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Lincoln Electric SVM107-B User's Manual

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1. 212 115V 230V 7 GND C STARTER Lee 85A 5K 9 Q RECTIFIER REGULATOR MEE MODULE WHITE WIRES 777 SLIP RING NEAREST LAMINATION olo OJO 5 5 0 815 g 9 5 2 a GENERATOR LEAD END CONNECTOR PIN NUMBERS NOTE GAVITENUMBERS N A GROUNDING THIS TERMINAL STOPS THE ENGINE 211 CAVITY 3 LEAD COLOR CODE B BLACK OR GRAY RED OR PINK W WHITE 221 CAVITY 1 U BLUE TERMINAL BLOCK GY GRAY CONNECTION 224 CAVITY 4 LOCATING TAB 208 CAVITY 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR ELECTRICAL SYMBOLS PER E1537 MIS968 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 Return to Section TOC Return to Master TOC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO 5 5 0 815 g 9 5 2
2. O10 5 5 0 15 g 9 5 2 1 GROUNDING THIS TERMINAL STOPS THE ENGINE GENERATOR LEAD END 7 NOTE CAVITY NUMBERS a PIN NUMBERS 4 BLACK 211 3 RED W WHITE 27 o Uc BUE LOCATING TAB V VIOLET 221 CAVITY 1 77 TERMINAL BLOCK CONNECTION 2 224C CAVITY 4 208 CAVITY 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR ELECTRICAL SYMBOLS PER E1537 7 19 966 1 8333 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 Return to Section TOC Return to Master TOC LINCOLN B ELECTRICAL DIAGRAMS Ga WIRING DIAGRAM KOHLER CSA MODEL K1419 2 RANGER 8 KOHLER CSA Wiring Diagram CCW EM 99 SHOW OUTPUT Ry IN RUN GROUND SCREW CONTROL Return to Master TOC POSITION AT BLOWER BAFFLE Return to Section TOC ae 77A 76A 75A 221 Li O Tir 210 54 54 SHOWN 1 C IDLER IN AUTO ht 2248 SOLENOID POSITION 8 HOUR METER 2 224
3. D 4 B Major Component D 5 O 5 0 g E a a o O 5 0 g E tc o O 5 0 g E a RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 2 WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the mainte nance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventila
4. GND JJ 115V A 230 V Y A 115 V Y 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 and Do not attempt to connect power receptacles in parallel Motor Starting Most 1 5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine since the full load current rating of a 1 5 hp motor is approximately 20 amperes 10 amperes for 230 volt motors The motor may be run at full load when plugged into only one side of the duplex receptacle Larger motors through 2 hp can be run provided the receptacle rating as previously stated is not exceeded This may necessitate 230V operation only RANGER 8 LINCOLN INSTALLATION TABLE ELECTRICAL DEVICE USE WITH THE RANGER 8 Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker Return to Section TOC Return to Master TOC Capacitive TV sets radios microwaves Voltage spikes or high voltage appliances with electrical control
5. 55 01 T303 TINA NI ALIAVHO 3 DOL J81Se N 0 DOL uonoeg DOL J81Se N 0 201 8 LINCOLN E 201 49159 0 DOL uonoesg 30 201 49159 0 901 uonoes oj 386 0 1 Z SLZZLN S310H 00 27 LL 6L 00 08 T mee 606 606 i 1 l I O Tm x TVAOW3H o 303 5 2 82 02 pe o lt 4 I 2 lt 1 D I T 7 1 40 2 o 2 Lu a 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 201 uonoes 201 uonoes 201 uonoes DOL uonoes uumeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O10 5 5 0 815 g 9 5 2
6. F 34 2 Typical Weld Output Waveform CC Mode Machine Loaded F 35 z Typical AC Weld Output Waveform Machine F 36 8 Abnormal Open Circuit Weld Voltage Waveform CV Mode one diode F 37 Abnormal Open Circuit DC Weld Voltage Waveform sene F 38 it Normal Open Circuit Weld Voltage Waveform CV Mode F 39 o Normal Open Circuit DC Weld Voltage F 40 Normal Open Circuit AC Weld Voltage F 41 Replacement Procedures F 43 Brush Removal and F 43 Field Capacitor and Rectifier Bridge Removal and Replacement F 47 Printed Circuit Board Removal and F 51 Output Rectifier Bridge Removal and F 55 Engine Rotor Removal and Replacement Kit 520788 F 59 o Retest After F 64 5 2 5 o O 5 D
7. 9 20 9 Gal 34 L GX620KI 3600 RPM 37 5 614 Honda Lubricatina Oll Honda ubricating Oil K2160 1 1 9 Qts 1 8 L RATED OUTPUT WELDER 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 WEIGHT 529 Ibs 240kg K1418 1 2 1074 mm 511 Ibs 232kg 1419 1 2 8 K2160 1 Based on a 10 min period RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 SPECIFICATIONS OUTPUT VOLTS AC OUTPUT VOLTS DC OUTPUT VOLTS DC INSTALLATION AC STICK TIG CC OUTPUT 225 OUTPUT RANGE 50 OUTPUT RANGE 100 150 200 250 OUTPUT AMPS DC STICK TIG CC OUTPUT 210 OUTPUT RANGE 50 OUTPUT RANGE 50 100 150 200 250 OUTPUT AMPS DC WIRE FEED CV OUTPUT 300 350 CV OUTPUT RANGE 50 100 150 200 250 OUTPUT 8 LINCOLN 5 300 350 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 0 815 EIS 2
8. TERMI SEE CONN m M CAPACITOR IGNITION CONTROL LT FLYWHEE REGULATOR L ALTERNATO STARTER SOLENOID B SUPPORT 115V 230V GND C SILVER 115V 5 SLIP RING NEAREST LAMINATION COLORED 5L TERMINALS WHITE WIRES ENGINE COMPONENTS olo O o FE 5 PEN elt 5 2 m ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR ELECTRICAL SYMBOLS PER E1537 WELDER LEAD END NOTE CAVITY NUMBERS N amp 208 CAVITY 3 v NON NECTOR PIN NUMBERS NLS 224 8 CAVITY 4 12 in 7 LOCATING TAB 5 o gt 9 S 212 CAVITY 1 277 lt TERMINAL BLOCK CONNECTION 75246 CAVITY 2 Ji 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 Return to Section TOC Return to Master TOC LINCOLN B ELECTRICAL DIAGRAMS WIRING DIAGRAM MODEL K1418 2 RANGER 8 ONAN VERSION Wiring Diagram S3 SHOWN IN COW RUN POSITION OUTPUT H1 GROUND SCREW 1 BLOWER BAFFLE L1 CONT
9. 5 8 RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 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 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
10. POWOES 7 115V Duplex cene Rr bait A 8 2 E NOD 8 Electrical Devices used w Ranger 8 A 9 Auxiliary Power While Welding mme nnne nnne nnns A 10 Stand by Power 10 Connection of Ranger 8 to Premises Wiring A 11 Q 7 5 8 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O10 515 0 g 9 5 2 Return to Section TOC Return to Master TOC 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 Make Model Description Horsepower Speed RPM Displacement Capacities cu in cu cm Onan P220 20 5 HP Fuel K1418 3 3600 RPM 9 Gal 34 L 2 cylinder Onan 39 9 653 Lubricating Oil 4 Cycle High Idle 3700 1 6 Qts 1 5 L Air Cooled Ed Kohler CH20 Gasoline 20 HP K1419 3 Engine 3600 RPM Full Load 3500 Aluminum Alloy Kohler 38 624 Kohler Lubricating Oil with Cast Iron 2 0 Qts 190 Liners Electrical Low Idle 2200 Fuel Ignition
11. a Return to Section TOC Return to Master TOC G 10 SCHEMATIC IDLER CONTROL PC BOARD LINCOLN B 28791 DIODES DIODES SNUBBER gt 016 144007 ELECTRICAL DIAGRAMS 3 TURNS 18 WIRE RESET IN 1 OUT 1 OUT2 Vss 8 BY PASS C CLOCK INH B A MONO IN OSC INH DECODE D 4536B TO IDLE 224 SWITCH TO 215 SOLENOID G 10 200B FIELD OVERCURRE COM PROTECTION NT D10 3A 600V REMOTE INPUT COM EE 120 2 5W C14 01 50V 4T 5 T 6 1 gt HYSTERESIS SWITCH GE 50V 5W 3 COM 075 27V DZ4 15V 1W R34 4 75 15128 11 xi LM2901 NOTES WITHOUT AFFECT 40V DZ3 600mA 15V Q3 IW T 18104 3 Gi HEAT SINK e 200V IRFP250 OVERCURRENT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NG THE INTERCHANGEABILITY OF A COMPLE PROTECTION EM 2 024 E BO
12. o 5 B tc Return to Section TOC Return to Master TOC o 7 5 48 TROUBLESHOOTING amp REPAIR FIELD CAPACITOR AND OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 11 RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR Rectifier Retaining Tab Cable Tie Capacitor PROCEDURE Remove the engine spark plug wires With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out 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 11 for location Leave the clips on for at least 5 seconds then remove 10 11 12 13 200 200 2008 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 Cut the cable tie and then snap the capacitor out of the assembly Loosen the two scr
13. Return to Master Return to Section TOC 224C 12 VOLT B 221 rx 4 BATTERY TERMINAL BLOCK SE CONN 3 NET i FOOT B C1 FIELD CAPACITOR a EEN D n xem OT JA SWITCH MODULE LATOR i SUPPORT 115V 230V B STARTER 1 GND C 11 CB2 SOLENOID i Lacy FLYWHEEL ALTERNATOR l 3A SLIP RING NEAREST LAMINATION ENGINE COMPONENTS SILVER COLORED 3B L TERMINALS WHITE WIRES O10 515 0 815 g 9 5 2 a GROUNDING THIS TERMINAL STOPS THE ENGINE E GENERATOR LEAD END NNECTOR PIN NUMBERS NOTE CAVITY NUMBERS LEAD COLOR CODE B BLACK 211 CAVITY RED W WHITE DON EN U BUDE LOCATING TAB V VIOLET 221 CAVITY dH 7 TERMINAL BLOCK CONNECTION 2 224C CAVITY 4 208 CAVITY 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR ELECTRICAL SYMBOLS PER E1537 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 y
14. B 5 5 Summary of Welding B 6 g E 5 o a o O 5 0 g E 5 o tc o O 5 0 g E 5 8 RANGER 8 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 5 2 OPERATION 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 FEATURES AC DC STICK WELDING Constant Current AC 40 225 Amps DC 40 210 Amps 100 Duty Cycle on 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 10096 Duty Cycle Excellent Performance with 068 1 7mm NR 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 C
15. sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 787 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 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 3 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 pho
16. uumeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 5 tc Return to Section TOC Return to Master TOC o 7 5 25 F 25 TROUBLESHOOTING amp 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 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Retu
17. 5 B Return to Section TOC Return to Master TOC o 7 5 32 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued Oscilloscope 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 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 F 8 for location of the adjust ment nut Adjust the speed until the period is 16 2 milliseconds 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 for location of the adjustment nut Adjust the speed until the period is 27 3 milliseconds Vibratach Method 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 Start the engine and observe the
18. A 2 2 E Stick TIG cc OUtDUt A 3 DC Stick TIG cc RAN KEENE N RAR nennen nenne nnne nennen enne A 3 DC Wirefeed cv inen nentes nnns A 3 Installation Iristr ctions eo iio iiti E ee i vende Pee tero er ici r rp 4 Safety T 4 Machine Grounding 4 Spark AITeStOE isses ehe nien n EE a ER S EYE NER GR E RENE R RR S A 4 O p Irc eS 4 9 Pre Operation Service 5 5 g GU 5 5 E Battery COnsetlDbiS A 5 Welding Output Cables aE 5 Gable Length Ss REPE 5 Angle of ire e oan eb iei era O A 6 High Altitude Operation Pc A 6 6 Connection of Wire Feeders cic ee RE ER Ex 6 7 O Additional Safety Precautions eines FR An RA RE 7 9 Welder Operation RR A 7
19. leads 3 and 5 where they connect to the 115 VAC receptacle See Figure F 3 Start the engine and run it at high idle 3650 RPM Set the output control to the maximum position position 10 Check the AC voltage reading It should be approximately 125 VAC Machine Case 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 Connect the volt ohmmeter probes to leads 6 and 3 where they connect to the 230 VAC receptacle 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 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC o 7 5 F 23 F 23 TROUBLESHOOTING amp REPAIR
20. 17 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST A 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram O10 515 0 815 g 9 5 2 a This procedure takes approximately 30 minutes perform Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 5 TROUBLESHOOTI
