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Lincoln Electric 100S Welder User Manual

Contents

1. DIAGRAMS L 1uoddns 55042 ANION 1003 3NI9N3 77 GION310S 4401NHS ualuvis 4 1 1 10 3105 15 YOLVNUYSLIV 133HM A14 2v AY3LLVS 8 SLN3NOdWOO 3NISN3 31000 uoivinoau NOILINOI a HOLIMS 3unssaud 110A 27244 HOSN3S iN3uuno TOYLNOD indino 4 GION310S unoH 1 NOILISOd OLAVA NI INMOHS fS J 75 1 NOLLNG 55 u3MO18 LV aNnous 02 5 NOILISOd NR NI NMOHS 5 VS2 8 YAONVY 86401 9 9 0 Z 6TVI RANGER 8 LINCOLN E Jequunu epoo 1uauudinbe Ju uu oe d i e 10 S J Sued y JO euo uo y LL apisul paysed si apod e 104 gt jenueui siy Aq gt 20 93e1n22e A uo 10 S
2. CO 31114 10 Y lo RANGE DIAGRAMS BNVILI 1304 1104 ANY NI 710 HLIM ALIAVYS dO YALNAD 7 LINCOLN E DIAGRAMS F 8 586 0 1 GLCZIW 5 ONILNNOW 39YIYYYIYIANN Le Scy 00 2 0070 00 11 TIWAOWAY udlild 401 SET qu o 1 ANVIL 130434 1104 ANY 3NION3 NI TIO ALIAVHO 40 YALNAD L4dvHS 40 b RANGER 8 LINCOLN E NOTES RANGER 8 LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantit
3. a B 5 ACCOSSOMIOCS AAE Tea nee name ee ends Section General Options Accessories eueeeeeeieeeieeesr resit ner netin nstnnnnntttnnntnnnsnnnnsrensnnns C 1 Recommended Equipment 2 Maintenance e Ls Section D Safety Precautions usines D 1 Routine Engine Maintenancoe U nennen nnns D 1 Engine Adjustments se D 2 SID RINGS RES D 2 Battery ener enn D 2 Engine Maintenance D 2 Troubleshooting Section E Safety Precautions cue tee tege respi detenta E 1 How to Use Troubleshooting E 1 Troubleshooting E 2 E 3 Wiring Diagrams amp Dimension Print ss Section F Parts S T a 229 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Ranger 8 K1418 1 K1418 2 CSA MEETS CANADIAN STD K1419 1 K1419 2 CSA MEETS CANADIAN STD K2160 1 CSA MEETS CANADIAN STD INPUT GASOLINE ENGINE Make Model Description Horsepower Speed RPM Displacement Capacities cu in cu cm Onan P216 16 HP
4. 9 Lo T ALIAVO 212 o o o 8Vl 9NILV201 U d L 21 5 Nid NOLO3NNOO ALIAV2 802 LESTA udd 5108 WAS 1V91419313 x Su38W N ALIAVO 31ON uvdu WOud GAMAIA NMOHS SLIN3NOdWOO LNOUd 3SVO 11 ava SIYM 31IHM SIVNINYIL SININOdWOID NOILVNIWV1 LS3uV3N 415 S wats LOUE IV SNS T En i ualuvis H HALUVLS WUolvino3u ae J 55042 22014 1 aniona Q7 HOLIDV4VD i 91314 19 1 1 335 32018 IYNIWYIL HOLIMS 2211 A i 3unssaud 110 1004 3NI9N3 Au311v8 110A DIAGRAMS qION310S OLN NI MOHS 75 EIZ NOLLNG LUVLS ERJ inauuno 9802 3144V8 u3MO18 LV NOILISOd TOYLNOD ANNOYS TU indino NI NMOHS NYNO 8
5. s ESSA due ranas cl ysl e danny READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 6 9 fsPBHEILTABSSUCFEU
6. 5541 3LON 8866 216919 dad S TOSINAS IVOlIH LO3 13 NMOHS SIN3NOdMWOO LNOYS 3SVO TIV NOLLO3NNOO AVH9 AD 92018 WNIWYSL L ALIAVO 122 ALIHM M 40 Gay 4 AV49 HO MOV1d 8 zit ALIAVO 802 gY SNILVOO1 rit ALIAVO 22 est ALIAVO LEZ ANISNA JHL 54015 SIHL 6 ALIAVO 31ON SH38AIN HOLO3NNOO QV31801VH3N39 S3HIM 3LIHM JINON CERO O2 HANTS 01V1n934 8314119 34 LS3YV3N 4118 VA 53899 1 S rez 1109 div 0c 4 9 Lu 2 AO 19 5 ds les LHOddns 4401NHS D 86082 7304 31naOoW qe HOLIMS H ANO F2 WE yN 10 1004 L vole EINIONS gt 1 vic 0 122 OZY J NOLIJNNOD avez ON 0 2 12 3NI1NI dV v 122 DIAGRAMS 2 L HOLVLS Sic HN
7. e SH7IAE 25 MASH 918 7145 714 iua duly bacs 5 Jaial gaal uc Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas o FIYR Y ERKE D PSB ET RRA FE e e AIR J pil gS jud ghil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas CHR EL uA CG F uv Ro egado Yel HAE AHSA AREY 3 lla Jai ve WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG
8. v8oz NOILISOd NI NMOHS 8 LESOT 9 GLEOT 6 NMOHS uf Su RANGER 8 LINCOLN E LL 996 61 L NOILDINNOD 49079 1VNIWH3L 122 28 ALIAVD 802 27 J svi amp ALIAV2 TIZ 28 2922 27 ES gt ALIAVO ILON 5 paysed si 941 5 Nid YOLIINNOD Jequunu epoo 1u uudinb SAID Ju uu oe d i e 10 SI eu J Sued y JO euo uo 58 Aq parao 93e1n22e you 3 juo e2uaJ9JaJ 10 SI SIUL 310 168134 34 5108 WAS 1 uvdu WOYS GAMAIA NMOHS SLN3NOdWOO 1 4 3SVO 11V 13710IA A 3n18 31IHM M aay 32v18 3003 1 d3NION3 JHL 54015 TVNIWYAL SIHL 9 VN NOILVNI WV LS3UV3N 415 002 112 4 2 Q13l4 ge vse ac 282 uj 5 JLIHM S1VNIWH AL 2 vf
9. 5 INSTALLATION A 5 Angle of Operation Internal combustion engines are designed to run in a level condition which is where the optimum perfor mance is achieved The maximum angle of operation for the engine is 15 degrees from horizontal in any direction If the engine is to be operated at an angle provisions must be made for checking 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 It will not give increased power which is decreased at higher altitudes Engine horsepower is reduced by 3 5 per 1000 feet for altitudes above 377 feet CAUTION Do not operate 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 shippe
10. 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 kill Do not touch electrically live parts 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 3 GA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off AW 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 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
