Lincoln Electric SVM107-B service manual AC/DC Stick Welding Constant Current

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B-2

B-2

OPERATION

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GENERAL DESCRIPTION

The Ranger8 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

Output Control for Fine Current Adjustment

Use with a broad range of AC & 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) NR®-211-MP Innershield® Electrode.

Limited MIG Welding with L-50 & 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 & DC TIG Welding Can be Done at All Constant Current Output Range Settings.

AUXILIARY POWER

8000 Watt AC 115/230 Volt 60 Hz. Generator.

Operates AC Power Tools.

Powers Battery Chargers.

Powers a 1.5 HP Motor (If Started Under No Load).

Lights Eighty 100 Watt Incandescent Bulbs.

Can be Used for Standby Power.

OTHER FEATURES

Bottom Mounted 9 Gallon Fuel Tank with a Convenient Top Fill and Fuel Gauge.

Polarity Switch for Selecting DC+, DC-, or AC Welding Output.

K930-1 TIG Module Available.

Remote Control Receptacle Kit Available.

Electronic Engine Idler. Engine Automatically Goes to Low Idle in 10 to 14 Seconds after Welding or Use of Auxiliary Power. Includes High Idle Switch.

Electric Starting.

Battery Charging Ammeter.

Full 8 KVA Auxiliary Output Receptacle.

Factory Installed Engine Hour Meter.

Engine Protection Shuts Engine Down in the Event of Low Oil Pressure.

Built-in Feet for Easy Mounting to Truck Bed or Trailer.

All Copper Alternator Windings and High Quality Insulation for Long-Life and Dependability.

Powder Painted Case and Base for Outstanding Corrosion Protection.

Quiet muffler with reversible exhaust feature; either right or left side of machine.

ENGINE OPTIONS

Three Engines are available for the Ranger 8 Welders; the Onan P220, the Kohler 20 HP Command®* and the Honda GX620KI. All three engines have the following features:

Air Cooled, 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.

Overhead Valves & Hydraulic Valve Lifters.

*These trademarks are the property of their respec- tive manufacturers.

RANGER 8

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Contents Rangertm Safety Electric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Auxiliary Power Welding Output50 100 150 200 250 300 350 Output Amps 20 B50 100 150 200 Installation Instructions Battery Connections OilAWG FuelAngle of Operation Connection of the LN-7 to the Ranger Welder OutputRanger Constant CurrentDuplex Receptacles Motor StartingElectrical Device USE with the Ranger Type Common Electrical Devices Possible ConcernsAuxiliary Power While Welding Standby Power ConnectionsConnection of Ranger 8 to Premises Wiring Figure A.1Ranger Table of Contents Operation Section AC/DC TIG Welding Constant Current DC Semiautomatic Wire Feed Welding Constant VoltageAC/DC Stick Welding Constant Current Control Switch Provides a fine welding current adjustment withinRange Switch settings in the STICK/TIG mode Welding voltage control with the Range switch setStarting/Shutdown Instructions Stopping the EngineTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick Constant Current Welding Summary of Welding Processes Stick AutoSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Routine Maintenance Engine OIL ChangeEngine OIL Refill Capacities Kohler Onan HondaOIL Filter Change Engine Adjustments Engine Maintenance PartsPre-Cleaner Slip RingsFigure D.1 Major Component Locations Ranger Table of Contents Theory of Operation Section Theory of Operation Rotor Field Feedback and Auxiliary Power Weld WINDING, REACTOR, Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger Table of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC board can be damaged by static electricity Static-SensitiveDevices Handle only atTroubleshooting Guide Output ProblemsObserve Safety Guidelines Detailed in the beginning of this manualTroubleshooting & Repair Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Engine Problems Troubleshooting & Repair Troubleshooting & Repair Welding Problems Ranger Materials Needed Rotor Voltage TestTest Description Test Procedure Rotor Resistance Test Rotor Resistance Test Troubleshooting & Repair Ranger Auxiliary and Field Winding Test To test the 115 VAC winding To test the 230 VAC windingTo test the field winding Ranger Output Rectifier Bridge Test Output Rectifier Bridge Test Charging Circuit Test Charging Circuit Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Oscilloscope Method High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply Typical DC Weld Output Waveform CV Mode Machine LoadedTypical DC Weld Output Waveform CC Mode Machine Loaded to 200 Amps AT 26 VDCTypical AC Weld Output Waveform Machine Loaded to 225 Amps AT 25 VDCAbnormal Open Circuit Weld Voltage Waveform CV Mode Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit Weld Voltage Waveform CV Mode Normal Open Circuit DC Weld Voltage Waveform CC Mode Normal Open Circuit AC Weld Voltage Waveform Ranger Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureSlip Rings Figure F.10 Brush LEADS/BRUSHES Retained with Cable TIERanger Field Capacitor AND/OR Rectifier Bridge Removal Replacement Replacement Field Capacitor AND/OR Rectifier Bridge RemovalProcedure Rectifier Bridge Removal and Replacement Ranger Printed Circuit Board Removal Replacement Printed Circuit Board Removal and Replacement ProcedurePrinted Circuit Board Removal Ranger Output Rectifier Bridge Removal Replacement Remove the case top, then reinstall the fuel cap Output Rectifier Bridge RemovalSection TOC Ranger ENGINE/ROTOR Removal and Replacement InstructionsENGINE/ROTOR Removal Figure F.14 Component LOCATIONS, ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Rotor Removal Procedure Figure F.15 Engine and Rotor Removed from StatorReplacement KIT S20788 Reassembly ProcedureRetest After Repair Table of Contents Diagrams Section Dimension Dimension Print Ranger 8 Honda & Kohler RANGER8Diagrams Connection of Ranger 8 to LN-7 & K240 Contactor KITElectrical Diagrams Wiring Diagram Onan NON CSA ModelK1418-2 Ranger 8 Onan CSA Version Wiring Diagram Wiring Diagram Onan CSA ModelK1419-1 Ranger 8 Kohler Wiring Diagram Wiring Diagram Kohler NON CSA ModelK1419-2 Ranger 8 Kohler CSA Wiring Diagram Wiring Diagram Kohler CSA ModelK2160-1 Ranger 8 Honda CSA Wiring Diagram Schematic IDLER/CONTROL PC Board 16482PC Board Assembly IDLER/CONTROL SVM Error Reporting Form