21. AUXILIARY AND FIELD WINDING TEST continued FIGURE F 4 LOCATION OF LEADS 7 AND 9 AT FIELD BRIDGE RECTIFIER 9 Field Bridge Rectifier Retaining Tab Cable Tie To test the field winding 1 Remove the fuel cap and lift bail rubber If the voltage readings are within specifica gasket With the 5 16 nut driver remove tions then the windings are good and func the case top and left side then reinstall tioning properly me tual cap 6 Reinstall the case side case top fuel cap 2 Connect the volt ohmmeter probes to leads and lift bail gasket 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 8650 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 RANGER 8 LINCOLN 24 NOTES RANGER 8 LINCOLN E F 24 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes
22. F 63 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT KIT S20788 continued REASSEMBLY PROCEDURE NOTE Lincoln Electric recommends that a new 8 bearing Lincoln part 9300 85 be installed when you replace the rotor and blower assem bly 1 Clean the tapered engine crankshaft Slide the rotor onto the shaft 2 Insert the rotor thru bolt and with the torque wrench tighten the bolt to 50 ft Ibs 11 3 Support the engine rotor assembly with the chain hoist Fit the rotor into the stator 12 frame being careful not to damage the rotor core against the stator The bearing will seat into its race about half way 13 4 Insert the four bolts and lock washers that hold the engine to the stator With the Attach leads to the oil pressure switch refer to wiring diagram Replace any cut cable ties Unplug the fuel tank connection and fuel hose and connect them Connect the idle linkage to the idler rod Snap the plastic clip back into place Connect the engine choke cable at the position marked during disassembly 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 Reposition the vertical fan baffle and secure it with the two screws 9 16 wrench draw the bolts up evenly in 13A For Onan Engine only Install the muffler order to seat the bearing properly Tighten to 22 ft Ib moving diagonally from bolt t
23. Make sure the welding cables are not coiled or too long TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Perform the Output Bridge Test 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 Check the operation of the Polarity Switch S2 Also check the associated wires for loose or faulty connections See Wiring Diagram Check for continuity from lead S2 to lead E 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 RANGER 8 LINCOLN 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Return to Section TOC Return to Master TOC No constant voltage CV welding Make sure the Range Switch Check the operation of the output Constant current CC and 51 is in the proper position Range Switch 51 and check the auxiliary power are operating CV and seated correctly the associated wires for loose normally or
24. 1 Return to Section TOC Return to Master TOC Return to Master TOC A 4 4 INSTALLATION 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 ELECTRIC SHOCK can kill Do touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or CA vent exhaust outside MOVING PARTS can injure Do not operate with doors open guards off lt 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 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 electric shock other equipment to which this engine driven welder supplies power must be grounded to the frame of the welder using a grounded type plug or be double insulated When this welder is mounted on a truck or trailer
25. Twin Cylinder Cast Aluminum Alloy Crankcase with Integral Cast Iron Cylinder Liners Electric Start with Solid State Battery Charging Module Solid State Breakerless Ignition Spin on Filter Low Oil Pressure Shutdown Protection Overhead Valves amp Hydraulic Valve Lifters These trademarks are the property of their respec tive manufacturers RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 0 2 5 ao Return to Section TOC Return to Master TOC o 7 5 OPERATION Ranger 8 Approximate Fuel Consumption ONAN 20 5 H P P220 6 Gallons Hour 2200 RPM 2 3 Liters Hour High Idle No Load 8 Gallons Hour 3700 RPM 3 0 Liters Hour 1 5 Gallons Hour AC CC Weld Output DC CC Weld Output DC CV Weld Output Auxiliary Power 8000 Watts 5 8 Liters Hour 1 6 Gallons Hour 6 1 Liters Hour 1 2 Gallons Hour 4 5Liters Hour 1 6Gallons Hour 6 1 Liters Hour Welder Controls Function and Operation Explanation of Symbols that Appear on this Equipment lt gt OFF High Idle ENGINE ON OFF Switch Low Idle 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 ENG
26. m m mim mm duum m m mms mom um ojs A E 5 X1 ce T Ll cc SSU 29 oz DKA E a e I z A 03 01 cc Lr 2 5 ly R41 ZIT ex gt exeo 62 J D 1 C15 R62 Ji o gt 010 AN Q T X3 IT gt vn VUNNS 7 013 lt 5 R6 B 5 R N olo 5 se ese N R9 mc oO n 8484 3 EIE a 04 G 11 IDENTIFICATION 111 11577 46 j 05 600v 513490 15 100 16 1 13490 102 047 100 4 72 13490 39 18 15 C8 C9 C21 3 T11577 52 0047 or 005 1400 C 10 C11 C 12 C19 C23 C24 6 516668 5 X 022 50 C13 C 14 C 15 C 16 C26 C28 1 50 C29 22111 13490 19 1 8720 27 513490 7 100750 e30 1 516668 7 820pr750 01 07 08 012 015 5 1121991 1N4004 712705 51 ___ 154 200 D4 011 014 _________ 3 12705 34 ___ 1 4936 712705 50 DIODE 010 013 2 712705 29 DIODE 016 1 112199 2 ____ 1N4007 022 023 024 1 3 T12702 29 ___ 1N4744 025 712702 26 1N4750 ZENER DIODE 026 1 1 1 1 712702 33 ___ 153478 027 1 112702 25 ___ 1453578 028 T1270217 1 53618 ZENER DIODE Ii J 518248 12 3 HEADER o1 1 52010
27. regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 10096 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders small current inrush for starting refrigerators weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Return to Section TOC Return to Master TOC Capacitive Inductive Computers high resolution TV sets An inductive type line condition complicated electrical equipment er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A RANGER 8 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the RANGER 8 O10 515 0 815 g 9 5 2 Return to Section TOC Return to Master TOC RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 515 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC A 10 A 10 INSTALLATION Auxiliary Power While Welding Simultaneous welding and
28. 213 to 215 then test for 12VDC from lead 213 to ground lead 5 See Wiring Diagram 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 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 Make sure there is NOT an external load on the weld termi nals nor the auxiliary power receptacles Return to Section TOC Return to Master TOC Ojo O10 515 0 gt g 9 5 2 a A 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 Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 5 tc Return to Section TOC Return to Master TOC o 7 5 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Engine will not go to high idle when attempting to weld Welding out
29. 2150 and 2250 RPM Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles FIGURE F 9 LOW IDLE ADJUSTMENT NUT 3 8 Low Idle Adjustment Nut Solenoid Housing 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 If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See Figure 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 F9 for location of the adjustment nut Adjust the nut until the fre quency reads between 35 8 and 375 Hz RANGER 8 LINCOLN P F 31 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o
30. 8 ROTOR SHAFT BEARING 9 ROTOR THRU BOLT Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 o 2 B Return to Master TOC F 61 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued ENGINE AND ROTOR REMOVAL PROCEDURE 1 Refer to Figure F 14 for component loca tions 2 Remove the engine spark plug wires 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 F 61 3 With the 5 16 nut driver remove the 6 16 Disconnect the idle linkage by unsnapping sheet metal screws from the case top the plastic clip at the engine end of the 4 Remove the rubber gasket cover seal idler rod Snap the clip back onto the rod from the lift bail to avoid losing it remove the rod for 5 5 Remove the fuel cap The rubber gasket for the fill tube will come off with the case 17 Disconnect the fuel line from the fuel tank sic top Plug the hose and also plug the connec 9 6 Remove the case top the reinstall the fuel tonat Ihe 081 tank To prevent essdpp 0 cap of gasoline fumes cjg 7 With the 5 16 nut driver remove the 5 IE tie cable en and PMOS leads 515 and 210 from the oil pressure switch screws holding the right case side and the tc 5 sc
31. DOUBLE POLE 50 AMP 115 230 VOLT PLUG NEMA TYPE 14 50 230 VOLT BREAKER N 50 115 230 ___ 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 applicable electrical codes RANGER 8 LINCOLN 5 12 NOTES RANGER 8 LINCOLN E A 12 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 201 uonoes DOL 0 uumeg 201 uonoes uumeg DOL uonoes uumeg Section 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION Operation Section B General DescriptiOD 2 Other Features RR B 2 Engine Options epo m OL Ue p eiie e Pa B 2 Approximate Fuel Consumption cccccccssssseeeeessneeeeceseeeeeeeescaeeeeeseaaeeeeeeasaaeeseessaeeeessseeeeesenss B 3 Controls ANG SOUS B 3 B 4 Before Starting the Engine B 4 Staing me EQUA vi see cas sete iniia B 4 Stopping the Engine 4 slc ERR 4 3 Welding ProCess
32. J If an optional remote output control is used connect it to this terminal strip or 6 pin Amphenol receptacle NOTE Terminal strip or 6 pin Amphenol receptacle not available on all power sources CAUTION Any speed up of the engine RPM by changing the governor setting or over riding the throttle linkage will cause an increase in the AC auxiliary voltage If this 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 RANGER 8 LINCOLN 5 G 5 WIRING DIAGRAM ONAN NON CSA MODEL ELECTRICAL DIAGRAMS K1418 1 RANGER 8 ONAN Wiring Diagram lt OUTPUT e TRY CONTROL S8 SHOWN IN RUN POSITION GROUND SCREW AT BLOWER BAFFLE Return to Section TOC Return to Master TOC 77A 76A 75A 218 o 54 SHOW IN AUTO POSITION IDLER SOLENOID Return to Section TOC Return to Master TOC 212 i 1 224C 15 2 gt e 208 224A ed i 12 VOLT BATTERY GND H Bs C1 FIELD CAPACITOR 6 I ENGINE 0 0 CROSS J4 GINE FOOT OIL PRESSURE i SWITCH
33. OF ACTION Check for the correct open cir cuit voltage OCV at the welder output terminals 80VAC Max 72VDC Max the correct voltage is present at the output terminals then check for loose connections on the heavy cur rent carrying leads inside the RANGER 8 See Wiring Diagram If the is low at the welder output terminals then Perform The Engine Throttle Adjustment 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 RANGER 8 LINCOLN 8 14 NOTES RANGER 8 LINCOLN E F 14 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg Return to Section TOC Return to Master TOC Return to Section TOC O10 515 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained pers
34. OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC _ MEANS MNA M LI This is NOT the typical DC output voltage waveform One output diode is not functioning Note the 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 O10 515 0 815 g 9 5 2 a Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC B B Internal 55 olg 8 2 g 2 cle aa dc RANGER 8 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 0 815 2 2 5 2 a Return to Section TOC Return to Master TOC F 39 F 39 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM CV MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM NAN AW ML MIME LM 20 volts 5 ms This is the ty
35. RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop Slip Rings A slight amount of darkening and wear of the slip rings and brushes is normal Brushes should be inspected when a general overhaul is necessary If brushes are to be replaced clean slip rings with a fine emery paper CAUTION Do not attempt to polish slip rings while engine is running WARNING WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery amp 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 6 5 Battery 1 When replacing jumping or otherwise connecting the batte