11. 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 23 FUMES AND GASES can be dangerous 5 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 phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Al
12. lt position the engine will run continuously at high idle When in AUTO operates as follows A idle position the idler Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds e Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle RANGER 8 LINCOLN 3 OPERATION B 3 Starting Shutdown Instructions Starting the Engine WARNING e Do not touch electrically live parts of electrode with skin or wet clothing Keep flammable material away Insulate yourself from work and ground Wear eye ear and body protection Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone Reg Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owner s Manual Remove all loads connected to the AC power recepta cles To start the engine set the Control switch in the Automatic lt position Use the choke co
13. pe AY3LLVS 110A DIAGRAMS 2 4 1 NOILISOd wOLAWs NI O uaa tSu OET NOLling LUVLS ss TT A1NO 5 947 wosNas GION310S 340 1nHS 9802 I 1N3UuUn2 3144V8 u3MO18 LY 10u1NO2 14100 NOILISOd NI NMOHS 5 ueJjbeig NOISu3A VSO NYNO 8 9660 9 VLEOT POD Z 81Tv T5 F 2 RANGER 8 LINCOLN E e DIAGRAMS F 3 Jequunu epo queuudinbo y 107 9 S eun JI pajsed si opo e 104 5 u L 996 61 1 28 802 22 7 EE 2 5NILV201 TIZ NOIL23NNOO 332048 1VNIWU3L SYISWAN ALIAVO ILON 7 1 9 I ALIAVO 122 Su38WnN 9N0OLO3NNOO v Jenueuu siy paano gt 10 jou 3I
14. sjaued aunso 2ue y JO euo uo AJUO 104 SI 5141 3 ON 164134 Hd 5108 WAS 1 12414 G3M3l NMOHS SLNJ3NOdWOO 1 4 3SVO 11 A 3n18 2 n M 2v18 8 3002 Qv31 3NISN3 JHL SdOLS SIHL ONIGNNOYDSD VN 0112 4 2 19 NOILVNIWY1 LS3uV3N 415 2 AOEZ ASTT vf 5 3LIHM SIVNINYIL gt 5 5 55042 1004 qION310S 34010 5 4 1 10 3105 1 HALUVIS SININOdWOI 3NI9N3j WOLVNU3I1V 133HMA 14 o 2v ta anaon uwolvinoau NOILINOI 8 110A 602 UNNOS 338 49078 1VNIWU31 2922 Homs i awnssawd i 10 WOSN3S VSL voL Tu BUIIIM indino YNOH GION310S NOILISOd NI Luvs ss
15. Output Control for Fine Current Adjustment Use with a broad range of AC amp DC Electrodes Including Fleetweld 5P DC SEMIAUTOMATIC WIRE FEED WELDING Constant Voltage CV Tap Setting for 60 200 Amps 100 Duty Cycle Excellent Performance with 068 1 7mm NRG 211 MP Innershield Electrode Limited MIG Welding with L 50 amp L 56 using blended Argon Shielding Gas The Recommended Wire Feeder is the LN 25 but Can Also be Used with the LN 7 Wire Feeder LN 7 and LN 25 without Contactor Requires the K240 Contactor Kit AC DC TIG WELDING Constant Current AC 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 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
16. Portuguese ATENCAO Japanese it ies BR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBO X HD OHBRBEEK BMA 34 ECL TCHHORERME HST F uv ER ET ABL BE 55 Rr de OE D 95568205 SEE ow nie SAISIR FA HAURA CHAS ETAT sp 5 J al Gail guet LINCOLN 8 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
17. SESOTL 9 ELEOT 9 8 1 RANGER 8 LINCOLN E N Jequunu epoo 1u uudinb y SAID e 10 3u unued q 225 S au J sjaued nsopu y JO euo uo y LL paysed si apod e 104 gt siy q P218A02 gt 10 eq jou 3 A uo 10 S SIUL 310 TEE8TW 996 61 1 NOIL23NNO2 ALIAWD 2922 32018 1VNIWN31 Me T ALIAVO ZIZ avi 1 ALIAV D 28 ALIAVD 29vpzz 7 Su38WnN YOLDINNOD 7 164134 5108 WAS 2 12314 X Su38WDN ALIAVO ILON 7 Vaud NMOHS SLINNOd WOO 1 4 3SVO 11 7 SIVNINUIL Se SIS SINANOdWOD NOILYNI WYT 153 9NIW 4115 VE MOLVNU317V 133HMA 14 3 i vse AT E xe 4 Semte ie GION3TOS NOILINOI AOEZ ASTT H ualuwvis 55082 2 sorta 3NI9N3 uvds HOLI2V dv HOLIMS 2093 3unssaud 2 335 32018 1VNIWUIL 3105 330 1nHS
18. itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A RANGER 8 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the RANGER 8 RANGER 8 LINCOLN 8 9 Auxilliary Power While Welding It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are permitted by following Table The permissible currents shown assume that current is being drawn from either the 115V or 230V supply not both at the same time Also the Output Control is set at 10 for maximum auxiliary power TABLE 111 SIMULTANEOUS WELDING AND POWER Permissible Auxiliary Current in Amperes 11
19. la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the informati
20. 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 pneumatic tires K893 1 Caster for Undercarriage Mounts to the front of the K889 2 to allow easy movement on smooth surfaces Includes 6 diameter hard rubber wheel and convenient toe on toe off locking brake K933 1 Four Wheel Undercarriage For Hand Moving Rear pneumatic tires front molded wheels K934 1 Cylinder Brackets For use with K933 1 for transporting either one LPG fuel cylinder or one weld ing gas cylinder K1737 1 FOUR WHEEL ALL TERRAIN UNDER CARRIAGE For moving by hand at construction sites Heavy duty puncture resistant pneumatic tires K1770 1 UNDERCARRIAGE FACTORY For mov ing by hand on a smooth surface One or two gas cylinders can be mounted on the rear of the undercar riage 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
