Lincoln Electric SVM107-B 20.5 H.P. P220, 20 H.P. GX620KI, Control Switch, Wire feed mode

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B-3

OPERATION

B-3

 

 

 

 

 

 

 

 

 

Ranger 8 Approximate Fuel Consumption

 

 

 

 

 

 

 

 

 

 

 

 

 

ONAN

KOHLER

 

HONDA

 

 

 

 

20.5 H.P. P220

20 H.P. COMMAND

 

20 H.P. GX620KI

 

 

 

 

 

 

 

 

 

 

 

Low Idle - No Load

.6 Gallons/Hour

.4 Gallons/Hour

 

.3 Gallons/Hour

 

 

 

2200 RPM

(2.3 Liters/Hour)

(1.5 Liters/Hour)

 

(1.3 Liters/Hour)

 

 

 

High Idle - No Load

.8 Gallons/Hour

.9 Gallons/Hour

 

.7 Gallons/Hour

 

 

 

3700 RPM

(3.0 Liters/Hour)

(3.5 Liters/Hour)

 

(2.7 Liters/Hour)

 

 

 

 

 

 

 

 

 

 

 

AC CC Weld Output

1.5 Gallons/Hour

1.3 Gallons/Hour

 

1.6 Gallons/Hour

 

 

 

225 Amps @ 25 Volts

(5.8 Liters/Hour)

(5.0 Liters/Hour)

 

(6.0 Liters/Hour)

 

 

 

DC CC Weld Output

1.6 Gallons/Hour

1.4 Gallons/Hour

 

1.7 Gallons/Hour

 

 

 

210 Amps @ 25 Volts

(6.1 Liters/Hour)

(5.3 Liters/Hour)

 

(6.3 Liters/Hour)

 

 

 

 

 

 

 

 

 

 

 

DC CV Weld Output

1.2 Gallons/Hour

1.2 Gallons/Hour

 

1.2 Gallons/Hour

 

 

 

200 Amps @ 20 Volts

(4.5Liters/Hour)

(4.5 Liters/Hour)

 

(4.6 Liters/Hour)

 

 

 

Auxiliary Power

1.6Gallons/Hour

1.4 Gallons/Hour

 

1.5 Gallons/Hour

 

 

 

8000 Watts

(6.1Liters/Hour)

(5.3 Liters/Hour)

 

(5.7 Liters/Hour)

 

 

 

 

 

 

 

 

 

Welder Controls - Function and Operation

Control” Switch

 

 

 

 

 

 

 

 

 

Explanation of Symbols that Appear on this Equipment

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ON

 

OFF

 

 

Low Idle

 

High Idle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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ENGINE “ON-OFF” Switch

When placed in the “ON” position, this switch energizes the engine ignition circuit. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine.

ENGINE “START” Push-Button Switch

Energizes engine starter motor.

“Polarity” Switch

CAUTION

Never change the “Polarity” switch setting while welding. This will damage the switch.

Range” Switch

 

 

 

 

 

 

 

Process

Maximum Current

 

 

on Each Setting

 

STICK/TIG - CC

50, 70, 90

 

6

Range Settings

125, 175, 210 DC/225 AC

 

 

 

WIRE FEED - CV

 

 

1

Range Setting

200

 

 

 

 

 

CAUTION

Never change the “RANGE” Switch setting while welding. This will damage the switch.

“IDLER” Switch

The idler switch has two positions, “HIGH” and “AUTO”.

When in “HIGH” ( ) position, the engine will run continuously at high idle.

When in “AUTO” ( / ) idle position, the idler operates as follows:

Welding

When the electrode touches the work, the welding arc is initiated and the engine accelerates to full speed.

After welding ceases (and no auxiliary power is being drawn), the engine will return to low idle after approximately 10 to 14 seconds.

Auxiliary Power

With the engine running at low idle and auxiliary power for lights or tools is drawn (approximately 100-150 watts or greater) from the receptacles, the engine will accelerate to high speed. 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

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Contents Rangertm Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Welding Output Auxiliary Power20 B 50 100 150 20050 100 150 200 250 300 350 Output Amps Installation Instructions Oil Battery ConnectionsAWG FuelAngle of Operation Welder Output Connection of the LN-7 to the RangerRanger Constant CurrentMotor Starting Duplex ReceptaclesType Common Electrical Devices Possible Concerns Electrical Device USE with the RangerStandby Power Connections Auxiliary Power While WeldingFigure A.1 Connection of Ranger 8 to Premises WiringRanger Table of Contents Operation Section DC Semiautomatic Wire Feed Welding Constant Voltage AC/DC Stick Welding Constant CurrentAC/DC TIG Welding Constant Current Provides a fine welding current adjustment within Control SwitchRange Switch settings in the STICK/TIG mode Welding voltage control with the Range switch setStopping the Engine Starting/Shutdown InstructionsWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG Constant Current Welding Stick Auto Summary of Welding ProcessesSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Engine OIL Change Routine MaintenanceEngine OIL Refill Capacities Kohler Onan HondaOIL Filter Change Engine Maintenance Parts Engine AdjustmentsPre-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 HOW to USE Troubleshooting Guide Troubleshooting & RepairStatic-Sensitive PC board can be damaged by static electricityDevices Handle only atOutput Problems Troubleshooting GuideDetailed in the beginning of this manual Observe Safety GuidelinesTroubleshooting & Repair Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Engine Problems Troubleshooting & Repair Troubleshooting & Repair Welding Problems Ranger Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Rotor Resistance Test Rotor Resistance Test Troubleshooting & Repair Ranger Auxiliary and Field Winding Test To test the 230 VAC winding To test the 115 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 Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Waveform CV ModeMachine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC ModeMachine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output WaveformAbnormal 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 Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.10 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger Field Capacitor AND/OR Rectifier Bridge Removal Replacement Field Capacitor AND/OR Rectifier Bridge Removal ReplacementProcedure Rectifier Bridge Removal and Replacement Ranger Printed Circuit Board Removal Replacement Procedure Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal Ranger Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger Instructions ENGINE/ROTOR Removal and ReplacementFigure F.14 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.15 Engine and Rotor Removed from Stator Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Table of Contents Diagrams Section Dimension RANGER8 Dimension Print Ranger 8 Honda & KohlerConnection of Ranger 8 to LN-7 & K240 Contactor KIT DiagramsWiring Diagram Onan NON CSA Model Electrical DiagramsWiring Diagram Onan CSA Model K1418-2 Ranger 8 Onan CSA Version Wiring DiagramWiring Diagram Kohler NON CSA Model K1419-1 Ranger 8 Kohler Wiring DiagramWiring Diagram Kohler CSA Model K1419-2 Ranger 8 Kohler CSA Wiring DiagramK2160-1 Ranger 8 Honda CSA Wiring Diagram 16482 Schematic IDLER/CONTROL PC BoardPC Board Assembly IDLER/CONTROL SVM Error Reporting Form