36. Return to Section TOC Return to Master TOC RANGER 8 LINCOLN Section 1 Section C 1 TABLE OF CONTENTS o O c ACCESSORIES Accessories 9 Optional 2 Recommended EquipiTierit aio ERR A MA ERE C 3 c RES C 3 Return to Master TOC Q 2 7 5 Return to Master TOC RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC o 7 5 2 2 ACCESSORIES OPTIONAL EQUIPMENT 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 Field Installed K957 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 2 Fender amp Light Kit K965 1 Cable Storage Rack K889 2 amp 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 K1631 1 Puncture Proof Wheel Kit For converting K889 2 to puncture proof pneum
37. Winding Voltage Test If machine is equipped with cir cuit breakers check for faulty breakers and loose or faulty connections on associated wiring 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 RANGER 8 LINCOLN FI FCTDIC TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine has low welding output 1 The brushes may be worn If the engine HIGH IDLE RPM is and low auxiliary output Contact your local Lincoln low then perform The Authorized Service Facility Adjustment Test The engine RPM may be low Perform the Rotor Voltage Test If the rotor voltage is low the Field Capacitor C1 or the Field Bridge D2 may be faulty Test and replace if necessary Check the Output Control Potentiometer Normal resis tance is 10 000 ohms Also check associated wiring for loose or faulty connections Return to Section TOC Return to Master TOC The Rotor may be faulty Perform the Rotor Resistance est Return to Section TOC Return to Master TOC The Printed Circuit Board may be faulty If th
38. a Return to Section TOC Return to Master TOC G 4 G 4 DIAGRAMS RANGER 8 LN 25 ACROSS THE ARC CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can Do not operate with panels open kill Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts 6 PIN AMPHENOL G TO WORK ELECTRODE TO WORK SWITCH TO THE WIRE FEED CV POSITION MOVING PARTS can injure Keep guards in place Keep away from moving parts Only qualified personnel should install use or service this equipment d aS OPTIONAL K444 1 REMOTE CONTROL LN 25 WIRE FEEDER v CLIP LEAD Tie 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 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 AC AUXILIARY POWER AND CV OUTPUT TO LN 7 CONNECT THE CONTROL CABLE GROUND LEAD TO THE FRAME KG E ROBO TERMINAL MARKED NEAR E ius a aa at NOTE 600 AMP CAPACITY THE TERMINAL STRIP OR TO POWER TERME
39. 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 K936 3 Remote Control Cable Control cable for connect ing the K930 2 TIG Module to a Ranger 8 equipped with a K892 1 Remote Kit 9 Socket to a grounded 115 V plug and a 6 pin MS connector Contains circuits 2 4 31 32 75 76 77 and ground K939 1 Docking Kit For mounting the K930 2 TIG Module unit on top of the Ranger 8 K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC o 7 5 ACCESSORIES RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes Electrode Holder amp Cable Work Clamp amp 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 re
40. case top lead and the 10 lead Blue from the recti 1 H Remove the rubber gasket cover seal from for positive NEAT SINK the lift bail 9 With the 1 2 wrench remove the heavy Remove the fuel cap The rubber gasket for Au en Blue rome Fee the fill tube will come off with the case top 9 10 With the 7 16 wrench remove the W1 lead Remove the case top then reinstall the fuel n and the heavy lead going to the S2 Polarity p switch 5 Sus p Ier 11 With the 7 16 wrench remove the S2 lead 9 9 and the heavy lead going to the S1 Range Remove the right case side by lifting up and Switch ols out 2 22 Dlo 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 5 0 815 2 2 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC F 57 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 12 With the 3 8 wrench and slot head screw 17 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 13 Remove the rectifier assembly by tilting it up and lifting it toward the front of t
41. faulty connections See Make sure the wire feeder is 7 Wiring Diagram connected correctly Check for continuity from lead C1 to lead W1 located in the main stator See Wiring Dia gram Return to Section TOC Return to Master TOC O10 515 0 gt g 9 5 2 a CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 10 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS Return to Section TOC Return to Master TOC Engine will not idle down to low Make sure the Idler Switch 54 1 With the Idler Switch S4 in the speed Machine has normal weld is in the Auto position Auto position check for the output and auxiliary power 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 If there is NOT 12VDC at leads
42. lifting up and out With the needle nose pliers gently remove the blue and the red wires from the brushes See Figure F 10 With the 7 16 wrench remove the brush holder assembly bracket from the stator frame 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 To change the brushes use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly 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 18 14 15 16 17 18 19 20 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 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 10 This will hold the brushes up so that you can easily install the holder 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 With the 7 16 wrench install the brush holder assembly bracket to the stator frame Slowly remove the non metallic retaine
43. observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram O10 515 0 815 g 9 5 2 a This procedure takes approximately 30 minutes to perform Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 5 F 22 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST continued FIGURE F 3 LOCATION OF LEADS 3 AND 5 115V a Lead 5 TEST PROCEDURE To test the 115 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 Connect the volt ohmmeter probes to
44. put is normal when Idler Switch is in HIGH position Automatic idle function works properly when the auxiliary power is loaded Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 1 Make sure the welding cables and connections are tight RECOMMENDED COURSE OF ACTION Check for broken or faulty con nections in the sensing leads 254 and 254 Make sure their connections are tight at the Electrode Output Terminal and also at the Polarity Switch See Wiring Diagram 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 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 1 MaKe sure the welding cables and connections are tight 2 Automatic idler may not func tion if the auxiliary power is loaded to less than 150 Watts Check for broken or faulty con nections in the sensing leads 4254 and 254 Make sure their connections are tight at the Electrode Terminal and also at the Polarity Switch See wiring diagram Check lead 3 making sure it is looped through the current sen sor on the Printed Circuit Board The Printed Circuit Board may be faulty A CAUTION If for any reason you do not understand the test procedure
45. running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 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 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 minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure 1 e In some cases it may be necessary to remove safety them with tape when possible 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 4 2 Never coil the e
46. speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 4 OPERATION Starting Shutdown Instructions Starting the Engine WARNING e Do not touch electrically live parts of electrode with skin or wet clothing S Insulate yourself from work and Keep flammable material away ground Wear eye ear and body protection 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 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 Control switch in the Automatic gt position Use
47. 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 Reinstall the case side fuel cap lift bail gasket case top and spark plug wire F 57 58 NOTES RANGER 8 LINCOLN E F 58 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 201 uonoes DOL 0 uumeg 201 uonoes uumeg DOL uonoes uumeg F 59 F 59 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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 proc
48. throughout this manu al Return to Section TOC Return to Master TOC 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 ate 5 5 DESCRIPTION 8 The following procedure will aid the technician in removing the output rectifier bridge for maintenance or replacement ala eic MATERIALS NEEDED 5 16 Nut driver 1 2 wrench 7 16 wrench 3 8 wrench Slot head screw driver Dow Corning 340 Wiring Diagram O10 515 0 815 g 9 5 2 This procedure takes approximately 60 minutes to perform Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC o o 2 5 B Return to Master TOC F 56 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 13 OUTPUT RECTIFIER CONNECTIONS To Polarity Switch Machine Front 4 Mounting Screws with Insulators olo 55 9 d PROCEDURE oiz Remove the engine spark plug wires For the remaining steps refer to Figure F 13 With the 5 16 nut driver remove the 6 sheet 8 With the 1 2 wrench remove the choke D E metal screws from the
49. to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Tools which come in contact with the PC board must be either conductive anti static or static dissipative 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 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 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 NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem 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 b If the orig
50. venir tout risque d incendie d 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 levage 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 fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste con
51. 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 that these are median measurements vibrat ach readings may vary slightly above or below 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 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 F 32 RANGER 8 gm ELECTRIC F 33 F 33 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM Return to Section TOC Return to Master TOC _ YT JA PAL LL 50 volts 5 ms O volts Return to S
52. 0 Volts RMS Duty Cycle 100 for both welding and auxiliary power Ranger 8 225 Amps AC 25 Volts 210 Amps DC 25 Volts Constant Current Constant Voltage 200 Amps DC 20 Volts Auxiliary Power The Ranger 8 can provide up to 8 000 watts of 115 230 volts AC single phase 60Hz power for continuous use The front of the machine includes three receptacles for connecting the AC power plugs one 50 amp 115 230 volt NEMA 14 50R receptacle and two 20 amp 115 volt NEMA 5 20R receptacles CAUTION Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the desired operating mode Set the CONTROL to 10 Voltage is now correct at the receptacles for auxil iary power 115 230 Volt Dual Voltage Receptacle The 115 230 volt receptacle can supply up to 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 RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC 5 5 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC A 8 A 8 INSTALLATION
53. 18 2 or K1419 2 CSA machines and machines with GFCI receptacles use K802 R K704 Accessory Kit Includes 35 ft 10 7m 2 0 AWG elec trode cable 30 ft 9 1m 2 0 AWG work cable headshield with No 12 filter GC300 work clamp and Cooltong amp 300 electrode holder Cables are rated at 300 amps 10096 duty cycle K892 1 Remote Control Receptacle Kit Includes a 6 pin MS type Amphenol receptacle and a local remote toggle switch that mounts in the case front Required when using a K930 2 Tig Module with an optional Amptrol or when using a Remote Control K857 25 ft 7 5m or 57 1 100 ft 30 4m REMOTE CON TROL Portable control provides same dial range as the out put control on the welder Has a convenient 6 pin plug for easy connection to the welder K894 1 Spark Arrester Kit Includes a heavy gauge steel approved spark arrester and clamp for easy mounting to muf fler exhaust pipe K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total current from the GFCI Duplex is limit ed to the 20 Amps Two kits are required K930 2 TIG Module Provides high frequency and shielding gas control for AC and DC GTAW TIG welding applications Its compact case is designed for easy carrying complete with