21. Fuel K1418 1 3600 RPM 9 Gal 34 L K1418 2 2 cylinder Onan 43 710 Lubricating Oil 4 Cycle High Idle 3700 1 8 Qts 1 7 L Air Cooled Kohler CH20 Gasoline 20 HP Fuel K1419 1 Engine 3600 RPM Full Load 3500 9 Gal 34 L K1419 2 Aluminum Alloy Kohler 38 624 Kohler Lubricating Oil with Cast Iron 2 0 Qts 1 9 L Liners Electrical Low Idle 2200 Honda GX620 Ignition 20 HP B I 2160 1 yon 18 onda 1 9 Qts 1 8 L RATED OUTPUT WELDER AC Constant Current 225A 25V 10096 DC Constant Current 210A 25V 10096 DC Constant Voltage 200A 20V 100 OUTPUT GENERATOR Auxiliary Power 8 000 Watts 60 Hz AC 70 Amps Q 115V 35 Amps 230V PHYSICAL DIMENSIONS DEPTH WEIGHT 42 3 in 529 Ibs 240kg 1418 1 2 1074 mm 511 Ibs 232kg K1419 1 2 amp K2160 1 Based 10 min period RANGER 8 LINCOLN 5 2 SPECIFICATIONS OUTPUT VOLTS AC OUTPUT VOLTS DC OUTPUT VOLTS DC INSTALLATION AC STICK TIG CC OUTPUT 225 OUTPUT RANGE A 50 OUTPUT RANGE 100 150 OUTPUT AMPS DC STICK TIG CC OUTPUT 200 210 OUTPUT RANGE 50 OUTPUT RANGE e 100 250 300 150 200 OUTPUT AMPS DC WIRE FEED CV OUTPUT 350 N N e 10 CV OUTPUT RANGE 100 150 200 250 OUTPUT AMPS 300 350 RANGER 8 LINCOLN 8 3 INSTALLATION A 3 INSTALLATION INSTRUCTIONS Safety Precautions
22. 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 Kohler Onan CH20S P216 First Month or 20 HRS 5 HRS 25 HRS The oil filter is to be changed at the second oil change Refer to the Engine Owner s Manual for more information RANGER 8 LINCOLN 4 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 switch to a setting that is equal to or slightly greater than the desired welding current The RANGE dial marking indicates the maximum current for that range Fine adjustment of the welding current is made by adjusting the output CONTROL or remote control For best arc stability use settings 5 through 10 The Ranger 8 can be used with a broad range of AC and DC stick electrodes See Welding Tips 1 included with the Ranger 8 for electrodes within the rating of this unit and recommended welding currents of each TIG Constant Current Welding The K930 TIG Module installed on a Ranger 8 pro vides high frequency and shielding gas control for AC and DC GTAW TIG welding pro
23. 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 249 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 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 Sem MAGNETIC FIELDS i may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the eng
24. 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 216 205 HONDA GX620 HONDA 15400 PR3 004 HONDA CODE 3179553 FRAM PH6811 Air Filter ONAN 140 2628 01 KOHLER 4708303 HONDA 17211 ZJ1 000 Element FRAM CA140PL FRAM CA79 HONDA CODE 4209672 ONAN 122 0645 FRAM PH3614 Air Filter Pre Cleaner KOHLER 1205001 FRAM PH3614 ONAN 140 1496 KOHLER 2408302 HONDA 17218 ZJ1 000 HONDA CODE 4209706 ONAN 149 2005 KOHLER 2505002 HONDA 16910 ZE8 005 FRAM G1 FRAM G1 HONDA CODE 2106235 ONAN 167 0263 CHAMPION RS14YC 025 GAP Spark Plugs Resistor Type CHAMPION RC12YC 030 GAP NKG BPR6ES Nippondenso W20EPR U in 76mm gap Oil capacity increases from 2 0 Qts to 2 1 Qts when using this filter RANGER 8 LINCOLN 1 TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained P
25. electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AX Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting k
26. 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 insulat ed joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provid ed on the front of the welder Spark Arrester Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations the K894 1 spark arrester must be installed and properly maintained A CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance Trailers The recommended trailer for use with this equipment for in plant and yard towing by a vehicle is Lincoln s K768 2 Consult applicable federal state and local laws regardin
27. 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 120A to 170A RANGER 8 LINCOLN 5 OPERATION Summary of Welding Processes ELECTRODE WHEN NOT PROCESS WELDING TIG K7930 1 K938 1 K936 K892 1 WITH AMPTROL WIRE FEED LN 25 WITH INTERNAL CONTACTOR WIRE FEED LN 7 WITH K240 CONTACTOR KIT RANGER 8 LINCOLN TO START WELDING Touch electrode to work Welding starts immediately and engine goes to high idle Press Amptrol contactor closes welding starts immediately Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 Press gun trigger contactor closes Welding starts immediately 1 OPTIONAL EQUIPMENT Field Installed K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc Order K957 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 2 Fender amp Light Kit K965 1 Cable Storage Rack K889 2 amp 3 Two Wheel Undercarriage For moving by hand Overall Width
