Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ________________________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter l...
Page 4 - iii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv 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 s...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; RANGER 8; Page; RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v RANGER 8 Page Safety .................................................................................................................................................i-iv Installation .........................................................................
Page 7 - TABLE OF CONTENTS; Trailer
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 RANGER 8 Installation Technical Specifications .....................................................................................................
Page 8 - INSTALLATION; INPUT - GASOLINE ENGINE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 RANGER 8 * Based on a 10 min. period. TECHNICAL SPECIFICATIONS - Ranger 8 (K1418-3 CSA MEETS CANADI...
Page 9 - SPECIFICATIONS
INSTALLATION A-3 A-3 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE A B OUTPUT AMPS OUTPUT VOL...
Page 10 - INSTALLATION INSTRUCTIONS; • be grounded to the frame of the welder using a
INSTALLATION A-4 A-4 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION INSTRUCTIONS Safety Precautions Machine Grounding Because this portable engin...
Page 11 - Some of the factors to be considered are as follows:; Pre-Operation Service; Oil; Welding Output Cables; CAUTION; GASOLINE; fuel can cause fire or; TOTAL COMBINED LENGTH OF; LUBRICATION SYSTEM CAPACITY
INSTALLATION A-5 A-5 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Some of the factors to be considered are as follows: 1. Design capacity of trailer vs. wei...
Page 12 - Angle of Operation; Shut off welder and allow; Location / Ventilation; Place the idler switch in the “AUTO” position.; • Damage to the fuel tank may cause
INSTALLATION A-6 A-6 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Angle of Operation Internal combustion engines are designed to run in alevel condition whi...
Page 13 - INSTRUCTIONS; Additional Safety Precautions; • Maximum Open Circuit Voltage at 3700 RPM is; Auxiliary Power
INSTALLATION A-7 A-7 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Connection of the LN-7 to the Ranger 8 • Shut the welder off. • Connect the LN-7 and the K...
Page 16 - Auxiliary Power While Welding
INSTALLATION A-10 A-10 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Standby Power Connections The Ranger 8 is suitable for temporary, standby, oremergency p...
Page 17 - CONNECTION OF RANGER 8 TO PREMISES WIRING
INSTALLATION A-11 A-11 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Connection of Ranger 8 to premises wiring mustbe done by a licensed electrician and must...
Page 18 - NOTES
NOTES A-12 A-12 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 19 - Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section B-1 Section B-1 RANGER 8 TABLE OF CONTENTS - OPERATION SECTION - Operation ............................................................................................................................... S...
Page 20 - OPERATION; GENERAL DESCRIPTION; AUXILIARY POWER; OTHER FEATURES; • Bottom Mounted 9 Gallon Fuel Tank with a; ENGINE OPTIONS
OPERATION B-2 B-2 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC GENERAL DESCRIPTION The Ranger ™ 8 is a twin-cylinder, gasoline driven, mul- tiprocess arc we...
Page 21 - Welder Controls - Function and Operation; Energizes engine starter motor.; Ranger 8 Approximate Fuel Consumption
OPERATION B-3 B-3 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HONDA 20 H.P. GX620KI .3 Gallons/Hour (1.3 Liters/Hour) .7 Gallons/Hour (2.7 Liters/Hour) 1.6...
Page 22 - Starting/Shutdown Instructions; Use the choke control as follows:; Honda
OPERATION B-4 B-4 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Starting/Shutdown Instructions Starting the Engine Be sure all Pre-Operation Maintenance has ...
Page 23 - Welding Process; For best arc stability, use settings 5; The only Innershield
OPERATION B-5 B-5 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Welding Process Stick (Constant Current) Welding Connect welding cables to the "TO WORK” ...
Page 25 - Accessories
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS -ACCESSORIES- Accessories Optional Equipment ....................................................................................................................C-2 Recommended Equipment ..........
Page 26 - ACCESSORIES; OPTIONAL EQUIPMENT; Includes one UL
ACCESSORIES C-2 C-2 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS ...
Page 27 - RECOMMENDED EQUIPMENT; STICK; K704 Accessory Kit which includes:; TIG
ACCESSORIES C-3 C-3 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cab...
Page 29 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 RANGER 8 TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Rou...
Page 30 - MAINTENANCE; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n; ENGINE OIL CHANGE
MAINTENANCE D-2 D-2 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Have qualified personnel do the maintenancework. Turn the engine off before working insidet...
Page 31 - OIL FILTER CHANGE
MAINTENANCE D-3 D-3 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Use 4-stroke motor oil that meets or exceeds therequirements for API service classification...
Page 32 - NKG BPR6ES; FRAM G1
MAINTENANCE D-4 D-4 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HONDA GX620KI HONDA 15400-PR3-004 (HONDA CODE 3179553) FRAM PH6811 HONDA 17211-ZJ1-000 (HON...
Page 35 - FIGURE E.1 – RANGER 8 BLOCK LOGIC DIAGRAM
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 RANGER 8 Theory of Operation ............................................................................................................. Section E Battery, Starter, Engine, Excitation, R...
