securely connected to the metal frame of the vehicle 6 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 fur
27. IM604 B RANGER 8 LPG For Machines with Code Number 10526 10541 10937 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 ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased OPERATOR S MANUAL SS 150 9002 A ited by Ir BOARD Manufactured Under a Quality Program Certified by ABS Quality Evaluations inc to ISO 9002 Requirements World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e CERHFICATE NUMBER 30278 Copyright 2002 Lincoln Global Inc Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects o
28. INCOLN 19 WHAT TO DO Refer to wiring diagram amp check related leads Refer to wiring diagram and check all related leads 200 224 200A 200B 201 201A Lift brushes and check rotor resistance between slip rings It should be approximately 4 ohms Replace with known good one Disconnect lead 9 at D2 and check for continuity between leads 9 and 7 Replace with known good one Replace with known good one Set switch on Automatic Idler Check for proper connection of leads 213 5E 215 209 209A 224 2244 Remove all external loads and short circuits Check for broken leads 213 and 215 Replace with known good one Replace P C Board with known good one Make certain work clamp is tightly connected to clean base metal Check for disconnected or broken leads in idler sensing circuit Check generator output Replace P C Board with known good one 20 TROUBLE D Engine will not go to high idle when using auxiliary power E Engine will not crank or is hard to crank Engine shuts down Engine does not develop full power Engine is hard to start TROUBLESHOOTING No voltage signal from the current sensor Auxiliary power load less than 100 to 150 watts Faulty P C Board Battery will not hold a charge Faulty Battery No or insufficient charging current Loose battery cable connection s Out of fuel Low oil level Air filter c
29. L or remote control For best arc stability use settings 5 through 10 The Ranger 8 can be used with a broad range of AC and DC stick electrodes See Welding Tips 1 included with the Ranger 8 for electrodes within the rating of this unit and recommended welding currents of each Welding Current Ranges are shown in the following tables AC CURRENT RANGES STICK WELDING 5 TO 10 ON CONTROL DIAL Range Setting s 40 70 Amps Current Range EE 125 70 125 Amps 175 90 175 Amps MAX 120 225 Amps DC CURRENT RANGES STICK WELDING 5 TO 10 ON CONTROL DIAL Range Setting Current Range 30 50 Amps Tee 125 70 125 Amps MAX 120 210 Amps TIG Constant Current Welding The TIG Module K930 1 installed on a Ranger 8 provides high frequency and shielding gas control for AC and DC GTAW TIG welding processes The TIG Module allows full range out put control Afterflow time is adjustable from 0 to 55 seconds When using the Ranger 8 for AC TIG welding of aluminum the TIG Module is to be set for CONTINUOUS HF The following settings and electrodes are recommended SETTINGS FOR PURE TUNGSTEN TUNGSTEN RANGE SWITCH APPROXIMATE DIAMETER SETTINGS CURRENT RANGE 1 8 70 90 or 125 80 150 Amps 3 32 50 70 or 90 45 130 Amps 1 16 50 or 70 40 80 Amps SETTINGS FOR 1 THORIATED TUNGSTEN TUNGSTEN RANGE SWITCH APPROXIMATE DIAMETER SETTINGS CURRENT RANGE 80 1 8 70 9
30. NOO ALIAVO 310N Qv31HOLVH3N39 54015 IVNIINH3I SIHL ONIGNNOHO S3HIM 3LIHW STVNINHAL is SIN3NOdMWOO ANISNA NOLLYNIAWT LG3HV3N 4115 un ve i HO1VNH3LTV T33HMAT4 i wee 38 ME RO QION3109 9 ASOLNHS 2 2 o HOLOH 9 AN9 15 LOY g OV AOEZ AGLL Hodans Wolvino3u S D wv 3NION3 GION310S Jj 8 m 110 j 003 gt gt 01315 19 Li 359 tes IVNINHAL 8 126 8 9700 vec Lie 802 WIRING DIAGRAM 90 H313N YNOH 8 10 3108 avec jee 5 soo 1 wOLNY NI 1D INMOHS 78 WS vol JOULNOO M3IH9S NAY NI LH 1ndino NMOHS 29 21 NOISH3A VSO H31HOM 1 8 LYSOL 9 92901 1 9191 RANGER 8 LPG LIN
31. The K936 4 control cable is required if remote control is not used RANGER 8 LPG LINCOLN 5 RECOMMENDED EQUIPMENT STICK Accessory Kit K710 which includes Electrode Holder amp Cable Work Clamp amp Cable Headshield Remote Control Receptacle Kit K892 1 and Remote Control Kit K857 are optional for remote current control TIG Magnum TIG Torch Magnum Parts Kit and Argon Gas TIG Module K930 1 Contactor Kit K938 1 Control Cable K936 Optional TIG Module Docking Kit K939 1 Arc Start Switch K1814 Hand Amptrol amp K963 Foot Amptrol K870 Remote Control Receptacle Kit K892 1 WIRE FEED LN 25 K449 Includes internal contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid Remote control Receptacle Kit K892 1 and Remote Voltage Control Kit 444 1 are required for voltage control at the feeder LN 7 Contactor Kit K240 is required Magnum Gun is required for gas shielded welding Innershield Gun is required for gasless welding RANGER 8 LPG LINCOLN 6 INSTALLATION INSTRUCTIONS Safety Precautions A 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 EL