28. 5V 230V Permissible Power Watts Unity Power Factor Max Stick or Wire Feed Setting None Output Selector Setting NO WELDING 8000 Standby Power Connections The Ranger 8 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The Ranger 8 can be permanently installed as a standby power unit for 230V 3 wire single phase 35 ampere service Connections must be made by a licensed 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 A WARNING following information can be used as a guide by the electrician for most applications refer also to the connection diagram shown in Figure 1 1 Install a double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service overcurrent protection INSTALLATION A 9 2 Take necessary steps to assure load is limited to the capacity of the Ranger 8 by installing a 35 amp 230V double pole circuit breaker Maximum rated load for the 230V auxiliary is 35 amperes Loading above 35 amperes will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 3 Install 50 amp 115 230V plug NEMA type 14 50 to the Doubl
29. BLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION No welder or output power Open in miscellaneous leads Open lead in flashing or field circuit Faulty rotor Faulty Potentiometer R1 Faulty stator Field winding Faulty Field rectifier D2 If all recommended possible areas of Faulty P C Board misadjustment have been checked and the problem persists Contact Engine will not idle down to low Idler switch on High Idle your local Lincoln Authorized speed Field Service Facility Insufficient voltage present between terminals 213 and 5E Voltage should be 12V DC External load on welder or auxiliary power Faulty wiring in solenoid circuit Faulty idler solenoid Faulty P C Board Engine will not go to high idle when Poor work lead connection to attempting to weld work No voltage signal from the current sensor No open circuit voltage on output studs Faulty P C Board A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 8 LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Engine will not go to high idle when using auxiliary power E
30. Docking Kit e K963 Hand Amptrol K870 Foot Amptrol 892 1 Remote Control Receptacle Kit K915 1 Adapter Cable WIRE FEED K449 LN 25 Includes internal contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid K892 1 Remote control Receptacle Kit and K444 1 Remote voltage Control Kit are required for voltage control at the feeder LN7 K240 Contactor Kit is required Magnum Gun is required for gas shielded welding Innershield Gun is required for gasless welding RANGER 8 LINCOLN 1 MAINTENANCE SAFETY PRECAUTIONS A 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 maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST kill Use in open well ventilated areas or
31. FORMATIVE CATALOGS Lincoln Welding School Titles Price Code Quantity Cost 80 New Lessons in Arc Welding 5500 L 5 Information Procedure Handbook Twelfth Edition 15 00 PH 1 How to Read Shop Drawings 5450 H Educational Video Information Incentive Management 3590 M T 529 New Approach to Industrial Economies 9500 NA Lames F Lincoln Arc Welding ______ The American Century of John Lincoln 500 AC __ Foundation Book Information WekingPrehealCalcuatr 300 wee WFLF 518 Pipe Welding Charis 5 DBD 2 SB ea Shipping Cosisifany TOTAL COST Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Name Address Telephone Signature as it appears on Charge Card s T T T TT TT eleme WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese 5 BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez n
32. Fa IM510 E RA NGER 8 J anuary 2002 For Machines with Code Numbers 10373 10374 10375 10376 10535 10536 10537 10538 or 10541 10886 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Wee Purchased OPERATOR S MANUAL ISO 9001 Ar ANSI RABE as Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LINCOLN Copyright 2002 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A 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 defects
33. 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 P216 Performer the Kohler 20 HP Command and the Honda GX620 three engines have the following features Air Cooled Twin Cylinder Cast Aluminum Alloy Crankcase with Integral Cast Iron Cylinder Liners Electric Start with Solid State Battery Charging Module Solid State Breakerless Ignition Spin on Oil Filter Low Oil Pressure Shutdown Protection In addition to the above the Kohler Command Engine has overhead valves and hydraulic valve lifters These trademarks are the property of their respec tive manufacturers RANGER 8 LINCOLN 2 OPERATION Ranger 8 Approximate Fuel Consumption ONAN P216 16 H P PERFORMER Low Idle No Load 2200 RPM High Idle No Load 3700 RPM DC CV Weld Output 200 Amps 20 Volts 1 7 Gallons Hour 6 5 Liters Hour Welder Controls Function and Operation Explanation of Symbols that Appear on this Equipment Low Idle High Idle Q ENGINE Switch When plac
34. OH 8 arona tes i o1nv NI y m INMOHS FS vS R VrSZ OSN3S HS AN3YYND i o O WoL 1 31448 H3MOT8 IONOS NI La 1ndino 25 NVYSVIC VSO VdNOH 8 9880 9p02 L 09LZH 5 RANGER 8 LINCOLN E F 6 DIAGRAMS F 6 RANGER 8 LN 25 ACROSS THE ARC CONNECTION DIAGRAM WARNING e Eee ma MOVING PARTS can injure Do not operate with panels open guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing ANS Only qualified personnel should install use Do not touch electrically live parts or service this equipment 6 PIN OPTIONAL K444 1 AMPHENOL REMOTE CONTROL LN 25 WIRE FEEDER TO WORK ELECTRODE CLIP LEAD WORK TO WORK E N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH TO THE WIRE FEED CV POSITION N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED
35. PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION ELECTRODE CABLE 21883 M11486 CONNECTION OF RANGER 8 TO LN 7 amp K240 CONTACTOR KIT CONNECTION OF LN 7 amp K240 CONTACTOR KIT WITH 115 VOLT AC AUXILIARY POWER AND CV OUTPUT CONTROL CABLE n o ONNECT THE CONTROL CABLE C K240 CONTACTOR KIT IROUNDACEADSTO ie PRAMEY gt 115V 50 60HZ 600 TERMINAL STRIP OR TO N UNPAINTED FRAME SCREW I I SOURCE I I ED i 77 76 75 1 FAUTO POWER N F amp N G Y SOURCE 21 1 euentum ueri iem 1 gt ELECTRODE CABLE TO LN 7 IWORK ELECTRODE 517742 TOWORK 40 5 92 installation An S16586 length remote voltage sensing work lead may be ordered for this purpose Connect it directly to the work piece independent of the welding work cable For convenience this extended 21 lead should be taped to the welding work lead ER STANDARD OUTPUT TERMINALS WARNING Turn the power off when making connections N A Use power source polarity switch to set for desired elec trode polarity Position the output selector switch on the power source to the CV position 3 conductor 16 power cord physica
36. at 115 230V 50 amps ACCESSORIES C 1 K802 N Power Plug Kit Provides four 115V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 115 230V 50 amps For K1418 2 or K1419 2 CSA machines and machines with GFCI receptacles use K802 R K704 Accessory Kit Includes 35 ft 10 7m 2 0 AWG elec trode cable 30 ft 9 1m 2 0 AWG work cable headshield with No 12 filter GC300 work clamp and Cooltong 300 electrode holder Cables are rated at 300 amps 100 duty cycle K892 1 Remote Control Receptacle Kit Includes a 6 pin MS type Amphenol receptacle and a local remote toggle Switch that mounts in the case front Required when using a K930 2 Tig Module with an optional Amptrol or when using a Remote Control K857 25 ft 7 5m or K857 1 100 ft 30 4m REMOTE CON TROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K894 1 Spark Arrester Kit Includes a heavy gauge steel approved spark arrester and clamp for easy mounting to muffler exhaust pipe K896 1 GFCI Receptacle Kit Includes two UL approved 115V ground fault circuit interrupter duplex type receptacles with covers and installation instructions Replaces the two factory installed 115V duplex receptacles Each receptacle of each GFCI duplex is rated at 15 amps but the maximum total current from each GFCI duplex is limited to 20 amps K930 2 TIG Modul
37. ble lectrode autour de n importe quelle partie LES MACHINES SOUDER ROBES TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 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 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 zones o l on pique le laitier LINCOLN 8 Mar 93 Relier la terre le chassis du poste conformement 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
38. cesses The TIG Module allows full range output control Afterflow time is adjustable from 0 to 55 seconds When using the Ranger 8 for AC TIG welding of aluminum the following settings and electrodes are recommended SETTINGS FOR PURE TUNGSTEN TUNGSTEN RANGE SWITCH DIAMETER in SETTINGS 1 8 70 90 or 125 80 150 Amps 3 32 50 70 or 90 45 130 Amps 116 50 or 70 40 80 Amps APPROXIMATE CURRENT RANGE SETTINGS FOR 1 THORIATED TUNGSTEN TUNGSTEN RANGE SWITCH DIAMETER SETTINGS 1 8 70 90 125 or 175 3 32 50 70 90 or 125 1 16 50 70 90 The 930 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 APPROXIMATE CURRENT RANGE 80 225 Amps 50 180 Amps 45 120 Amps OPERATION B 4 Wire Feed Welding Processes Constant Voltage The only Innershield electrode recommended for use with the Ranger 8 is NR9 211 MP The electrode sizes and welding ranges that can be used with the Ranger 8 are shown in the following table Diameter Wire Speed in Range In Min Approximate Current Range 75A to 120A 120A to 170A 125A to 210A 80 110 70 130 The Ranger 8 is recommended for limited weld ing GMAW gas metal arc welding The recom mended electrodes are
39. d 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 Electric Wire Feeders A WARNING Shut off welder before making any electrical connections Wire Feed Constant voltage Connection of the LN 25 to the Ranger 8 e 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 e Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carri
40. e Provides high frequency and shield ing gas control for AC and DC GTAW TIG welding applica tions Its compact case is designed for easy carrying com plete with a handle High frequency bypass is built in The K938 1 Contactor Kit must be field installed in the TIG Module when used with a Ranger 8 Additionally the K936 3 control cable is required if remote control is used If remote control is not used the K936 4 control cable is required 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 casefront which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs RANGER 8 LINCOLN 8 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 requires K938 1 Contactor Kit K939 3 Control Cable see Optional Equipment Optional K939 1