Page 36 - THEORY OF OPERATION
BATTERY, STARTER, ENGINE,ROTOR, STATOR, AND IDLERSOLENOID The 12VDC battery powers the starter motor. Whenthe engine is started and running, the battery circuitvoltage is fed, through the printed circuit board, to therotating field coil in the rotor via a brush and slip ringconfiguration. This excit...
Page 41 - Test Procedures
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section F-1 Section F-1 RANGER 8 Troubleshooting & Repair Section ................................................................................. Section F How to Use Troubleshooting Guide ....................
Page 42 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The; Step 3. PERFORM COMPONENT TESTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...
Page 43 - PC BOARD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING & REPAIR F-3 F-3 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Sometimes machine failures appear to be due to PCboard failures. These pro...
Page 44 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Contact The Lincoln Electric
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning ...
Page 45 - Check the open circuit voltage
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-5 F-5 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning ...
Page 46 - Make sure the Output Control
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning ...
Page 47 - If the engine HIGH IDLE RPM is
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-7 F-7 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning ...
Page 49 - Make sure the Range Switch
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-9 F-9 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning ...
Page 50 - ENGINE PROBLEMS; is in the “Auto” position.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...
Page 53 - WELDING PROBLEMS; The welding cable may be too
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-13 F-13 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginnin...
Page 55 - ROTOR VOLTAGE TEST; TEST DESCRIPTION; This procedure takes approximately 30 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-15 F-15 RANGER 8 ROTOR VOLTAGE TEST Service and repair should be performed by only Lincol...
Page 56 - FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST; Slip Rings; TEST PROCEDURE; then reinstall the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-16 F-16 RANGER 8 ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Slip...
Page 57 - ROTOR RESISTANCE TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ROTOR RESISTANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthor...
Page 58 - FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS; then replace the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-18 F-18 RANGER 8 ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RI...
Page 59 - A. Set the ohmmeter on the high scale
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 RANGER 8 13. Measure the resistance to ground. A. Set the ohmmeter on the high sc...
Page 62 - AUXILIARY AND FIELD WINDING TEST; To test the 115 VAC winding:
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-22 F-22 RANGER 8 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LE...
Page 63 - AC; To test the field winding:
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-23 F-23 RANGER 8 AUXILIARY AND FIELD WINDING TEST (continued) Retaining Tab Field Bridge ...
Page 65 - This procedure takes approximately 60 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-25 F-25 RANGER 8 WARNING OUTPUT RECTIFIER BRIDGE TEST Service and repair should be perfor...
Page 66 - OUTPUT RECTIFIER BRIDGE TEST; FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER LEADS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-26 F-26 RANGER 8 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.5 – LOCATION OF OUTPUT...
Page 67 - This procedure takes approximately 20 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-27 F-27 RANGER 8 WARNING CHARGING CIRCUIT TEST Service and repair should be performed by ...
Page 68 - CHARGING CIRCUIT TEST; FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR; Engine
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 RANGER 8 CHARGING CIRCUIT TEST (continued) FIGURE F.6 – LOCATION OF VOLTAGE REGUL...
Page 69 - This procedure takes approximately 35 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-29 F-29 RANGER 8 WARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be per...
Page 70 - ENGINE THROTTLE ADJUSTMENT TEST; FIGURE F.7 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD; Blower Paddle
TROUBLESHOOTING & REPAIR F-30 F-30 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – BLOWER PADDLE M...
Page 71 - Frequency Counter Method
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-31 F-31 RANGER 8 ENGINE THROTTLE ADJUSTMENT TEST (continued) Throttle linkage Choke Cable...
Page 73 - volts; SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY); HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-33 F-33 RANGER 8 CH1 16.2 ms 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div ................
Page 74 - TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE); MACHINE LOADED; MACHINE LOADED TO 200 AMPS AT 20 VDC
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-34 F-34 RANGER 8 SCOPE SETTINGS Volts/Div .....................20V/Div.Horizontal Sweep.....
Page 75 - TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-35 F-35 RANGER 8 This is the typical DC output voltagegenerated from a properly operating...
Page 76 - TYPICAL AC WELD OUTPUT WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-36 F-36 RANGER 8 This is the typical AC output voltagegenerated from a properly operating...
Page 77 - ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE); HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-37 F-37 RANGER 8 This is NOT the typical CV outputvoltage waveform. One output diodeis no...
Page 78 - ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-38 F-38 RANGER 8 This is NOT the typical DC (+) outputvoltage waveform. One output diodei...
Page 79 - NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 RANGER 8 This is the typical CV output voltagegenerated from a properly operating...
Page 80 - NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-40 F-40 RANGER 8 This is the typical DC output voltagegenerated from a properly operating...
Page 81 - NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-41 F-41 RANGER 8 This is the typical AC output voltagegenerated from a properly operating...
Page 83 - BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-43 F-43 RANGER 8 BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be perfo...
Page 84 - PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-44 F-44 RANGER 8 BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark ...
Page 85 - SLIP RINGS; Cable
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-45 F-45 RANGER 8 SLIP RINGS A slight amount of darkening and wear of theslip rings and br...
Page 88 - FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL; RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-48 F-48 RANGER 8 FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continu...