32. ain that the cylinder valve is CLOSED before attempting to attach the fuel supply hose coupler to the cylinder Connect the coupler to the fuel cylinder and tighten by hand After connecting the fuel supply to the supply cylinder open the valve on the fuel cylinder and leak test by brushing a 50 50 soap and water solution on to the fol lowing connections Both ends of the fuel hose where it enters the metal connector The threaded fitting on the end of fuel hose attached to the Ranger 8 LPG fuel shut off solenoid The fuel hose coupler and the connection to the cylinder valve 7 The stem of the cylinder valve and where the valve is attached to the top of the cylinder All other fittings on top of the fuel cylinder If growing bubbles appear there is a leak Re tighten connection or replace defective component Retest to make sure that there is no leak Leak test must be performed each time the fuel cylin der is replaced Always close the cylinder valve when the machine is not being used The specification for aluminum lift truck cylinders are shown below 12 3 8 OD 28 1 8 43 1 2 Ib Footring Outside Diameter 33 1 2 Ib Capacity LP Gas Cylinder Volume Cu In LBS 33 5 2219 43 5 2873 Note The Ranger 8 LPG cannot be used with vapor draw LP gas cylinders such as those used for recreation vehicles trailers grilles and boats The Ranger 8 is shipped w
33. au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obte
34. cable electrical codes RANGER 8 LPG LINCOLN 16 16 CAUTION Certain Electrical devices cannot powered by the RANGER 8 LPG See Table 2 TABLE A 2 ELECTRICAL DEVICE USE WITH THE RANGER 8 LPG Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent NONE light bulbs electric range hot pan skillet coffee maker Capacitive TV sets radios microwaves Voltage spikes or high voltage appliances with electrical control regulation can cause the capaci tative 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 These devices may require large drills well pumps grinders small refrigerators weed and hedge trimmers 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 A ferroresonant power conditioner is required and liabilities still exist The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the RANGER 8 LPG RANGER 8 LPG LINCOLN 5 17 MAINTENANCE Safety Precautions A WARNING
35. e et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail
36. fueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e some cases it may be necessary to remove safety alle minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f
37. he battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last Hardware Both English and Metric fasteners are used in this welder Engine Maintenance Parts kag Kohler 1205001 Air Filter Element Kohler 4708303 FRAM CA79 Air Filter Kohler 2408302 Pre Cleaner Spark Plugs Resistor Type CHAMPION RC12YC 030 GAP RANGER 8 LPG LINCOLN 5 19 TROUBLE A No welder or output power B Engine will not idle down to low speed C Engine will not go to high idle when attempting to weld TROUBLESHOOTING 1 Open in miscellaneous leads Open lead in flashing or field circuit Faulty rotor Faulty Potentiometer R1 Faulty stator Field winding Faulty Field rectifier D2 Faulty P C Board Idler switch on High Idle Insufficient voltage present between terminals 213 5E Voltage should be 12V DC External load on welder or auxiliary power Faulty wiring in solenoid circuit Faulty idler solenoid Faulty P C Board Poor work lead connection to work No voltage signal from the current sensor No open circuit voltage on output studs Faulty P C Board RANGER 8 LPG L
38. he engine RPM by changing the gov ernor setting or over riding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes above 140 volts the LN 7 control circuit will be damaged The engine governor setting is pre set at the factory do not adjust above RPM specifications listed in engine welder oper ating manual RANGER 8 LPG LINCOLN DIMENSION PRINT Ranger 8 LPG Kohler 24 DIMENSION PRINT CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK UNDERCARRIAGE MOUNTING HOLES 11 31 30 28 9 09 9 09 19 14 oO uo ur RANGER 8 LPG LINCOLN 5 24 NOTES RANGER 8 LPG LINCOLN NOTES RANGER 8 LPG LINCOLN NOTES RANGER 8 LPG LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding 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 contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for a