41. e Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 115 230V plug is available in the optional plug kit 4 Plug this cable into the 50 amp 115 230V receptacle on the Ranger 8 case front RANGER 8 LINCOLN 10 INSTALLATION A 10 Figure 1 CONNECTION OF RANGER 8 TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR 60 Hz 3 Wire COMPANY METER 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 PROTECTION 50 AMP 115 230 VOLT PLUG NEMA TYPE 14 50 1 E 50 AMP 115 230 VOLT Yg go 2 NOTE No 8 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Connection of Ranger 8 to premises wiring must be done by a licensed electrician and must com ply with the National Electrical Code and all other applicable electrical codes RANGER 8 LINCOLN 1 1 GENERAL DESCRIPTION The 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 All Settings Output Selector with 6 Ranges
42. ed in the ON position this switch energizes the engine ignition circuit When placed in the OFF position the ignition circuit is de energized to shut down the engine ENGINE START Push Button Switch Energizes engine starter motor Polarity Switch A CAUTION Never change the Polarity switch setting while welding This will damage the switch gt Range Switch Process Maximum Current on Each Setting STICK TIG CC 50 70 90 6 Range Settings 125 175 210 DC 225 AC WIRE FEED CV 1 Range Setting 200 A CAUTION Never change the RANGE Switch setting while welding This will damage the switch KOHLER 20 H P COMMAND HONDA 20 H P GX620 1 5 Liters Hour 1 5 Liters Hour 1 3 Liters Hour 9 Gallons Hour 9 Gallons Hour 7 Gallons Hour 3 5 Liters Hour 3 5 Liters Hour 2 7 Liters Hour 3 5 Li AC CC Weld Output 1 5 Gallons Hour 1 3 Gallons Hour 1 6 Gallons Hour DC CC Weld Output 1 7 Gallons Hour 1 4 Gallons Hour 1 7 Gallons Hour 1 4 Gallons Hour 1 2 Gallons Hour 1 2 Gallons Hour 4 6 Liters Hour 1 5 Gallons Hour 5 7 Liters Hour 1 4 Gallons Hour 5 3 Liters Hour u Control Switch Provides a fine welding current adjustment within the Range Switch settings in the STICK TIG mode and welding voltage control with the Range switch set in the wire feed mode IDLER Switch The idler switch has two positions HIGH and AUTO When in HIGH
43. elles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c
44. ersonnel 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 malfunctions 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 symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 8 LINCOLN 2 TROU
45. es no welding current e 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 8 6 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 diagram 517742 can be found in the back of this manual Place the RANGE switch to the WIRE FEED position and the POLARITY switch to the desired polarity e Place the IDLER switch in the HIGH idle position The engine idling device may not function when welding in the WIRE FEED mode Adjust wire feed speed at the LN 7 and adjust the welding voltage with the output CONTROL at the welder NOTE If the output CONTROL is set below 3 the K240 contactor may not pull in Connection of K930 TIG Module to the Ranger 8 The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW TIG welding See 528 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 w
46. g 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 4 Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework Pre Operation Service CAUTION READ the engine operating and maintenance instruc tions supplied with this machine WARNING a GASOLINE fuel can cause fire or fj 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 SAE 10W 30 oil Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Make certain that the oil filler cap is tightened securely Refer to the engine Owner s Manual for specific oil recommenda tions LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Onan P218 1 8 Quarts 1 7 Liters Kohler 205 2 0 Quarts 1 9 Liters Honda GX620 1 9 Quarts 1 6 Liters Fuel E Fi
47. i la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra iAH NTWSHRELTFSU An ecran 2452 84 2x9 HIE Weal Ju Gu gone uil oh puni das AI uae pally Jai DA dua aa e Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e 24 pd LU THEN e i 9 Vi B T IF PF o 12 AS AA uie 082231 351 Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use para a vista ouvido corpo e B HRUBS ISUCRSREUCT ez 119 59
48. ine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety minimize exposure to fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the
49. ith any other high frequency equip ment the bypass capacitor must be installed order kit T12246 INSTRUCTIONS Additional Safety Precautions Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read and understand all Safety Precautions before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manual INSTALLATION Welder Operation Welder Output Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS e Duty Cycle 100 for both welding and auxiliary power Ranger 8 225 Amps 25 Volts 210 Amps DC Q 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 con tinuous 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 The CSA machine has one 50 amp 115 230 volt NEMA 14 50R receptacle and two 15 amp 115 volt NEMA 5 15R receptacles A CAUTION Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the desired operating mode Set the CONTROL to 10 Voltage is now correct at the receptacle
