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Lincoln Electric RANGER 8 SVM107-B Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN INDEX
SVM107-B
July, 2002
TM
RANGER 8
9972 thru 10886
For use with machine code numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

SERVICE MANUAL

Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric RANGER 8 SVM107-B

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM107-B July, 2002 RANGER 8 9972 thru 10886 For use with machine code numbers: 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 .

  • Page 2: Safety

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety...i-iv Installation ...Section A Operation...Section B Accessories...Section C Maintenance ...Section D Theory of Operation ...Section E Troubleshooting and Repair...Section F Electrical Diagrams ...Section G Parts Manual...P-229 RANGER 8...
  • Page 7 Angle of Operation...A-6 High Altitude Operation ...A-6 Location/Ventilation ...A-6 Connection of Wire Feeders ...A-6/A-7 Additional Safety Precautions...A-7 Welder Operation ...A-7 Auxiliary Power ...A-7 115V Duplex Receptacles...A-8 Motor Starting ...A-8 Electrical Devices used w/Ranger 8 ...A-9 Auxiliary Power While Welding ...A-10 Stand-by Power Connections...A-10...

  • Page 8: Installation

    3600 RPM (Kohler) Low Idle 2200 20 HP @ 3600 RPM (Honda) RATED OUTPUT - WELDER Welding Output * AC Constant Current 225A / 25V / 100% OUTPUT - GENERATOR Auxiliary Power 8,000 Watts, 60 Hz AC 35 Amps @ 230V...

  • Page 9: Ac Stick/Tig (Cc) Output

    SPECIFICATIONS INSTALLATION AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC STICK / TIG (CC) OUTPUT A 210 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC WIRE FEED (CV) OUTPUT CV OUTPUT RANGE OUTPUT AMPS RANGER 8...

  • Page 10: Installation Instructions

    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. INSTALLATION When this welder is mounted on a truck or trailer, it’s frame must be securely connected to the metal frame of the vehicle.

  • Page 11: Pre-Operation Service

    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. greater lengths primarily for the purpose of minimizing cable voltage drop.

  • Page 12: Angle Of Operation

    Also, locate the welder so that engine exhaust fumes are properly vented to an outside area.

  • Page 13: Additional Safety Precautions

    - 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.

  • Page 14: 115 V Duplex Receptacles

    *Current Sensing for Automatic Idle. (Receptacle viewed from front of Machine) 115 V Duplex Receptacles The 115V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle (Refer to Tables I and II).
  • Page 15 Capacitive/Inductive Computers, high resolution TV sets, The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the RANGER 8. INSTALLATION TABLE lll complicated electrical equipment.

  • Page 16: Auxiliary Power While Welding

    A-10 Auxiliary Power While Welding Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown assume that current is being drawn from either the 115V or 230V supply (not both at the same time). Also, the “Output Control”...

  • Page 17: Connection Of Ranger 8 To Premises Wiring

    A-11 CONNECTION OF RANGER 8 TO PREMISES WIRING 230 VOLT POWER 230 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 115/230 VOLT PLUG NEMA TYPE 14-50 50 AMP, 115/230 VOLT...
  • Page 18 A-12 A-12 NOTES RANGER 8...
  • Page 19 Section B-1 - OPERATION SECTION - Operation...Section B General Description ...B-2 Other Features ...B-2 Engine Options ...B-2 Approximate Fuel Consumption...B-3 Controls and Settings ...B-3 Engine Operation ...B-4 Before Starting the Engine ...B-4 Starting the Engine ...B-4 Stopping the Engine ...B-4 Break-in Period ...B-4 Welding Process ...B-5 Summary of Welding Processes...B-6...

  • Page 20: 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) •...

  • Page 21: Approximate Fuel Consumption

    (4.5Liters/Hour) Auxiliary Power 1.6Gallons/Hour 8000 Watts (6.1Liters/Hour) Welder Controls - Function and Operation Explanation of Symbols that Appear on this Equipment Low Idle ENGINE “ON-OFF” Switch When placed in the “ON” position, this switch energizes the engine ignition circuit. When placed in the “OFF”...