54. 5 d RANGE SWITCH 2 E AC ELECTRODE 5 OUTPUT CHOKE POLARITY TERMINAL cc REACTOR AC BRIDGE SWITCH LAA AAAA O WORK STATOR TERMINAL MECHANICAL _ ROTATION ROTOR O STARTER ENGINE SLIP ROTOR O _ _ RINGS eJ FLYWHEEL ALTERNATOR 0 r3 STATOR gt IDLER 5 SOLENOID isse c 5 D PRINTED a CIRCUT BOARD BATTERY FIELD C CAPACITOR EET 115 amp 230VAC RECEPTACLES OUTPUT CONTROL T FIELD BRIDGE FIGURE E 1 RANGER 8 BLOCK LOGIC DIAGRAM Return to Master TOC RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 5 5 0 815 g 9 5 2 fe Return to Section TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 BATTERY STARTER ENGINE ROTOR STATOR AND IDLER SOLENOID AC ELECTRODE I O TERMINAL CHOKE POLARITY Were QU TEU BATTERY i REACTOR BRIDGE gt SWITCH ALAIN IA WORK STATOR TERMINAL MECHANICAL ROTATION ROTOR STARTER E
55. 55 olg 8 2 g 2 aa dc RANGER 8 LINCOLN 5 35 F 35 TROUBLESHOOTING amp REPAIR TYPICAL DC WELD OUTPUT WAVEFORM CC MODE MACHINE LOADED Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 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 O10 515 0 815 g 9 5 2 Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div olo Coupling DC B Internal 55 olg 2 g 2 3a 8 LINCOLN F 36 F 36 TROUBLESHOOTING amp REPAIR TYPICAL AC WELD OUTPUT WAVEFORM MACHINE LOADED Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 20 volts 5 ms 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 resista
56. 6 1 ____ w H S SBLY SS o3 _ n1 712704 69 ___ 2N4403 o4 1 T12704 54 N CHANNEL 55 1 112704 52 85170 TRANSISTOR 55 e S a 712704 47 5 MP 7 300 VOLT PNP R3 1 518380 1 THERMISTOR 94 1 2 714648 23 __ 20 5w R6 R9 2 524002 1200 9 12072 5w R7 R8 R34 R54 4 S19400 4751 _ 4 75K R 10 R11 RI2 15 R16 R45 19400 1002 10K 1 4W R66 R67 R68 R69 R70 R71 R72 R73 R74 519400 1372 __ 13 7 1748 111 519400 3322 33 2K 1 4 217 ________________ 1 S19400 1333 __ 133 1 4 _________________ 1 519400 4752 _ 47 5K 1 4 R19 R31 2 519400 2672 __ 26 7 1 4W 820 R65 2 519400 3321 _ 3 32 1748 R21 1 11648 24 _ 10 559 R23 1 519400 3320 332 1 4 29 _ 1 1 1 1 19400 3922 39 2 1 4w R32 1 519400 1003 __ 100 1 4 3s 1 1 519400 1502 5K 1744 R39 R56 2 519400 1001 IK 1 4W R40 R60 _ 2 519400 6813 681K 1 4W R41 _ 8 1 712300 77 0 1 OHMS 7WATT WIRE WOUND Rag R53 1 42 519400 2212 _ 22 IK 1 4 R43 R44 R47 R48 R49 R50 19400 4750 475 1 4W 6 1 519400 5232 52 3K Ro2 1 11 S19400 2941 _ 2 94K 1 4w oz 1 519400 6811 e6 81K 1 4w Rog 11648 14 390 5 R62 1 518380 3 PTC THERMISTOR R63 R64 2 519400 6881 68 1 1 4W T
57. ARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER UNLESS OTHERWISE SPECI ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMAL ON ALL ANGLES 1 50 MATERIAL TOLERANCE t WITH PUBLISHED STANDARDS FIED TOLERANCE Oh ge Sht No 8 2 96E _ 11 22 96 7 18 97 S IS 002 F A DEGREE E 9 25 92 12 4 97 TO AGREE 4 16 98H 7 14 20000 2 18 94 GENERAL INFORMATIO ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V RESISTORS Ohms DIODES 1A 400V FILENAME M16482 3G THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A SCALE DR EB DATE 10 13 92 NONE UNLESS OTHERWISE SPECIFIED 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED EQUIP TYPE LAST NO USED LABELS SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT COMMON CONNECTION 7 3 FRAME CONNECTION EARTH GROUND CONNECTION G8000 RANGER 8 IDLER FIELD CONTROL SUBJECT SCHEMATIC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual SUP S D G NO no M16482 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo OJO 5 5 0 815 g 9 5 2 Return to Master G 11 PC BOARD ASSEMBLY IDLER CONTROL 1 04 4 00 E
58. BJOS 98 Eee ase gt LANA 2 diu ol AAN AN 25 lt eq 9 9 u e gt WA 2 SN 5 gt CY S CN lt V C M 2 2 5 477 8 Ne E CNS 5 C Zi gt 5 DOL 0 DOL 0 DOL Je1se N 0 DOL Je1se N 0 DOL DOL uunjeg DOL uunjeg DOL uunjeg D 6 NOTES RANGER 8 LINCOLN E 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 201 uonoes DOL 0 uumeg 201 uonoes uumeg DOL uonoes uumeg Section E 1 Section E 1 TABLE OF CONTENTS o THEORY OF OPERATION SECTION 5 3 Theory of Operation tr rte reet it RR RR ERE RR Section E Battery Starter Engine Excitation Rotor Stator and Idler 2 5 E Rotor Field Feedback and Auxiliary Power esee E 3 Weld Winding Reactor and Range Switch esses enne E 4 Output Bridge Choke Polarity Switch and Output E 5 o O
59. CHOKE HUM TERMINAL REACTOR BRIDGE AAA Las an Anara WORK STATOR 5 TERMINAL MECHANICAL ROTATION STARTER ENGINE ROTOR ae RINGS ALTERNATOR STATOR TENDER e SOLENOID PRINTED CIRCUT BOARD BATTERY E FIELD alle CAPACITOR 115 amp 230VAC RECEPTACLES OUTPUT CONTROL A 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo 5 5 0 815 g 9 5 2 fe Return to Section TOC Return to Master TOC Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 5 OUTPUT BRIDGE CHOK
60. Charging Circuit Test The starter motor or starter solenoid may be faulty The Engine may be hard to crank due to a mechanical fail ure in the engine The oil pressure switch may be faulty Replace if necessary The fuel shut off solenoid may be faulty Kohler Engines only Due to wear the engine may be in need of repair CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 5 tc Return to Section TOC Return to Master TOC o 7 5 13 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The welding arc is cold Engine runs normally 3700 RPM no load Auxiliary power is functioning nor mally Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check for loose or faulty con nections at the weld output ter minals and welding cable con nections 2 The welding cable may be too long or coiled causing an excessive voltage drop RECOMMENDED COURSE
61. E POLARITY SWITCH AND OUTPUT TERMINALS STARTER ENGINE FLYWHEEL ALTERNATOR DSI RANGE BATTERY SWITCH i ELECTRODE OUTPUT CHOKE EO F TERMINAL REACTOR AC BRIDGE SWITCH Lo MECHANICAL ROTATION ROTOR SLIP ROTOR RINGS ire E G IDLER STATOR SOLENOID PRINTED CIRCUT BOARD FIELD CAPACITOR 115 8 230VAC RECEPTACLES OUTPUT CONTROL Zx FIELD _ BRIDGE OUTPUT BRIDGE CHOKE POLARITY SWITCH AND OUTPUT TERMI NALS 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 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 Ifa 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 The filtered DC current path is through the Polarity Switch and on to the Output output is Terminals filtered NOTE Unshaded
62. INE START Push Button Switch Energizes engine starter motor Polarity Switch CAUTION Never change the Polarity switch setting while welding This will damage the switch Range Switch Process Maximum Current on Each Setting 50 70 90 125 175 210 DC 225 AC STICK TIG CC 6 Range Settings WIRE FEED CV 1 Range Setting 200 CAUTION Never change the RANGE Switch setting while welding This will damage the switch KOHLER 20 H P COMMAND 1 5 Liters Hour 9 Gallons Hour 8 5 Liters Hour 1 3 Gallons Hour 1 4 Gallons Hour 1 2 Gallons Hour 1 4 Gallons Hour 5 3 Liters Hour Control Switch Provides a fine welding current adjustment within the Range Switch settings in the STICK TIG mode and welding voltage control with the Range switch set in the wire feed mode HONDA 20 GX620KI 3 Gallons Hour 1 3 Liters Hour 7 Gallons Hour 2 7 Liters Hour 1 6 Gallons Hour 6 0 Liters Hour 1 7 Gallons Hour 6 3 Liters Hour 1 2 Gallons Hour 4 6 Liters Hour 1 5 Gallons Hour 5 7 Liters Hour 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 4 lt idle position the idler operates as follows Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full
63. ITOR 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O10 515 0 815 g 9 5 2 Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
64. In general these tests can be con ducted without removing the case wrap around cover 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 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 A 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 LINCOLN 8 F 2 Return to Section TOC Return to Master TOC Return to Section TOC O10 E 515 0 815 2 2 5 2 Return to Sectio
65. LECTRICAL DIAGRAMS LI LI I A R48 d steals g lesg 1 9 oc RE a N ce MIO e gt lt a T 5H R58 R5 R4 821 n L C4 1 X S Ilolo 2 KS o X e 1 ui RIN X ec X o
66. ND AUXILIARY 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 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 and 230 are connected to the appropriate receptacles and offer 8000 watts total of AC power NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 5 0 815 g 9 5 2 Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE 4 WELD WINDING REACTOR AND RANGE SWITCH RANGE SWITCH D L 9 ELECTRODE OUTPUT
67. NG amp REPAIR ROTOR RESISTANCE TEST continued FIGURE F 2 LOCATION OF ROTOR SLIP RINGS Lead 219 TEST PROCEDURE 1 With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Conduct the test with the gasoline engine OFF Remove the spark plug wires to prevent accidental engine kickback or starting 9 10 11 12 Lead 200A Isolate the rotor electrically by removing the generator brush leads Refer to Figure 2 as you perform the remaining steps Remove lead 219 from the negative brush Remove lead 200A from the positive brush Measure the resistance across the rotor slip rings A Set the ohmmeter on the low scale X1 B Place one meter probe on one of the rotor slip rings Place the other probe on the other slip ring C Check the resistance across the slip rings It should read between 4 and 5 ohms F 18 RANGER 8 LINCOLN 5 19 19 TROUBLESHOOTING amp REPAIR 13 Measure the resistance to ground A Set ohmmeter on the high scale X100 000 B Place one probe on either of the sl
68. NGINE SLIP ROTOR RINGS FLYWHEEL 0 ALTERNATOR TS ids STATOR e SOLENOID prc PRINTED CIRCUT BOARD Hafifi FIELD CAPACITOR gt E OUTPUT CONTROL 2 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 115 amp 230VAC RECEPTACLES 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 The flywheel alternator located on the engine supplies charging current for the battery circuit The battery circuit provides power for the printed circuit board a
69. National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master Return to Master TOC o 2 7 5 Return to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes 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 on soude dans des endroits humides ou sur un plancher met allique 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 defonc tionnement 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 tensio
70. P 713640 12 38 si o 1 915128 11 14 PIN QUAD COMPARATOR x2 1 d 518504 O 515128 4 q ric Lw224 515018 13 16 PIN 1 C 55 xo 1 1 1 na1 sSi5128 10 IC 431 VOLTAGE REF UNLESS OTHERWISE SPECIFIED CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT 7 14 2000 INDUCTANCE HENRYS L 8484 3 Return to Section TOC 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 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO 5 5 0 815 g 9 5 2 Return to Section TOC Return to Master TOC 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
71. RANGER B mE For use with machine code numbers 9972 thru 10886 Return to Master TOC View Safety Info Safety Depends on You P 5 Lincoln arc welding and cutting E equipment is designed and built 2 with safety in mind However 2 4 your safety can be increased by proper installation D gt and thoughtful operation on M SN cc your part DO NOT INSTALL MASS 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 55 2 gjo 2 al u SERVICE MANUAL LI NCOLN p Copyright 2002 Lincoln Global Inc View Safety Info 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 Return to Master TOC Return to Master Return to Master TOC Q 2 7 5 Return to Master TOC SAFETY WARNING 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 defect