50. ll the fuel tank with clean fresh lead free gasoline Observe fuel gauge while filling to prevent overfilling INSTALLATION A 4 Battery Connections This welder is shipped with the negative battery cable disconnected Make sure that the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine If the battery is discharged and does not have enough power to start the engine see the battery charging instructions in the Battery section Welding Output Cables With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodically and tightened if neces sary Loose connections will result in overheating of the output studs When welding at a considerable distance from the welder be sure you use ample size welding cables Listed below are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 225 Amps 100 Duty Cycle 225 Amps 40 Duty Cycle 0 50 Ft 3 1 AWG 50 100 Ft 3 AWG 1 100 150 Ft 2 AWG 1 AWG 150 200 Ft 1 AWG 1 AWG 200 250 Ft 1 0 AWG 1 0 AWG RANGER 8 LINCOLN
51. lly suitable for the Tape up bolted connection where lead 21 is extended installation and plug rated at 115 volts 15 amperes AC DOLAR 2 N H switch on power source must be in high idle position 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 N J If an optional remote output control is used connect it to this terminal strip or 6 pin Amphenol receptacle NOTE amperes Terminal strip or 6 pin Amphenol receptacle not available N D Leads 21 and GND do not appear on LN 7 s with codes on all power sources below 7026 CAUTION Any speed up of the engine RPM by changing the governor setting or over riding the throttle linkage will cause an increase in the AC auxiliary voltage If this volt age goes above 140 volts the LN 7 control circuit will be damaged The engine governor setting is pre set at the fac tory do not adjust above RPM specifications listed in engine welder operating manual N E Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications If LN 7 is equipped with a meter kit extend lead 21 using 14 or larger insulated wire physically suitable for the RANGER 8 LINCOLN n 386 06 1 Z SLZLLN S310H ONILNNOW 00727 gt 00706 je 08 8
52. n even though they have been cleaned For information purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode or s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright
53. nd 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 filter are not changed according to the manufacturer s recommendation 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 period ically 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 han dle from maximum to minimum setting twice each morning before starting to weld RANGER 8 LINCOLN 2 MAINTENANCE D 2 Engine Adjustments OVERSPEED IS HAZARDOUS WARNING The maximum allowable high idle speed for this machine is 3750 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increa
54. neeling 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 6 c and 8 LINCOLN 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards
55. ngine will not crank or is hard to crank Engine shuts down Engine does not develop full power Engine is hard to start 1 No voltage signal from the current sensor Auxiliary power load less than 100 to 150 watts Faulty P C Board Battery will not hold a charge Faulty Battery If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility No or insufficient charging current Loose battery cable connection s Out of fuel Low oil level Fuel filter clogged Air filter clogged Spark plugs do not have specified gap Spark plugs are fouled A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 8 LINCOLN 8 Jequunu epoo 1u uudinb 3 e 10 225 S eu J sjaued inso 5u y JO euo uo y LL apisul paysed si apod jejnonied e 104 5 siy Aq paaano gt 10 93e1n22e eq 3 A uo 10 S SIUL 310 996 61 1 NOIL23NNO2 i z amp ALIA 32018
56. ntrol as follows Onan Engine If the engine is cold pull the choke control out Do not use the choke if the engine is warm or hot Kohler Engine Always pull the choke control out when starting the engine cold warm or hot Place the Engine switch in the ON position Honda Engine Always pull the choke control out when starting the engine cold Place the Engine switch in the ON position Push the START button and crank the engine until it starts Release the button as soon as the engine starts Do not push the START button while the engine is running because this will cause damage to the ring gear and or starter motor After the engine has started slowly return the choke control to the full in position choke open After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the Ranger 8 because the fuel tank is mounted below the engine Break in Period It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in period approxi mately 50 running hours