  • Page 22: Starting The Engine

    Starting/Shutdown Instructions Starting the Engine WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. • Keep flammable material away. • Insulate yourself from work and ground. Wear eye, ear, and body protection. • Keep your head out of the fumes. •...

  • Page 23: Welding Process

    Welding Process Stick (Constant Current) Welding Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. "Polarity” switch to the desired polarity. “RANGE” switch to a setting that is equal to or slightly greater than the desired welding current. “RANGE”...

  • Page 24: Summary Of Welding Processes

    CONTROL CABLE PROCESS USED STICK 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 OPERATION Summary of Welding Processes ELECTRODE IDLE WHEN NOT MODE WELDING AUTO HIGH Cold AUTO Cold HIGH Cold RANGER 8...
  • Page 25 Section C-1 Accessories Optional Equipment...C-2 Recommended Equipment...C-3 Stick..C-3 TIG...C-3 Wirefeed ...C-3 TABLE OF CONTENTS -ACCESSORIES- RANGER 8 Section C-1...
  • Page 26 K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CON- TROL - Portable control provides same dial range as the out- put control on the welder. Has a convenient 6 pin plug for easy connection to the welder. K894-1 Spark Arrester Kit - Includes a heavy gauge steel, approved spark arrester and clamp for easy mounting to muf- fler exhaust pipe.

  • Page 27: Recommended Equipment

    RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K892-1 Remote Control Receptacle Kit and K857 Remote Control Kit are optional for remote current control. 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:...
  • Page 28 NOTES RANGER 8...
  • Page 29 Section D-1 Maintenance ...Section D Routine Maintenance...D-2 Engine Maintenance...D-2 Change the Oil ...D-2 Engine Oil Refill Capacities ...D-2 Change the Oil Filter ...D-3 Engine Adjustments ...D-4 Slip Rings ...D-4 Engine Maintenance Parts ...D-4 Major Component Locations ...D-5 TABLE OF CONTENTS -MAINTENANCE- RANGER 8 Section D-1...

  • Page 30: Maintenance

    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.

  • Page 31: 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).

  • Page 32: Engine Adjustments

    • 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.

  • Page 33: Major Component Locations

    FIGURE D.1 - MAJOR COMPONENT LOCATIONS MAINTENANCE RANGER 8 1. OUTPUT TERMINALS (LOCATION) 2. ENGINE CONTROLS 3. AUXILIARY POWER RECEPTACLES 4. OUTPUT CONTROL PANEL 5. OUTPUT BRIDGE/CHOKE/REACTOR 6. FUEL TANK FILL 7. GASOLINE ENGINE 8. ROTOR/STATOR ASSEMBLY 9. BATTERY 10. MACHINE BASE 11.
  • Page 34 NOTES RANGER 8...
  • Page 35 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E Battery, Starter, Engine, Excitation, Rotor, Stator, and Idler Solenoid...E-2 Rotor Field Feedback and Auxiliary Power ...E-3 Weld Winding, Reactor, and Range Switch...E-4 Output Bridge, Choke, Polarity Switch, and Output Terminals...E-5 MECHANICAL ROTATION STARTER...

  • Page 36: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID MECHANICAL ROTATION STARTER ENGINE FLYWHEEL ALTERNATOR IDLER SOLENOID BATTERY OUTPUT CONTROL 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...
  • Page 37 THEORY OF OPERATION FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER MECHANICAL ROTATION STARTER ENGINE FLYWHEEL ALTERNATOR IDLER SOLENOID BATTERY OUTPUT CONTROL ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the full wave field bridge.