39. i la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR LiH ELE LATE MLMPT APSSAPREBS e E GUB GH Oa CRM ER Xe a Sal Weal AMI Qi el all oa Y O el ai 1 d o lala AA ll DA dan ule Y Jio Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM o Eia RH m ET IFM o eis Jo ALD al gll pis Ac AI uie Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF EU RRR HRSESOREME ez 119 59 diye ule lag al gil eg 4 aun y REA
40. ith the engine crankcase filled with SAE 10W 30 oil Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Make certain that the oil filler cap is tightened securely Refer to the engine Owner s Manual for specific oil recommendations LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Kohler 205 2 0 Quarts 1 9 Liters RANGER 8 LPG LINCOLN 8 Battery Connections This welder is shipped with the negative battery cable disconnected Make sure that the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine If the battery is discharged and does not have enough power to start the engine see the battery charging instructions in the Battery section Welding Output Cables With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodically and tightened if neces sary Loose connections will result in overheating of the output studs When welding at a considerable distance from the welder be sure you use ample size welding cables Listed below are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable vol
41. larity Switch for Selecting DC DC or AC Welding Output 1 K930 1 TIG Module Available for high frequency and shielding gas control for AC and DC GTAW TIG welding applications Remote Control Receptacle Kit Available Electronic Engine Idler Engine Automatically Goes to Low Idle in 10 to 14 Seconds after Welding or Use of Auxiliary Power Includes High Idle Switch Electric Starting Battery Charging Ammeter Full 8 kVA Auxiliary Output Receptacle Factory Installed Engine Hour Meter Engine Protection Shuts Engine Down in the Event of Low Oil Pressure Built in Feet for Easy Mounting to Truck Bed or Trailer All Copper Alternator Windings and High Quality Insulation for Long Life and Dependability Powder Painted Case and Base for Outstanding Corrosion Protection Quiet muffler with reversible exhaust feature either right or left side of machine ENGINE The Kohler 20 HP Command LPG engine offers the following features Air Cooled Twin Cylinder Overhead valves Hydraulic valve lifters Cast Aluminum Alloy Crankcase with Integral Cast Iron Cylinder Liners Electric Start with Solid State Battery Charging Module Solid State Breakerless Ignition Spin on Oil Filter Low Oil Pressure Shutdown Protection LPG regulator and vaporizer This trademark is the property of Kohler Co RANGER 8 LPG LINCOLN SPECIFICATIONS Machine AC Constant Current 25 100
42. ll students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training
43. logged Spark plugs do not have specified gap Spark plugs are fouled RANGER 8 LPG LINCOLN 20 WHAT TO DO Check for disconnected or broken leads in idler sensing circuit Idler may not function with less than 100 to 150 watt load Set idler switch to high idle Replace P C Board with known good one Replace with known good one Check the connection of the lead from the voltage regulator on the engine to the charging ammeter and the battery Check and tighten connection at battery at starter at engine foot or at frame Replace LPG fuel cylinder Check oil level and add oil as required Replace Adjust to specified gap Replace spark plugs See Engine Owner s Manual JOQUINU epoo eu aw e 104 2219S ejqi6Gejr si eui j sjeued eunsoj oue y Jo euo uo y pejsed si epoo uejnomed 0 oyioeds siy Aq UE 20 eq jou Ajuo 104 SI SIUL 310 DEEN 26919 H3d SIOSWAS VOIHLO3 13 NES uvau Q3AIA NMOHS SLN3NOdWOO LNOYS ASVO TIV 30018 TVNIAH3L 227 LE 122 1310IA A EH 8V1 9NILV2OT1 ama n SES v N 6 ALIAVO 802 Ire ALAYO 0788 77 7 G ALIAVO 2 X ovi8 8 2003 90109 av31 SH38WnN Nid HOLO3N
44. ments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop RANGER 8 LPG LINCOLN 18 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 A CAUTION Do not attempt to polish slip rings while engine is running Battery A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove 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 18 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover 2 If t
