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Lincoln Electric SVM107-B manual

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Table of contents for the manual

  • Page 1

    SVM107-B July , 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTI[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated a[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. U[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufactu[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return 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 sûreté générales suiv- antes: Sûreté Pour [...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v RANGER 8 Page Safety .................................................................................................................................................i-iv Installation .......................................................................................................................[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 RANGER 8 Installation T echnical Specifications ....................................................................................................... ......A-2 AC Stick/TIG (cc) Output .........[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 RANGER 8 * Based on a 10 min. period. TECHNICAL SPECIFICA TIONS - Ranger 8 (K1418-3 CSA MEETS CANADIAN STD.) (K1419-3 CSA MEETS CANADIAN STD.) (K2160-1 CSA[...]

  • Page 9

    INST ALLA TION A-3 A-3 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE A B OUTPUT AMPS OUTPUT VOLTS AC (RMS) 0 50 100 150 200 250 0 10 20 30 40 50 60 70 [...]

  • Page 10

    INST ALLA TION A-4 A-4 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION INSTRUCTIONS Safety Precautions Machine Grounding Because this portable engine driven welder or genera- tor creates it’s own powe[...]

  • Page 11

    INST ALLA TION A-5 A-5 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Some of the factors to be considered are as follows: 1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachmen[...]

  • Page 12

    INST ALLA TION A-6 A-6 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Angle of Operation Internal combustion engines are designed to run in a level condition which is where the optimum perfor- mance is achieved. The [...]

  • Page 13

    INST ALLA TION A-7 A-7 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Connection of the LN-7 to the Ranger 8 • Shut the welder off. • Connect the LN-7 and the K240 contactor kit per instructions on the connection[...]

  • Page 14

    INST ALLA TION A-8 A-8 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 15 V Duplex Receptacles The 1 15V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulat[...]

  • Page 15

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-9 A-9 RANGER 8 T ABLE lll ELECTRICAL DEVICE USE WITH THE RANGER 8. T ype Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NO[...]

  • Page 16

    INST ALLA TION A-10 A-10 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Standby Power Connections The Ranger 8 is suitable for temporary , standby , or emergency power using the engine manufacturer ’s rec- ommended[...]

  • Page 17

    INST ALLA TION A-11 A-11 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Connection of Ranger 8 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other[...]

  • Page 18

    NOTES A-12 A-12 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 19

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 RANGER 8 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B General Description .......................[...]

  • Page 20

    OPERA TION B-2 B-2 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 g[...]

  • Page 21

    OPERA TION B-3 B-3 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HONDA 20 H.P . GX620KI .3 Gallons/Hour (1.3 Liters/Hour) .7 Gallons/Hour (2.7 Liters/Hour) 1.6 Gallons/Hour (6.0 Liters/Hour) 1.7 Gallons/Hour (6.3 Li[...]

  • Page 22

    OPERA TION B-4 B-4 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Starting/Shutdown Instructions Starting the Engine Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’ s Manua[...]

  • Page 23

    OPERA TION B-5 B-5 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W elding Process Stick (Constant Current) Welding Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set t[...]

  • Page 24

    OPERA TION B-6 B-6 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO ST ART PROCESS USED MODE WELDING WELDING STICK No AUTO Hot T ouch electrode to w[...]

  • Page 25

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -ACCESSORIES- Accessories Optional Equipment ............................................................................................................. .......C-2 Recommended Equipment ...........................................................[...]

  • Page 26

    ACCESSORIES C-2 C-2 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONAL EQUIPMENT (Field Installed) K957-1 HEA VY DUTY , TWO WHEEL TRAILER FOR SMALL WELDERS - For road, of f-road and in-plant and yard towing. (Fo[...]

  • Page 27

    ACCESSORIES C-3 C-3 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K892-1 Remo[...]

  • Page 28

    NOTES C-4 C-4 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 RANGER 8 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Routine Maintenance ....................................[...]

  • Page 30

    MAINTENANCE D-2 D-2 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Have qualified personnel do the maintenance work. T urn the engine off before working inside the machine. In some cases, it may be necessary to remov[...]

  • Page 31

    MAINTENANCE D-3 D-3 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 [...]

  • Page 32

    MAINTENANCE D-4 D-4 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HONDA GX620KI HONDA 15400-PR3-004 (HONDA CODE 3179553) FRAM PH681 1 HONDA 1721 1-ZJ1-000 (HONDA CODE 4209672) HONDA 17218-ZJ1-000 (HONDA CODE 4209706[...]

  • Page 33

    MAINTENANCE D-5 D-5 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D.1 - MAJOR COMPONENT LOCA TIONS 7 8 9 10 11 1 2 3 4 5 6 1. OUTPUT TERMINALS (LOCA TION) 2. ENGINE CONTROLS 3. AUXILIAR Y POWER RECEPT ACLES 4[...]

  • Page 34

    NOTES D-6 D-6 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 35

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 RANGER 8 Theory of Operation ............................................................................................................. Section E Battery , Starter , Engine, Excitation, Rotor , Stator , and Idler Solenoid .................[...]