  • Page 38: Theory Of Operation

    THEORY OF OPERATION FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH MECHANICAL ROTATION STARTER ENGINE FLYWHEEL ALTERNATOR IDLER SOLENOID BATTERY OUTPUT CONTROL 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.
  • Page 39 THEORY OF OPERATION FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS MECHANICAL ROTATION STARTER ENGINE FLYWHEEL ALTERNATOR IDLER SOLENOID BATTERY OUTPUT CONTROL OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding is delivered, through the reactor and range switch, to the output bridge and polarity switch.
  • Page 40 NOTES RANGER 8...
  • Page 41 Section F-1 TROUBLE SHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F4 - F-13 Test Procedures Rotor Voltage Test ...F-15 Rotor Resistance Test ...F-17 Auxiliary and Field Winding Test ...F-21 Output Rectifier Bridge Test...F-25 Charging Circuit Test ...F-27 Engine Throttle Adjustment Test ...F-29...

  • Page 42: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 43: Pc Board Troubleshooting Procedures

    - 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.

  • Page 44: Troubleshooting Guide

    Engine runs normally. 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).
  • Page 45 Engine runs normally. 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).
  • Page 46 Engine runs normally. 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).
  • Page 47 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).
  • Page 48 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). POSSIBLE AREAS OF...
  • Page 49 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). detailed in the beginning of this manual.
  • Page 50 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).
  • Page 51 “HIGH” position. 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). detailed in the beginning of this manual.
  • Page 52 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). POSSIBLE AREAS OF...
  • Page 53 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). detailed in the beginning of this manual.
  • Page 54 F-14 F-14 NOTES RANGER 8...

  • Page 55: Rotor Voltage Test

    F-15 TROUBLESHOOTING & REPAIR 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.
  • Page 56 F-16 TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Brushes TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2.

  • Page 57: Rotor Resistance Test

    TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST 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-...
  • Page 58 F-18 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS TEST PROCEDURE 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.
  • Page 59 F-19 TROUBLESHOOTING & REPAIR 13. Measure the resistance to ground. A. Set the ohmmeter on the high scale (X100,000). B. Place one probe on either of the slip rings. Place the other probe on any good, unpainted machine ground stud works well. C.
  • Page 60 F-20 F-20 NOTES RANGER 8...

  • Page 61: Auxiliary And Field Winding Test

    TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST 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.
  • Page 62 F-22 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 Receptacle Lead #3 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;...
  • Page 63 F-23 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4 - LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER 201A To test the field winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver, remove the case top and left side;...
  • Page 64 F-24 F-24 NOTES RANGER 8...

  • Page 65: Output Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST 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.
  • Page 66 F-26 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER LEADS Pigtail Diode Output rectifier Bridge Assembly Machine Front TEST PROCEDURE 1. Remove the spark plug wires to prevent accidental engine kickback or starting. 2.

  • Page 67: Charging Circuit Test

    F-27 TROUBLESHOOTING & REPAIR 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.

  • Page 68: Location Of Voltage Regulator

    F-28 TROUBLESHOOTING & REPAIR CHARGING CIRCUIT TEST (continued) FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. Set the voltmeter for AC volts and place one meter probe on each of the two out- side leads that attach to the engine voltage regulator.

  • Page 69: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST 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.
  • Page 70 F-30 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Blower Paddle TEST PROCEDURE This test can be conducted by any one of four methods. Strobe-tach Method: 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top.
  • Page 71 F-31 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 HIGH IDLE ADJUSTMENT NUT Throttle linkage Choke Cable 11. 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.
  • Page 72 F-32 TROUBLESHOOTING & 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.

  • Page 73: Normal Open Circuit Voltage Waveform (115 Vac Supply

    F-33 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 16.2 ms 50 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 74 F-34 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE) MACHINE LOADED TO 200 AMPS AT 20 VDC MACHINE LOADED 20 volts This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 75 F-35 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE) MACHINE LOADED TO 200 AMPS AT 26 VDC MACHINE LOADED 5 ms 20 volts 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.

  • Page 76: Typical Ac Weld Output Waveform - Machine Loaded

    F-36 TROUBLESHOOTING & REPAIR TYPICAL AC WELD OUTPUT WAVEFORM MACHINE LOADED TO 225 AMPS AT 25 VDC MACHINE LOADED 5 ms 20 volts 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.