45. molded wheels and two durable two ply nylon 4 80 4 00 8 pneumatic tires rated at 30 psi The spring loaded handle provides convenient comfortable steer ing The undercarriage comes equipped with a sturdy frame that is capable of supporting the weight of the machine K934 1 and K934 2 brackets are available for mounting gas cylinders on the undercarriage Bracket for Mounting a Gas Cylinder or a LPG Fuel Cylinder to a K933 1 K934 1 Easily mounts on the back of the K933 1 Four Wheel Undercarriage to carry either a welding gas cylinder or a lift truck type LPG fuel cylinder with a capacity of 33 5 Ibs or 43 5 Ibs of fuel Bracket for Mounting a Welding Gas Cylinder and a LPG Fuel Cylinder to a K933 1 K934 2 Easily mounts on the back of the K933 1 Four Wheel Undercarriage to carry both a welding gas cylinder and a lift truck type LPG fuel cylinder with a capacity of 33 5 Ibs or 43 5 Ibs of fuel Canvas Cover K886 1 To protect the Ranger 8 when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent Power Plug Kit K802 R Provides four 115V plugs rated at 15 amps each and one dual voltage full kVA plug rated at 115 230V 50 amps Accessory Kit K710 Includes 30 ft 9 1m 3 AWG electrode cable 25 ft 7 6m 3 AWG work cable headshield with No 12 filter GC300 work clamp and Cooltong 300 electrode holder Cables are rated at 225 amps 40 duty cycle
46. nir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la deb
47. ore servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas XLFFYA Y EAKCRU gt PRE RET BRAY FE e HMDS RK AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CRMREBIFELEWTEEU CHRRIARRARS SHAE Ro e 20 Sel AE Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai dul jua Sarin e os Qui BALL cal sd ue Aie Ao pha NM Jl ale Ads cuts UI ai l Jai y e Aale Viel Al all LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K RA CL
48. r other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 mm MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before re
49. rancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This
50. tage drop TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 225 Amps 225 Amps 40 Duty Cycle 100 Duty Cycle 0 50 Ft 3 AWG 1 AWG 50 100 Ft 3 AWG 1 AWG 100 150 Ft 2 AWG 1 AWG 150 200 Ft 1 AWG 1 AWG 200 250 Ft 1 0 AWG 1 0 AWG RANGER 8 LPG LINCOLN 9 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 25 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 High Altitude Operation The Ranger 8 LPG requires no adjustment for high altitude operation Muffler Relocation A WARNING Shut off welder and allow muffler to cool before touching muffler The Ranger 8 is shipped with the exhaust coming out on the left side The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and installing the cover on the opposite side Operating the Ranger 8 without the cover in place will result in a higher noise level and no increase in machine output Location Ventilation The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid heated air coming out of the welder recirculating
51. ther 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 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 insulat ed joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provid ed on the front of the welder Spark Arrester Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations the K894 1 spark arrester must be installed and properly maintained A CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance Trailers 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 Some of the factors to be considered are as follows 1
52. ther the 115V or 230V supply not both at the same time NOTE Voltage and permissible watts decrease as CONTROL is adjusted to settings less than 10 It is recommended that at settings less than 10 only incandescent lighting loads be connected to the auxil iary power receptacles TABLE SIMULTANEOUS WELDING AND POWER Output Selector Setting Permissible Power Watts Unity Power Factor Permissible Auxiliary Current in Amperes 115V or 9 230V Max Stick or Wire Feed Setting None 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 A 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 LPG LINCOLN 15 Install double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service overcurrent protection Take necessary steps to assure load is limited