57. on must be followed to avoid minor personal injury or damage to this equipment TABLE CONTENTS Page CES ELLE Li Ce Le mE Section Technical Specifications sr 1 2 Installation Safety Precautions uuu a eee ug ed oen ac t A 3 Machine Grounding u au 3 Spark Arreste d s 3 Trailers itera ae pie ERG A 3 Pre Operation Engine Service ss A 4 0 n suku AT LAE 4 Fueli doct r 4 Connections ut itque e eei eder ip 4 Welding Cable Connections A 4 Angle of Operation dte BU ua UEM A 5 High Altitude Op ration s oct nu added ceed itr ttes th dt drei desit A 5 Location and Ventilation se A 5 Welding Cable Connections ss A 5 Connection of Wire Feeders sise A 5 Connection of Tig Module 1 u A 6 Additional Safety Precautions A 6 Auxiliary Power Receptacles and PIUQS 2 A 6 A 7 Motor Ste rtm Gis uu u lu unte
58. position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY i PR CAUTIONS DE S RET 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer to
59. r Re nt deter ette ds A 7 Electrical Device Used with the Ranger 8 A 8 Auxiliary Power While A 9 Premises erteilt deve iii deg bead ees Asie A 10 555 end Section General Descriptions x tata e geleitet B 1 Design Features dede e Dic ed uec EUR B 1 Other Features e Eine UU B 1 Engine OptiOns 2 5 ur ee n e h Sasa dr ee en t ptis B 1 Fuel CONSUMPTION eri died OI Ep S IO tte m er p qme B 2 Controls and Settings uyu roc eee eve d eve ERE cz D RE eet B 2 Welder Generator Controls sisi B 2 B 3 Engine Operations hi an edt de ete o ege dudes es ib B 3 Starting the Engine Moe B 3 Safety Precautions uu in e e deer vede te eee Ea B 3 RAI B 3 Break me deed ese ah Tana uya u Lov eae e cuter B 3 Welding Process i ecrit A eee ad hee ie B 4 Stick Constant Current Welding ss B 4 TIG Constant Current Welding ss B 4 DC Wire Feed Welding Processes CV a B 4 Summary of Welding Processes
60. receptacle rating as previously stated is not exceeded This may necessitate 230V opera tion only TABLE I Maximum Current Draw from 115V Duplex Receptacles No Welding K1418 1 and K1419 1 K1418 2 K1419 2 and K2160 1 CSA Machines Each Half of Each 115V Duplex Total From Both 115V Duplexes Each Half of Total From Each 115V Both 115V Duplex Duplexes 20 20 20 20 0 NEMA 5 20P Plug required for 20Amp Draw TABLE Maximum Current Draw from 115V GFCI Duplex Receptacles No Welding Load From K1418 1 and K1419 1 K1418 2 K1419 2 and K2160 1 115V 230V CSA Machines Dual Voltage Each Half of Total From Each Half of Total From Receptacle Each 115V Both 115V Each 115V Both 115V Duplex Duplexes Duplex Duplexes 0 15 40 15 30 1 1 KW 15 40 15 30 3 4 KW 15 40 15 30 5 7 KW 15 20 15 20 8 0 KW 0 0 0 0 Maximum current draw from each 115V GFCI Duplex is 20 amps Maximum current draw from each 115V GFCI Duplex is 15 amps RANGER 8 LINCOLN 8 INSTALLATION TABLE Ill ELECTRICAL DEVICE USE WITH THE RANGER 8 Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE Capacitive TV sets radios microwaves appliances with electrical control Voltage spikes or high voltage regulation can cause the capac
61. s for auxil iary power 115 230 Volt Dual Voltage Receptacle The 115 230 volt receptacle can supply up to 35 amps of 230 volt power to a two wire circuit up to 35 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 colunm RANGER 8 LINCOLN 7 GND 527 1 i 115 V A 230 V Y 115 V Y 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 INSTALLATION A 7 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
62. se 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 A CAUTION Do not attempt to polish slip rings while engine is running A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove bat A VAN from welder 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 Battery When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity
63. ted Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders Please Invoice only if order is over 50 00 I Check or Money Order Enclosed U S Funds only Credit Card p s 1111 414444111 1 E LI lise THIS FORM TO ORDER sooks OR FREE IN
64. utes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales 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 metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie aux tinc
65. vent exhaust outside MOVING PARTS injure Do not operate with doors open guards off amp 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 moving parts when starting operating or repairing the equipment Routine Maintenance Atthe 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 A 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 P216 GX620 6 Months or 100 HRS 50 HRS 100 HRS 1 Year or 200 HRS m 200 HRS 100 HRS The above schedule is for normal operating condi tions More frequent oil changes are required with dusty high temperature a
66. ways 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 5 e Also see item 1 b Mar 95 SAFETY WELDING SPARKS can gt cause fire or explosion 6 Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosio
67. y discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have gradua

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