  • Page 77: Abnormal Open Circuit Weld Voltage Waveform (Cv Mode, One Diode Open

    F-37 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 5 ms 20 volts This is NOT the typical CV output voltage waveform. One output diode is not functioning.

  • Page 78: Abnormal Open Circuit Dc Weld Voltage Waveform

    F-38 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 5 ms 50 volts This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning.

  • Page 79: Normal Open Circuit Weld Voltage Waveform (Cv Mode

    F-39 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 5 ms 20 volts This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 80: Normal Open Circuit Dc Weld Voltage Waveform

    F-40 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 5 ms 50 volts This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 81: Normal Open Circuit Ac Weld Voltage Waveform

    F-41 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 82 F-42 F-42 NOTES RANGER 8...

  • Page 83: Brush Removal And Replacement

    TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT 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.
  • Page 84 F-44 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wires. 2. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 3. Remove the rubber gasket (cover seal) from the lift bail. 4.
  • Page 85 F-45 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. should be inspected when a general overhaul is necessary. If brushes are to be replaced, clean slip rings with a fine emery paper.
  • Page 86 F-46 F-46 NOTES RANGER 8...

  • Page 87: Field Capacitor And Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL 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-...
  • Page 88 F-48 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR 201A PROCEDURE 1. Remove the engine spark plug wires. 2. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 3.
  • Page 89 F-49 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE - RECTIFIER BRIDGE REMOVAL AND REPLACEMENT 1. To remove the rectifier bridge, first you will have to remove the field capacitor. Follow Steps 1 - 10 above. 2.
  • Page 90 F-50 F-50 NOTES RANGER 8...

  • Page 91: Printed Circuit Board Removal And Replacement

    TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this man- ual.
  • Page 92 F-52 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT FIGURE F.12 - PRINTED CIRCUIT BOARD LOCATION In Line Connectors 5/16" Screw (4) PROCEDURE Before starting the following procedure, refer to topic “PC Board Procedures” at the beginning of this section. 1.
  • Page 93 F-53 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) CAUTION Be sure to follow the recommended static- free methods for handling printed circuit boards. Failure to do so can result in perma- nent damage to the equipment. 12. With the 1/4” nut driver, remove four screws holding the printed circuit board.
  • Page 94 F-54 F-54 NOTES RANGER 8...

  • Page 95: Output Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL 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-...
  • Page 96 F-56 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.13 - OUTPUT RECTIFIER CONNECTIONS To S1 Range Sw. Choke To Polarity Switch Machine Front PROCEDURE 1. Remove the engine spark plug wires. 2. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top.
  • Page 97 F-57 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 12. With the 3/8” wrench and slot head screw 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-...
  • Page 98 F-58 F-58 NOTES RANGER 8...
  • Page 99 TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT 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-...
  • Page 100 F-60 F-60 TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL 1. STATOR COWLING COVER 2. BLOWER FAN 3. IDLE LINKAGE 4. BRUSH HOLDER BRACKET 5. ENGINE LIFT BAILS 6. STATOR/ENGINE MOUNTING BOLTS 7. ROTOR 8.
  • Page 101 F-61 TROUBLESHOOTING & REPAIR 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. 3. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 4.
  • Page 102 Pull out the thru-bolt. 3. Install the appropriate long thru-bolt (two are provided) supplied with Lincoln Electric Rotor Removal Kit S20788. The slot head must face out. Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft, about 3/4”.

  • Page 103: Engine Rotor Removal And Replacement (Kit S20788

    TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT (KIT S20788) (continued) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace the rotor and blower assem- bly. 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft.