Page 92 - PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT; FIGURE F.12 - PRINTED CIRCUIT BOARD LOCATION; In Line
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-52 F-52 RANGER 8 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.12 - ...
Page 93 - PRINTED CIRCUIT BOARD REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-53 F-53 RANGER 8 Be sure to follow the recommended static-free methods for handling print...
Page 96 - OUTPUT RECTIFIER BRIDGE REMOVAL; FIGURE F.13 - OUTPUT RECTIFIER CONNECTIONS; Machine Front; metal screws from the case top.; then reinstall the fuel; screws holding the right case side.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-56 F-56 RANGER 8 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.13 ...
Page 97 - These must be in
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-57 F-57 RANGER 8 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 12. With the...
Page 99 - Lincoln Electric Rotor Removal Kit (S20788); This procedure takes approximately 3 hours to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-59 F-59 RANGER 8 WARNING ENGINE/ROTOR REMOVAL AND REPLACEMENT Service and repair should b...
Page 100 - ENGINE/ROTOR REMOVAL AND
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-60 F-60 RANGER 8 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – COMPONENT...
Page 101 - ENGINE/ROTOR REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-61 F-61 RANGER 8 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) ENGINE AND ROTORREMOVAL...
Page 102 - ROTOR REMOVAL PROCEDURE; double check that the; FIGURE F.15 - ENGINE AND ROTOR REMOVED FROM STATOR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-62 F-62 RANGER 8 ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the en...
Page 103 - REASSEMBLY PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-63 F-63 RANGER 8 REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bearin...
Page 104 - RETEST AFTER REPAIR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-64 F-64 RANGER 8 RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for...
Page 106 - DIAGRAMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC DIAGRAMS G-2 G-2 RANGER 8 8.80 42.25 10.33 9.09 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 21.21 30.28 9.2...
Page 108 - CONNECTION OF RANGER 8 TO LN-7 & K240 CONTACTOR KIT
DIAGRAMS G-4 G-4 RANGER 8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONNECTION OF RANGER 8 TO LN-7 & K240 CONTACTOR KIT WARNING: Turn the power off when makin...
Page 109 - ELECTRICAL DIAGRAMS; WIRING DIAGRAM - ONAN NON CSA MODEL
ELECTRICAL DIAGRAMS G-5 WIRING DIAGRAM - ONAN NON CSA MODEL 1 2 V O L T S T A R T E R A M 1 + - I D L E R S O L E N O I D C R 1 2 0 9 2 1 3 2 1 5 B A T T E R Y S 3 T O S P A R K P L U G S I G N I T I O N C O N T R O L 2 1 6 A 2 1 2 2 1 2 ( C A V I T Y # 1 ) ( N O T E C A V I T Y N U M B E R S ) L O ...
Page 110 - WIRING DIAGRAM - ONAN CSA MODEL
ELECTRICAL DIAGRAMS G-6 WIRING DIAGRAM - ONAN CSA MODEL 1 2 V O L T S T A R T E R I D L E R S O L E N O I D C R 1 2 0 9 2 1 3 2 1 5 B A T T E R Y T O S P A R K P L U G S I G N I T I O N C O N T R O L 2 1 6 A 2 1 2 ( C A V I T Y # 1 ) ( N O T E C A V I T Y N U M B E R S ) L O C A T I N G T A B T E R ...
Page 111 - WIRING DIAGRAM - KOHLER NON CSA MODEL
ELECTRICAL DIAGRAMS G-7 WIRING DIAGRAM - KOHLER NON CSA MODEL S T A R T E R C R 1 S T A R T E R S O L E N O I D 1 2 V O L T I D L E R S O L E N O I D 2 1 3 B A T T E R Y A C A C B + S W I T C H R E G U L A T O R F L Y W H E E L A L T E R N A T O R B - H O U R M E T E R 5 E 5 D S 4 2 2 4 B 2 2 4 2 1 ...
Page 112 - WIRING DIAGRAM - KOHLER CSA MODEL
ELECTRICAL DIAGRAMS G-8 WIRING DIAGRAM - KOHLER CSA MODEL S T A R T E R C R 1 S T A R T E R S O L E N O I D 1 2 V O L T I D L E R S O L E N O I D 2 1 3 B A T T E R Y A C A C B + S W I T C H R E G U L A T O R F L Y W H E E L A L T E R N A T O R B - H O U R M E T E R 5 E 5 D S 4 2 2 4 B 2 2 4 2 1 3 &#...
Page 113 - WIRING DIAGRAM - HONDA CSA MODEL; RA
ELECTRICAL DIAGRAMS G-9 WIRING DIAGRAM - HONDA CSA MODEL RA (CSA) - WIRING DIAGRAM K2160-1 NGER 8 HONDA M19988 A 25A CB7 208C R = RED OR PINK B = BLACK OR GRAY 208B 210 221 5H BUTTON START S5 208A - + AM1 IN "RUN" "S3" SHOWN POSITION S3 N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE. ...
Page 115 - X X X
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-vided for reference only....
Page 116 - SVM ERROR REPORTING FORM; Please give detailed description below:
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col-umn troubleshoo...
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