72. ROBLEMS SYMPTOMS No weld output the auxiliary power 230 115VAC is operating normally Engine runs normally Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the open circuit voltage 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 f 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 Authorized Field Service Facility Check the welding cables clamps and electrode holder for loose or broken connections RECOMMENDED COURSE OF ACTION Disconnect lead W1 from the 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 Check the Reactor Range Switch 51 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 Check the Choke L1 Polarity Switch 52 and associated wires for loose or faulty connec tions Check the choke wind
73. ROL 77A 76A 75A Return to Section TOC Return to Master TOC GROUND LEAD LPG VERSION ONLY 2 ss START 216 BUTTON 213 213 s4 SHOWN IDLER IN AUTO 224B SOLENOID POSITION Return to Section TOC Return to Master TOC 12 VOLT BATTERY 2244 Si 4 SHUT OFF f SOLENOID LPG VERSION TEE CONN ONLY C1 FIELD CAPACITOR OIL PRESSURE 200A SWITCH i ULATOR STARTER SUPPORT IGNITION 1 SOLENOID STARTER i CONTROL E TO ON 1 FLYWHEEL ALTERNATO i SILVER SLIP RING NEAREST LAMINATION COLORED TERMINALS 4 WHITE WIRES O10 515 0 815 g 9 5 2 a WELDER LEAD END ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR 7 NOTE CAVITY NUMBERS M ELECTRICAL SYMBOLS PER E1537 E ECTOR PIN NUMBERS 208 CAVITY 3 v lt _ 224A8C CAVITY 4 LOCATING TAB Y 212 CAVITY 1 7 X TERMINAL BLOCK 534C CAVITY 2 CONNECTION M18332 NOTE This dia
74. Return to Master TOC D 3 MAINTENANCE 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 be used above 82 F 27 C See Engine Owner s Manual for more specific informa tion on oil viscosity recommendations 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 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 engin
75. S AN UNPAINTED FRAME SCREW SOURCE e o 1 i 77 76 75 i i FAUTO POWER N F amp N G i E SOURCE i HRSG eee ELECTRODE CABLE TO LN 7 NJ 317742 WELDER STANDARD OUTPUT TERMINALS 10 2 92 WARNING 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 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 D Leads 21 and GND do not appear on LN 7 s with codes below 7026 N E Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N F If LN 7 is equipped with a meter kit extend lead 21 using 14 or larger insulated wire physically suitable for the installation An 16586 length remote voltage sensing work lead may be ordered for this purpose Connect it directly to the work piece independent of the welding work cable For convenience this extended 21 lead should be taped to the welding work lead N G Tape up bolted connection where lead 21 is extended N H Idler switch on power source must be in high idle position N
76. SAE 10W 30 oil Check the oil level before starting the engine If itis not up to the full mark on the dip stick add oil as required Make certain that the oil filler cap is tightened securely Refer to the engine Owner s Manual for specific oil recommendations LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Onan P220 1 6 Quarts 1 5 Liters Kohler 205 2 0 Quarts 1 9 Liters Honda GX620KI 1 9 Quarts 1 6 Liters Fuel g Fill the fuel tank with clean fresh lead free gasoline Observe fuel gauge while filling to prevent overfilling Battery Connections This welder is shipped with the negative battery cable disconnected Make sure that the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine If the battery is dis charged 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 w
77. Section TOC Return to Master TOC 50 volts 5 ms 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 O10 5 5 0 815 g 9 5 2 a SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Ojo Coupling DC Trigger Internal 55 PEN 8 2 88 JE RANGER 8 LINCOLN 42 NOTES RANGER 8 LINCOLN E F 42 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg 43 43 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT A 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test proc
78. See Figure 15 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 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 1 THRU BOLT 2 ROTOR 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 Ibs with the torque or impact wrench 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 RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 5 5 0 815 g 9 5 2 a Return to Section Return to Master TOC Return to Master TOC
79. ad 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 TIG Constant Current Welding 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 When using the Ranger 8 for AC TIG welding of alu minum the following settings and electrodes are recommended SETTINGS FOR PURE TUNGSTEN RANGE SWITCH SETTINGS 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 TUNGSTEN DIAMETER in APPROXIMATE CURRENT RANGE SETTINGS FOR 1 THORIATED TUNGSTEN TUNGSTEN RANGE SWITCH APPROXIMATE DIAMETER in SETTINGS CURRENT RANGE 1 8 70 90 125 or 175 80 225 Amps 3 32 50 70 90 or 125 50 180 Amps 1 16 50 70 90 45 120 Amps 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 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
80. agram S17742 can be found in the back of this manual e Place the RANGE switch to the WIRE FEED position and the POLARITY switch to the desired polarity Place the IDLER switch in the HIGH idle position The engine idling device may not function when welding in the WIRE FEED mode 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 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 112246 INSTRUCTIONS Additional Safety Precautions Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read and understand all Safety Precautions before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manual Welder Operation Welder Output Maximum Open Circuit Voltage at 3700 RPM is 8
81. 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 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 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shieldin
82. areas of Block Logic Diagram are the subject of discussion RANGER 8 LINCOLN 8 6 NOTES RANGER 8 LINCOLN 6 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 201 uonoes DOL uonoes 0 uumeg 201 uonoes DOL uonoes Section F 1 Section F 1 TABLE OF CONTENTS 8 TROUBLE SHOOTING 8 REPAIR SECTION 5 2 Troubleshooting amp Repair Section gt How to Use Troubleshooting Guide F 2 PC Board Troubleshooting F 3 E Troubleshooting Guide F4 F 13 Test Procedures Rotor Voltage cm C OU F 15 Rotor Resistance F 17 Auxiliary and Field Winding Test F 21 Output Rectifier Bridge TeSt nnne nennen F 25 G arging d sm F 27 Engine Throttle Adjustment Test eese nnne nnne nnns F 29 e Oscilloscope Waveforms F 33 Normal Open Circuit Voltage Waveform 115 F 33 5 Typical DC Weld Output Waveform CV Mode Machine Loaded
83. aring wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control 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 and 8 LINCOLN 5 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes
84. ashing 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 3 switch is in the position 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 If the Rotor Voltage Test is 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 A 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 RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE P
85. at MAXIMUM position 10 Output values of each receptacle can vary within the range shown but must be within 2 volts of each other Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 Section G 1 Section G 1 TABLE OF CONTENTS DIAGRAMS SECTION 5 3 Diagrams Sectlon ise recen e isa Section G Dimension Print Ranger 8 G 2 c 3 Dimension Print Ranger 8 Honda amp Kohler G 3 2 Connection 5 9 4 Wiring Diagram Ranger 8 Onan Non CSA G 5 Wiring Diagram Ranger 8 Onan CSA Model eene G 6 Wiring Diagram Ranger 8 Kohler Non CSA sese G 7 Wiring Diagram Ranger 8 Kohler CSA Modeel sseseseseeseseeereeeeneeen nennen G 8 Wiring Diagram Ranger 8 Honda CSA G 9 3 Idler Control PC Board G 10 D Idler Control PC Board ener nnne nnns G 11 g E 5 o a o O 5 0 g E 5 o tc o O 5 0 g E 5 8 RANGER 8 LINCOLN 8 2 G 2 DIAGRAMS DIMENSION PRINT RANGER 8 ONAN 386 05 1 LN S310H Sc 007 08 098 00
86. atic tires K893 1 Caster for Undercarriage Mounts to the front of the K889 2 to allow easy movement on smooth surfaces Includes 6 diameter hard rubber wheel and convenient toe on toe off locking brake K933 1 Four Wheel Undercarriage For Hand Moving Rear pneumatic tires front molded wheels K934 1 Cylinder Brackets For use with K933 1 for transporting either one LPG fuel cylinder or one 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 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 K1745 1 SINGLE GAS CYLINDER HOLDER For use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protection K886 1 Canvas Cover To protect the Ranger 8 when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent K802 R Power Plug Kit Provides four 115V plugs rated at 15 amps each and one dual voltage full KVA plug rated at 115 230V 50 amps K802 N Power Plug Kit Provides four 115V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 115 230V 50 amps For K14
87. c 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 Shut the welder off Connect the electrode cable from the LN 25 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of the welder Position the welder Polarity switch to the desired polarity either DC or DC Position the RANGE switch to the WIRE FEED position Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carries no welding current Place the idler switch in the AUTO position Adjust wire feed speed at the LN 25 and adjust the welding voltage with the output CONTROL at the welder NOTE The welding electrode is energized at all times unless an LN 25 with built in contactor is used If the output CONTROL is set below 3 the LN 25 contactor may not pull in RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 0 2 5 tc Return to Section TOC Return to Master TOC o 7 5 7 INSTALLATION Connection of the LN 7 to the Ranger 8 e Shut the welder off e Connect the LN 7 and the K240 contactor kit per instructions on the connection di
88. can be used with the Ranger 8 are shown in the following table Diameter Wire Speed in Range In Min Approximate Current Range 80 110 75A to 120A 70 130 120A to 170A 40 90 125A to 210A 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 The welding ranges that can be used with the Ranger 8 are shown in the following table Diameter Wire Speed in Range In Min Approximate Current Range 75 to 120A 80 110 70 130 120A to 170A RANGER 8 LINCOLN 5 OPERATION Summary of Welding Processes CONTROL CABLE TO START PROCESS USED WELDING STICK AUTO Hot Touch electrode to work Welding starts immediately and engine goes to high idle TIG K7930 1 K938 1 Press Amptrol contactor K936 K892 1 closes welding WITH AMPTROL starts immediately Return to Section TOC Return to Master TOC starts immediately and engine goes to high idle NOTE Output Control must be set above 3 WIRE FEED LN 7 WITH K240 CONTACTOR KIT Press gun trigger contactor closes Welding starts immediately Return to Section TOC Return to Master TOC WIRE FEED LN 25 WITH No Press gun trigger LN 25 INTERNAL CONTACTOR contactor closes Welding O10 515 0 815 g 9 5 2 a
89. creased power which is decreased at higher altitudes Engine horsepower is reduced by 3 596 per 1000 feet for altitudes above 377 feet A 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 Contact your local Onan Kohler or Honda Authorized Dealer for high altitude jet kits that are available from the engine manufacturer A WARNING Muffler Relocation Shut off welder and allow muffler to cool before touching muffler The Ranger 8 is shipped with the exhaust coming out on the left side The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and installing the cover on the opposite side Operating the Ranger 8 without the cover in place will result in a higher noise level and no increase in machine output 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 A 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 Connection of Lincoln Electri