  • Page 104: Retest After Repair

    Output values of each receptacle can vary within the range shown but must be within 2 volts of each other. RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 2150-2250 3700-3750 WELDER DC OUTPUT Open Circuit Load Volts Volts 67 - 72 21 - 26.5...
  • Page 105 Section G-1 Section G-1 TABLE OF CONTENTS DIAGRAMS SECTION Diagrams Section...Section G Dimension Print Ranger 8 (Onan) ...G-2 Dimension Print Ranger 8 (Honda & Kohler) ...G-3 Connection Diagrams ...G-4 Wiring Diagram Ranger 8 Onan Non CSA Model...G-5 Wiring Diagram Ranger 8 Onan CSA Model...G-6 Wiring Diagram Ranger 8 Kohler Non CSA Model ...G-7 Wiring Diagram Ranger 8 Kohler CSA Model...G-8 Wiring Diagram Ranger 8 Honda CSA Model ...G-9...
  • Page 106 DIAGRAMS DIMENSION PRINT – RANGER 8 (ONAN) RANGER 8...
  • Page 107 DIAGRAMS DIMENSION PRINT – RANGER 8 (HONDA & KOHLER) RANGER 8...
  • Page 108 N.B. 3 conductor #16 power cord physically suitable for the installation and plug rated at 115 volts 15 amperes AC. N.C. Plug into 115 volt AC receptacle on welder control panel or other 115 volt AC supply rated at a minimum of 500 volt- amperes.

  • Page 109: Electrical Diagrams

    (SEE CONN.) SPARK PLUGS REGULATOR IGNITION CONTROL CAPACITOR FLYWHEEL ALTERNATOR ENGINE COMPONENTS WELDER LEAD END (NOTE CAVITY NUMBERS) 208 (CAVITY #3) 224A&C (CAVITY #4) LOCATING TAB 212 (CAVITY #1) TERMINAL BLOCK 224C (CAVITY #2) CONNECTION 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.
  • Page 110 ONLY) SPARK PLUGS REGULATOR IGNITION CONTROL CAPACITOR FLYWHEEL ALTERNATOR ENGINE COMPONENTS WELDER LEAD END (NOTE CAVITY NUMBERS) 208 (CAVITY #3) 224A&C (CAVITY #4) LOCATING TAB 212 (CAVITY #1) TERMINAL BLOCK 224C (CAVITY #2) CONNECTION 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.
  • Page 111 WIRING DIAGRAM - KOHLER NON CSA MODEL "S3" SHOWN IN "RUN" POSITION 208A START BUTTON 208B "S4" SHOWN IN "AUTO" 224B POSITION 224A 224A 224C TERMINAL BLOCK (SEE CONN.) N.A. PRESSURE SWITCH IGNITION REGULATOR MODULE FLYWHEEL ALTERNATOR ENGINE COMPONENTS N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE. LEAD COLOR CODE: B = BLACK R = RED...
  • Page 112 WIRING DIAGRAM - KOHLER CSA MODEL K1419-2 RANGER 8 KOHLER (CSA) - Wiring Diagram "S3" SHOWN IN "RUN" POSITION 208A START BUTTON 208B "S4" SHOWN IN "AUTO" 224B POSITION 224A 224A 224C TERMINAL BLOCK (SEE CONN.) N.A. PRESSURE SWITCH IGNITION REGULATOR MODULE FLYWHEEL ALTERNATOR...
  • Page 113 WIRING DIAGRAM - HONDA CSA MODEL "S3" SHOWN IN "RUN" POSITION 208A START BUTTON 208B "S4" SHOWN IN "AUTO" 224B POSITION 224A 211B 224C 4 AMP SEE DETAIL IN LINE DIODE CONNECTION 224E 225A 208D 210A N.A. PRESSURE SWITCH IGNITION MODULE 20 AMP CHARGE COIL...

  • Page 114: Electrical Diagrams

    1A, 400V (UNLESS OTHERWISE SPECIFIED) SUPPLY POWER SUPPLY SOURCE POINT COMMON CONNECTION FILENAME: M16482_3G FRAME CONNECTION EARTH GROUND CONNECTION EQUIP. G8000/RANGER 8 IDLER/FIELD CONTROL THE LINCOLN ELECTRIC CO. TYPE SCHEMATIC CLEVELAND, OHIO U.S.A. SUBJECT NONE SCALE I.E.B. 10/13/92 CHK. SUP’S’D’G.
  • Page 115 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.
  • Page 116 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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