53. tion of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the oil and oil filter are not changed according to the manufacturer s recommendation 3 Air Cleaner With normal operating conditions the maintenance schedule for cleaning and re oil ing the foam pre filter is every 25 hours and replacement of the air cleaner filter every 100 hours More frequent servicing is required with dusty operating conditions Refer to the mainte nance section of the Engine Owner s Manual for more information 4 Refer to the maintenance section of the Engine Owner s Manual for the maintenance schedule spark plug servicing and cooling system servic ing 5 Blow out the machine with low pressure air periodically In particularly dirty locations this may be required once a week 6 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 han dle from maximum to minimum setting twice each morning before starting to weld Engine Adjustments OVERSPEED IS HAZARDOUS WARNING 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 Adjust
54. 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 15 below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 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 Plug this cable into the 50 amp 115 230V receptacle on the Ranger 8 case front Figure 1 CONNECTION OF RANGER 8 TO PREMISES WIRING 230 VOLT 3 Wire COMPANY Service METER 230 Volt POWER 115 VOLT 60 Hz GROUNDED CONDUCTOR LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES E DISCONNECT AND SERVICE GROUND OVERCURRENT 230 VOLT PROTECTION DOUBLE POLE CIRCUIT 230 VOLT BREAKER 50 AMP 115 230 VOLT PLUG NEMA TYPE 14 50 1 V 50 115 230 VOLT De P ll RR NOTE No 8 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS A 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 appli
55. urable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays 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 5 5 5 5 5 a Welding may produce fumes gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 6 5 LINCOLN 5 Shielding gases used for arc welding can displace air and cause inj
56. ury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 e
57. xiliary Power The Ranger 8 can provide up to 8 000 watts of 115 230 volts AC single phase 60 Hz power for con tinuous use The front of the machine includes three receptacles for connecting AC power plugs one 50 amp 115 230 volt NEMA 14 50R receptacle and two 15 amp on Codes 10541 Below 20 amp on Codes 10937 Above 115 volt NEMA 5 15R recepta cles ELECTRODE WHEN NOT WELDING TO START WELDING Touch electrode to work Welding starts immediately and engine goes to high idle Press Amptrol contactor closes welding starts immediately Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 Press gun trigger contactor closes Welding starts immediately A 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 aux iliary power 115V 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 RANGER 8 LPG LINCOLN 14 The current rating of any plug used with the system must be at least equal to the current load through the associated receptacles see tables below Do not attempt to connect power receptacles
58. xplosion 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 CYLINDER may explode 22238 Sr if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders
59. y Precautions before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manual Welder Operation Welder Output Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS Duty Cycle 100 for both welding and auxiliary power Ranger 8 LPG Constant Current 225 Amps AC 25 Volts 210 Amps DC 25 Volts Constant Voltage 200 Amps DC 20 Volts Ranger 8 LPG Typical Fuel Consumption KOHLER CH20S COMMAND 1 60 Ib Hour 0 73 kg Hour 2 40 Ib Hour 1 09 kg Hour 5 40 Ib Hour 2 45 kg Hour 3 4 Load 7 00 Ib Hour 3 18 kg Hour Full Load 8 50 Ib Hour 3 86 kg Hour Low Idle No Load High Idle No Load 1 2 Load RANGER 8 LPG LINCOLN 11 Welder Controls Function and Operation Explanation of Symbols that Appear on this Equipment oo o OFF Low Idle High Idle ENGINE Switch When placed in the ON position this switch energizes the engine ignition circuit When placed in the OFF position the ignition circuit is de energized to shut down the engine ENGINE START Push Button Switch Energizes engine starter motor Polarity Switch A CAUTION Never change the Polarity switch setting while welding This will damage the switch i Range Switch Process Maximum Current on Each Setting 50 70 90 125 175 210 DC 225 AC STICK TIG CC 6 Range Settings
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