90. e and check the oil level If necessary add oil to the upper limit mark on the dipstick 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 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 Blow out the machine with low pressure air odically In particularly dirty locations this may be required once a week Output Ranger Selector and Polarity Switches Switch contacts should not be greased To keep contacts clean rotate the switch through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 o 2 5 tc Return to Section TOC Return to Master TOC o 7 5 4 0 4 MAINTENANCE Engine Adjustments OVERSPEED IS HAZARDOUS WARNING The maximum allowable high idle speed for this machine is 3750
91. e bridge used this corner may be beveled and or marked with 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 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 Check that the leads are not grounded and for clearance and tightness Reinstall the case side fuel cap lift bail gas ket and case top RANGER 8 LINCOLN 5 50 NOTES RANGER 8 LINCOLN E F 50 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 51 F 51 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs
92. e engine HIGH IDLE RPM is OK then the engine may have lost horsepower and be in need of major repair O10 515 0 gt g 9 5 2 a 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 Return to Section TOC Return to Master TOC RANGER 8 gm ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 5 tc Return to Section TOC Return to Master TOC o 7 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No DC welding output AC welding output and auxiliary power is nor mal No AC welding output DC welding output and auxiliary power is nor mal POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make sure the Polarity Switch is in the proper position and is seated correctly Make sure the electrode and polarity are correct for the process being used Make sure the Polarity Switch is in the proper position and is seated correctly Make sure the electrode is cor rect for the process being used
93. ection TOC Return to Master TOC 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 O10 5 0 815 2 2 5 2 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div olo Coupling DC o Trigger Internal 55 olg 8 2 g 2 aa JE RANGER 8 LINCOLN 34 34 TROUBLESHOOTING amp REPAIR TYPICAL DC WELD OUTPUT WAVEFORM CV MODE MACHINE LOADED Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 20 volts 5 ms 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 O10 515 0 815 g 9 5 2 a SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling innen DC Internal FE
94. ed trailer for use with this equipment for in plant and yard towing by a vehicle is Lincoln s K768 2 Consult applicable federal state and local laws regarding specific requirements for use on public highways If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor dam age the welding equipment RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 5 INSTALLATION 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 CAUTION READ the engine operating and maintenance instruc tions supplied with this machine WARNING GASOLINE fuel cause fire f explosion 4 Stop engine while fueling Do not smoke when fueling Do not overfill tank Keep sparks and flame away from tank Wipe up spilled fuel and allow fumes to clear before starting engine The Ranger 8 is shipped with the engine crankcase filled with
95. edures apply to the Onan engine although there may be a few slight wiring variations Return to Section TOC Return to Master TOC MATERIALS NEEDED Lincoln Electric Rotor Removal Kit 820788 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 Ibs Feeler gauge 017 O10 515 0 815 g 9 5 2 a 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 RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC F 60 F 60 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 14 COMPONENT LOCATIONS ENGINE ROTOR REMOVAL Return to Section TOC Return to Master TOC o o 2 5 B Return to Master o 515 o 15 1 STATOR COWLING COVER 2 amp 8 IDLE LINKAGE 4 BRUSH HOLDER BRACKET 5 ENGINE LIFT BAILS 6 STATOR ENGINE MOUNTING BOLTS 7 ROTOR
96. edures 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 5 16 open end wrench 7 16 wrench Slot head screw driver Needle nose pliers O10 515 0 815 g 9 5 2 This procedure takes approximately 30 minutes to perform Return to Section TOC Return to Master TOC RANGER 8 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC O10 5 5 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC F 44 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT continued PROCEDURE Remove the spark plug wires With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube with come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by
97. ent sensing leads 254 and 254A see 5 5 gine spars pug the Wiring Diagram These leads attach O12 2 With the 5 16 nut driver remove the 6 to the current sensor located on the print 2 2 sheet metal screws from the case top ed circuit board 2 tle 3 Remove the rubber gasket cover seal from 11 Remove lead 3 from the 115 recep 5 5 the lift bail tacle Thread the lead through the hole in i c 4 Remove the fuel cap The rubber gasket for ouman s from the printed circuit board It will prob the fill tube will come off with the case top ably be necessary to cut any cable ties 5 Remove the case top then reinstall the restraining the wiring Use the diagonal fuel cap cutters 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 5 out 8 Wlth the 5 16 nut driver remove the printed S 15 circuit board cover See Figure F 12 55 o gle 5 2 dc RANGER 8 LINCOLN 5 F 53 F 53 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 12 With the 1 4 nut driver remove four screws holding the printed circ
98. ews on the top of the capacitor Lead 200 attaches to the posi tive terminal Lead 201 attaches to the negative terminal terminal 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 Reinstall the case side fuel cap lift bail gasket case top and spark plug wires RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B Return to Section TOC Return to Master TOC Q 7 5 49 TROUBLESHOOTING amp 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 Depress the retainer clip on the molded plastic holder and slide the rectifier bridge out With the needle nose pliers gently remove the 6 wires from the rectifier bridge 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 th
99. formement au code de l lectricit et aux recommendations du fabricant Le dispositif 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 debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Sea hy esas i iv Section Operation Section B fele i M Section C Ihe aet arae deli ev e deo I Section D Theory of Section E Troubleshooting and Section F Electrical Diagrams Section G Rugs aai M P 229 RANGER 8 LINCOLN 5 Section 1 Section 1 TABLE OF CONTENTS INSTALLATION SECTION O 5 0 5 Installation g Technical Specifications ee nad et
100. frequency counter oscilloscope or vibratach Black or red marking pencil O10 515 0 815 g 9 5 2 a This procedure takes approximately 35 minutes to perform Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B tc Return to Section TOC Return to Master TOC o 7 5 30 TROUBLESHOOTING amp 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 Strobe tach Method 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 3 Remove the fuel cap The rubber gasket for the fill tube will come off with the case top 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 Connect the strobe tach according the manufacturer s instructions Reconnect the spark
101. g Diagram This procedure takes approximately 20 minutes to perform O10 515 0 815 g 9 5 2 Return to Section TOC Return to Master TOC RANGER 8 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B Return to Section TOC Return to Master TOC Q 7 5 F 28 TROUBLESHOOTING amp REPAIR CHARGING CIRCUIT TEST continued FIGURE LOCATION OF VOLTAGE REGULATOR TEST PROCEDURE 1 Start the engine and run it at high idle 3650 RPM 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 F6 for location Check for 42 52 VAC at the voltage regula tor 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 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 5 Gro
102. g 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 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 publication Precautions for Safe Handling of Compressed Gases in Oylinders 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
103. gram 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 Return to Section TOC Return to Master TOC LINCOLN B ot ELECTRICAL DIAGRAMS WIRING DIAGRAM KOHLER NON CSA MODEL K1419 1 RANGER 8 KOHLER Wiring Diagram RR RUN GROUND SCREW OUTPUT R1 IN RUN 2 POETON AT BLOWER BAFFLE LI CONTROL Return to Section TOC Return to Master TOC 3 b 77A 76A 75A por O reg 210 54 ri S4 SHOWN 1 C IDLER IN AUTO 5 SOLENOID POSITION T HOUR METER 2 224 Return to Master Return to Section TOC 12 VOLT B BATTERY TERMINAL BLOC SEE CONN C1 FIELD CAPACITOR 200A OL A STARTER 1 1 PRESSURE SOLENOID 1 SWITCH 4 ENGINE 115V 230V IGNITION LATOR L 1 CROSS AC B STARTER SUPPORT GND C 11 TI FLYWHEEL ALTERNATOR i SILVER SLIP RING NEAREST LAMINATION i COLORED ENGINE COMPONENTS TERMINALS WHITE WIRES
104. he machine 14 Reassembly Refer to the Wiring Diagram for proper connections to the positive and 19 negative sides of the rectifier assembly The two sides of the bridge are marked and respectively NOTE Use Dow Corning 340 on all aluminum electrical connection surfaces 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 20 RANGER 8 LINCOLN 5 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 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 With the 1 2 socket wrench install the choke lead and the 10 lead Blue to the rectifier positive heat sink Note
105. he rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Set the volt ohmmeter to the DC volts position Connect the positive meter probe to the brush nearest the rotor lamination lead 200A See Figure F 1 for location 10 12 Lead 200A Lead 219 Connect the negative meter probe to the other brush lead 219 Start the engine and run it at high idle 3650 RPM Set the output control to the MAXIMUM position position 10 Check the voltage reading on the volt meter It should read between 37 and 46 VDC If the voltage reading is low or not pre sent the generator field is not functioning properly Perform the Rotor Resistance The Field Diode Bridge D2 the Field Capacitor C1 and or the Printed Circuit Board may be faulty 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 RANGER 8 LINCOLN 5 F 16 17
106. high temperature and other severe operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the oil and oil fil ter are not changed according to the manufacturer s recommendation ENGINE OIL CHANGE 7 Drain the oil while the engine is warm to assure rapid and complete draining Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain valve and attach the 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 Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely ENGINE OIL REFILL CAPACITIES Without oil filter replacement 1 7 US qt 1 4 Imp qt 1 6 liter Kohler 1 5 US qt 1 2 Imp qt 1 4 liter Onan P220 OHV 1 59 US qt 1 3 Imp qt 1 5 litre Honda LX620KI With oil filter replacement 2 0 US qt 1 7 Imp at 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 620 RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 5 5 0 815 2 2 5 2 Return to Section TOC Return to Master TOC
107. hold the vertical fan baffle in rotor from the stator frame supporting the olo place Slide the baffle forward toward the rotor by hand to prevent damage to the O rectifier bridge heat sink assembly rotor core eli 515 15 Hold the rotor shaft with locking pliers and 25 Move the engine and rotor assembly to a 6 9 unscrew the blower fan the fan Tue o amp bench The engine is balance with the counterclockwise You do not need to rotor still attached therefore support the olg remove the fan from the machine but be n end of the rotor with a wooden two by cjg sure it is completely unscrewed from the 515 four before unhooking the chain hoist 5185 rotor shaft 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 5 F 62 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 15 ENGINE AND ROTOR REMOVED FROM STATOR 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 With an impact wrench remove the rotor thru bolt
108. inal 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 6 Always indicate that this procedure was followed when warranty reports are to be submitted 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 RANGER 8 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 5 tc Return to Section TOC Return to Master TOC o 7 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major Physical Electrical Damage is Evident No weld output and no auxiliary power Engine runs normally POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Lincoln Service local Field 1 Contact your Authorized Facility 1 Check the brushes for wear and proper contact to the rotor slip rings TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact The Lincoln Electric Service Dept 1 800 833 9353 WELD 1 Perform the Rotor Voltage Test 2 Check for the presence of 12VDC at the pc board from lead 216 to frame ground This is the fl
109. ing for continuity and test to be sure it is NOT grounded to the choke iron Check the weld output termi nals and associated wires for loose or faulty connections 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 RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 5 tc Return to Section TOC Return to Master TOC o O 77 iv o gt TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No auxiliary power welding output is normal Engine runs normally POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 If machine is equipped with cir cuit breakers check circuit breakers CB1 thru CB5 Reset if tripped Make sure the Output Control R1 is set at the maximum position Check for loose or faulty plug s at the power receptacle s TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the auxiliary power receptacles and associated wires for loose or faulty connec tions Perform the Auxiliary and Field
110. iod 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 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 Honda Kohler Onan CH20S P220 5 HRS 25 HRS First Month or 20 HRS RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 OPERATION Welding Process Stick Constant Current Welding Connect welding cables to the TO WORK and ELECTRODE studs Start the engine Set the Polarity switch to the desired polarity Set the RANGE switch to a setting that is equal to or slightly greater than the desired welding current The RANGE dial marking indicates the maximum current for that range Fine adjustment of the welding current is made by adjusting the output CONTROL or remote control For best arc stability use settings 5 through 10 The Ranger 8 can be used with a bro
111. ip rings Place the other probe on any good unpainted ground The machine ground stud works well Return to Section TOC Return to Master TOC C Checkthe 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 Return to Section TOC Return to Master TOC 5 5 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 5 20 NOTES RANGER 8 LINCOLN E F 20 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg F 21 F 21 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST A 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
112. 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 In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder Spark Arrester Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations the K894 1 spark arrester must be installed and properly maintained CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance Trailers The recommend
113. lectrode lead around your body 2 4 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 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running Connect the work cable to the workpiece as close as possible to the area being welded 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 8 Return to Master TOC Return to Master TOC Q 2 7 5 Return to Master TOC 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 we
114. mited 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 815 2 2 5 2 a Return to Section TOC Return to Master TOC A 11 A 11 INSTALLATION Figure A 1 CONNECTION OF RANGER 8 TO PREMISES WIRING 230 VOLT 230 Volt POWER LM 4 115 VOLT 60 kiz COMPANY d 3 Wire 115 VOLT METER GROUNDED CONDUCTOR 277 NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 230 VOLT PROTECTION
115. n TOC Return to Master TOC Return to Master TOC F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK 9 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 CAUTION Sometimes machine failures appear to be due to 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 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 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 PC board can be damaged by static electricity 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 to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame
116. n 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 au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement 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 inflammables 1 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 pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr
117. nce grid bank O10 5 5 0 815 g 9 5 2 a Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 37 37 TROUBLESHOOTING amp REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM CV MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 O10 515 0 815 g 9 5 2 a Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC B B Internal 55 olg aa 2 2 RANGER 8 LINCOLN B 38 F 38 TROUBLESHOOTING amp REPAIR ABNORMAL
118. nd 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 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 5 5 0 815 g 9 5 2 Return to Section TOC Return to Master TOC Return to Master TOC _ THEORY OF OPERATION ai FIGURE E 3 ROTOR FIELD FEEDBACK AND AUXILIARY POWER RANGE SWITCH NC nm ELECTRODE OUTPUT __ POLARITY TERMINAL REACTOR AC BRIDGE _WORK STATOR TERMINAL MECHANICAL ROTATION STARTER ENGINE ROTOR on RINGS FLYWHEEL ALTERNATOR G NNN T que STATOR SOLENOID CONO PRINTED CIRCUT BOARD BATTERY FIELD CAPACITOR dm 115 amp 2 RECEPTACLES OUTPUT CONTROL FIELD BRIDGE ROTOR FIELD FEEDBACK A
119. o bolt 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 16 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 18 19 the proper 017 minimum air gap is achieved 6 Fasten the ground lead to the right engine mounting bolt and install both bolts 7 Install the brush holder bracket back into the stator frame Refer to the topic Removal and Replacement in this section of the manual 14 15 17 20 support hardware on the Onan engine Install the two cowling covers at the rear of the stator Connect the black plug in front of the fuel tank fill spout Connect the leads to the starter solenoid and replace any cable ties cut during disas sembly Install the battery Connect the positive battery cable then the negative battery cable BE SURE TO CONNECT THE POS ITIVE BATTERY CABLE FIRST Replace the battery cover Reinstall the case side fuel cap lift bail gasket and case top Connect the spark plug wires Conduct the Retest after proce dure
120. onnel 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 RANGER 8 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 5 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST continued FIGURE F 1 LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Brushes Slip Rings TEST PROCEDURE T With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove t
121. onstant 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 Bottom Mounted 9 Gallon Fuel Tank with a Convenient Top Fill and Fuel Gauge Polarity Switch for Selecting DC DC or AC Welding Output K930 1 TIG Module Available Remote Control Receptacle Kit Available Electronic Engine Idler Engine Automatically Goes to Low Idle in 10 to 14 Seconds after Welding or Use of Auxiliary Power Includes High Idle Switch Electric Starting Battery Charging Ammeter Full 8 KVA Auxiliary Output Receptacle Factory Installed Engine Hour Meter Engine Protection Shuts Engine Down in the Event of Low Oil Pressure Built in Feet for Easy Mounting to Truck Bed or Trailer All Copper Alternator Windings and High Quality Insulation for Long Life and Dependability Powder Painted Case and Base for Outstanding Corrosion Protection Quiet muffler with reversible exhaust feature either right or left side of machine ENGINE OPTIONS Three Engines are available for the Ranger 8 Welders the Onan P220 the Kohler 20 HP Command and the Honda GX620KI All three engines have the following features Air Cooled
122. ork and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 225 Amps 100 Duty Cycle 225 Amps 40 Duty Cycle 0 50 Ft 3 AWG 1 AWG 3 AWG 1 AWG 50 100 Ft 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 515 0 gt 2 2 5 2 a Return to Section TOC Return to Master TOC Return to Master TOC A 6 INSTALLATION 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 and maintain ing the oil at the normal FULL oil capacity in the crankcase in a level condition 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 will not give in
123. our code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Master TOC LINCOLN B 9 9 ELECTRICAL DIAGRAMS WIRING DIAGRAM HONDA CSA MODEL 21601 RANGER 8 HONDA CSA WRING DIAGRAM H1 53 SHOWN OUTPUT IN RUN GROUND SCREW CONTROL POSITION Aoc AT BLOWER BAFFLE 208 5 77A 76 75A S5 START L L CURRENT SENSOR Return to Master TOC Return to Section TOC BUTTON 254A 254A WORK S4 SHOWNI ELECTRODE IN AUTO SOLENOID AA REACTOR POSITION T 9 HOUR METER C1 215 STATOR Return to Section TOC Return to Master TOC 211B D9 4 221 4 AMP IN LINE sx SEE DETAIL 1234 21 DIODE 10 NO 1 7 mem 211A 21104 2080 221 2240 STARTER az ENGINE X FOOT OIL C1 FIELD 2 1 7 APACITOR PRESSURE NA BIR 8 GND H 200A CAPACITOR SWITCH IGNITION ENGINE m MODULE FUEL CROSS SHUTOFF SUPPORT J4 rl
124. pective heat sinks See Figure E5 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 Replace any shorted or open diode the tests indicate Reconnect the diode pigtails and heavy leads to their respective studs Reinstall the case side case top fuel cap lift bail gasket and spark plug wires F 26 RANGER 8 LINCOLN 5 F 27 F 27 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wirin
125. 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 RANGER 8 LINCOLN Return to Section TOC Return to Master TOC o o 2 5 B Return to Master F 52 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued FIGURE F 12 PRINTED CIRCUIT BOARD LOCATION Current Sensor 5 16 Screw 4 Current Sensing Leads 12 Pin Molex Plug PROCEDURE Before starting the following procedure refer to d Pu plug the topic Board Troubleshooting 5 e Procedures at the beginning of this section 10 Detach the two in line connectors from the i Rem vethe endine spark Glug wires curr
126. pical 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 WIQOGN Internal RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 815 g 9 5 2 a Return to Section TOC Return to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM 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 COUPIING 2 2 Hager cuire Internal RANGER 8 LINCOLN 5 41 41 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM Return to Section TOC Return to Master TOC O volts Return to
127. plug wires and start the engine Direct the strobe tach light on the blower paddle and synchronize it to the rotating mark With the machine at HIGH IDLE the tach should read between 3650 and 3750 RPM With the machine at LOW IDLE the tach should read between 2150 and 2250 RPM RANGER 8 LINCOLN 8 F 30 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 5 B tc Return to Section TOC Return to Master TOC Q 7 5 F 31 Throttle linkage 11 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 8 HIGH IDLE ADJUSTMENT NUT 3 8 High Idle Adjustment Nut If either of the readings 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 tach reads between 3650 and 3750 RPM 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
128. power loads are permitted by following Table 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 1 Install a double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service overcurrent protection 2 Take necessary steps to assure load is limited to the capacity of the Ranger 8 by installing a 35 amp TABLE I 230V double pole circuit breaker Maximum SIMULTANEOUS WELDING AND POWER rated load for the 230V auxiliary is 35 amperes Loading above 35 amperes will reduce output Output Selector Permissible Power Permissible Auxiliary voltage below the allowable 1096 of rated Setting Watts Unity Power voltage which may damage appliances or other Factor Orie 230V motor driven equipment Max Stick or Wire Feed Setting 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 125 Stick Setting 50 amp 115 230V plug is available in the 90 Stick Setting optional plug kit 70 Stick Setting 4 Plug this cable into the 50 amp 115 230V receptacle on the Ranger 8 case front 50 Stick Setting 6300 NO WELDING 8000 Each duplex receptacle is li
129. quires K938 1 Contactor Kit K939 3 Control Cable see Optional Equipment Optional K939 1 Docking Kit K963 Hand Amptrol amp 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 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 LINCOLN C 4 NOTES RANGER 8 LINCOLN E 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg Section 0 1 Section 0 1 TABLE OF CONTENTS MAINTENANCE FLUR Section D gt Routine Maintenance svi ERE baee D 2 Engine Maintenance sii RE 0 2 5 Change the Qil sssrin D 2 Engine Refill 0 2 Charige the Oil Filtet itr et etr 0 3 Engine 5 c C M D 4 Nes ne D 4 Engine Maintenance
130. r from the brush holder and let the brushes snap back against the slip rings With the needle nose pliers connect the red and the black wires to the appropriate terminals on the brushes The red wire is inboard Check the wire connections for clearance and tightness Reinstall the case side fuel cap lift bail gasket case top and spark plug wires F 44 RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 5 0 815 EIS 2 1 Return to Section TOC Return to Master TOC F 45 F 45 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT continued SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal Brushes A CAUTION should be inspected when a general overhaul is necessary If brushes are to be replaced clean Do not attempt to polish slip rings while engine slip rings with a fine emery paper is running FIGURE F 10 BRUSH LEADS BRUSHES RETAINED WITH CABLE TIE 1 mi Y M Tii 7 16 Brush Assembly Bracket Bolts RANGER 8 LINCOLN 46 NOTES RANGER 8 LINCOLN E F 46 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg 47 47 TROUBLESHOOTING amp REPAIR FIELD CAPAC
131. rews holding the left case side 19 With the 9 16 wrenches remove the 8 Remove the case sides by lifting up and ground ead Mhe ngne engine Duff mounting bolt 20 With the 7 16 wrench remove the brush 9 With the 3 8 wrench remove the battery holder bracket and leads 219 amp 900A cover from the stator frame 10 Disconnect the negative battery cable 5 then the positive battery cable BE SURE 208 E Ps e jo TO DISCONNECT THE NEGATIVE pp e TERY CABLE FIRST Remove the battery 21 Support the engine with a chain hoist Lift sic and set it aside bails are provided on the top of the engine 9 3 11 With the diagonal cutters cut the cable A ties around the leads from the starter sole 22 With the 9 16 wrench remove the right and disconnect the leads Remove and left engine foot mounting bolts 5 23 With the 9 16 wrench remove the four tc 12 Disconnect the large black plug in front of bolts that hold the stator to the engine the fuel tank spout There is one lock washer per bolt 13 With the 3 8 wrench remove the cowling 24 With the chain hoist unweight the engine covers at the rear on the stator both sides gently Use a pry bar to carefully pry of the machine between the engine and the stator frame in 14 WIth the 3 8 wrench remove the two bidder te Unseat the Beating OD end ot i the rotor shaft Separate the engine and screws that
132. rn to Section TOC Return to Master TOC o 7 5 26 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST continued FIGURE F 5 LOCATION OF OUTPUT RECTIFIER LEADS Pigtail Output rectifier Bridge Assembly Machine Front TEST PROCEDURE Remove the spark plug wires to prevent accidental engine kickback or starting With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Conduct the test with the gasoline engine OFF Locate the Output Rectifier Bridge behind the machine case front 10 Ohmmeter Probes 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 Electrically isolate the diode pigtails by bending them back into free air With an ohmmeter or diode tester check each of the four diodes from their pigtails to their res
133. ry 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 If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last Hardware Both English and Metric fasteners are used in this welder Engine Maintenance Parts EE ONAN P220 KOHLER CH20S HONDA GX620KI HONDA 15400 PR3 004 HONDA CODE 3179553 FRAM PH6811 ONAN 122 0737 FRAM PH4967 KOHLER 1205001 FRAM PH3614 Air Filter ONAN 187 6068 KOHLER 4708303 HONDA 17211 ZJ1 000 Element FRAM CA79 HONDA CODE 4209672 Air Filter KOHLER 2408302 HONDA 17218 ZJ1 000 Pre Cleaner N A HONDA CODE 4209706 Fuel Filter ONAN 187 6119 KOHLER 2505002 HONDA 16910 ZE8 005 FRAM G1 HONDA CODE 2106235 Spark Plugs ONAN 187 6161 CHAMPION RC12YC NKG BPR6ES Resistor CHAMPION N9YC 030 GAP Nippondenso W20EPR U Type 025 GAP in 76mm gap capacity increases from 2 0 to 2 1 Qts when using this filter RANGER 8 LINCOLN 5 cc E 9 585 k gt 3 bdo g cag m aU rado uo 20 zx SESE
134. s and other reproductive harm cancer birth defects or 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 a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 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 FIELDS 1 c Do not add the fuel near an open flame weld ing arc or when the engine is
135. s 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 RANGER 8 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 o 2 5 tc Return to Section TOC Return to Master TOC Q 7 5 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Engine will not crank or cranks very slow The Engine shuts off Engine does not develop full power POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Check for loose or faulty battery cable connections 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 The Engine may be low on or out of fuel The Oil level may be low Check and fill to proper level The fuel filter may be clogged The fuel filter may be clogged Replace if necessary The air filter may be clogged Replace if necessary The spark plug s may be faulty Replace if necessary TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 If the battery is replaced or tests good then the charging circuit may be faulty Perform the
136. sgene a highly toxic gas and other irritating products 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 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 Mar 95 Return to Master Return to Master TOC o 2 7 5 Return to Master TOC WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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
137. ted areas or vent exhaust outside 3 MOVING PARTS can injure Do not operate with doors open or guards off N Stop engine before servicing Keep away from moving parts See additional warning information throughout this operator s manual and the Engine manual as well Read the Safety Precautions in the front of this manual and the engine instruction manual before working on this machine 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 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 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 OIL Maintenance schedule for changing the oil and oil filter after break in Kohler Onan Honda CH20S P220 GX620KI 6 Months or 100 HRS 50 HRS 100 HRS 1 Year or 200 HRS Oil Filter 200 HRS 100 HRS The above schedule is for normal operating conditions More frequent oil changes are required with dusty
138. the choke control as follows Onan Engine If the engine is cold pull the choke control out Do not use the choke if the engine is warm or hot Kohler Engine Always pull the choke control out when starting the engine cold warm or hot Place the Engine switch in the ON position Honda Engine Always pull the choke control out when starting the engine cold Place the Engine switch in the ON position Push the START button and crank the engine until it starts Release the button as soon as the engine starts Do not push the START button while the engine is running because this will cause damage to the ring gear and or starter motor After the engine has started slowly return the choke control to the full in position choke open After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the Ranger 8 because the fuel tank is mounted below the engine Break in Period It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in per
139. the following topic in this section of the manual F 63 RANGER 8 LINCOLN 5 64 64 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine e 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 f you repair or replace any electrical components Return to Section TOC Return to Master TOC ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 2150 2250 NA 3700 3750 3100 3600 WELDER DC OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Maximum 67 72 21 26 5 205 240 Return to Section TOC Return to Master TOC WELDER AC OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Maximum 73 80 25 32 225 275 WELDER CV OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Wire Feed CV 29 33 19 22 200 220 AUXILIARY POWER RECEPTACLE OUTPUT 230 Volt Receptacle 115 Volt Receptacle Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps o 7 5 Q 5 2 5 tc Voltage Voltage 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 OUTPUT CONTROL switch set
140. uit 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 Return to Section TOC Return to Master TOC 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 Ojo O10 515 0 815 2 2 5 2 a Return to Section TOC Return to Master TOC RANGER 8 LINCOLN 54 NOTES RANGER 8 LINCOLN E F 54 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 uunjeH 201 uonoes DOL uonoes 0 uumeg 201 uonoes uumeg DOL uonoes uumeg F 55 F 55 TROUBLESHOOTING amp 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
141. 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 LINCOLN 5
142. und Lead Green Voltage AC Lead If the DC voltage reading is incorrect or not present the voltage regulator may be faulty Replace the entire voltage regulator module If the DC voltage reading is correct check the associated wiring and circuitry See the Wiring Diagram F 28 RANGER 8 LINCOLN 5 29 29 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 open end or box wrench Strobe tach

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