  • Page 36

    BA TTER Y , ST ARTER, ENGINE, ROTOR, ST A TOR, 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 cir cuit board, to the r otating field coil in the r otor via a brush and slip ring configuration. This excitation (“flashing”) voltage mag[...]

  • Page 37

    ROTOR FIELD FEEDBACK AND AUXILIAR Y POWER The AC voltage developed in the field winding is fed to the full wave field bridge. The DC output of the bridge is filtered by the field capacitor and contr olled by the printed circuit boar d according to the output contr ol setting. This filtered and contr olled voltage is fed to the rotor winding via the[...]

  • Page 38

    WELD WINDING, REACTOR, AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch. The inductance in the reactor of fers an impedance to current flow . The reactor coil is tapped at various points. As the range switch is ro- tated, differ ent amounts of reactor coil ar e brought into the current path. As mor e turns of re[...]

  • Page 39

    OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding is delivered, thr ough the reactor and range switch, to the output bridge and polarity switch. Depending upon the setting of the polarity switch, either AC volt- age or DC voltage is delivered to the output terminals. If AC output is sele[...]

  • Page 40

    NOTES E-6 E-6 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 41

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 RANGER 8 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide .....................................................................[...]

  • Page 42

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may [...]

  • Page 43

    TROUBLESHOOTING & REP AIR F-3 F-3 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connect[...]

  • Page 44

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

  • Page 45

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

  • Page 49

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not unde[...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

  • Page 52

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-12 F-12 RANGER 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF M[...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 RANGER 8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF M[...]

  • Page 54

    NOTES F-14 F-14 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 RANGER 8 ROTOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repa[...]

  • Page 56

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-16 F-16 RANGER 8 ROTOR VOL T AGE TEST (continued) FIGURE F .1 - LOCA TION OF LEAD 200A AND 219 FOR ROTOR VOL T AGE TEST Slip Rings Brushes Lead 219 + - Lead 200A TROUBLESHOOTIN[...]

  • Page 57

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ROTOR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in [...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 RANGER 8 ROTOR RESIST ANCE TEST (continued) FIGURE F .2 – LOCA TION OF ROTOR SLIP RINGS Lead 219 Lead 200A + - TEST PROCEDURE 1. With th[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 RANGER 8 13. Measure the r esistance to ground. A. Set the ohmmeter on the high scale (X100,000). B. Place one probe on either of the slip[...]

  • Page 60

    NOTES F-20 F-20 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 RANGER 8 W ARNING AUXILIAR Y AND FIELD WINDING TEST Service and repair should be performed by only Lincoln Electric factory trained person[...]

  • Page 62

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 RANGER 8 AUXILIAR Y AND FIELD WINDING TEST (continued) FIGURE F .3 – LOCA TION OF LEADS #3 AND #5 Lead #3 Lead #5 1 15V Receptacle Machi[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 RANGER 8 AUXILIAR Y AND FIELD WINDING TEST (continued) Retaining Ta b Field Bridge Rectifier 7 9 Capacitor 201 201A 200 200A 200B Cable T [...]

  • Page 64

    NOTES F-24 F-24 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 RANGER 8 W ARNING OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. [...]

  • Page 66

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 RANGER 8 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .5 – LOCA TION OF OUTPUT RECTIFIER LEADS Ohmmeter Probes + Pigtail Diode Outp[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 RANGER 8 W ARNING CHARGING CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unautho[...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 RANGER 8 CHARGING CIRCUIT TEST (continued) FIGURE F .6 – LOCA TION OF VOL T AGE REGULA TOR V oltage Regulator Ground Lead (Green) Engine[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 RANGER 8 W ARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personne[...]

  • Page 70

    TROUBLESHOOTING & REP AIR F-30 F-30 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .7 – BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD Blower Paddle TEST PROC[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-31 F-31 RANGER 8 ENGINE THROTTLE ADJUSTMENT TEST (continued) Throttle linkage Choke Cable 3/8" High Idle Adjustment Nut Solenoid Housing 3/8&[...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 RANGER 8 ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 115 V AC r eceptacle, accor d[...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 RANGER 8 CH1 16.2 ms 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Coupli[...]

  • Page 74

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 RANGER 8 SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep.....5 ms/Div . Coupling ............................DC [...]

  • Page 75

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 RANGER 8 This is the typical DC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents [...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 RANGER 8 This is the typical AC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents [...]

  • Page 77

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 RANGER 8 This is NOT the typical CV output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. One [...]

  • Page 78

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 RANGER 8 This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. [...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 RANGER 8 This is the typical CV output voltage generated from a pr operly operating machine. Note that each vertical division repr esents [...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 RANGER 8 This is the typical DC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents [...]

  • Page 81

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 RANGER 8 This is the typical AC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents [...]

  • Page 82

    NOTES F-42 F-42 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 RANGER 8 BRUSH REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained person- n[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 RANGER 8 BRUSH REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wires. 2. With the 5/16” nut driver , remove the [...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 RANGER 8 SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a gene[...]

  • Page 86

    NOTES F-46 F-46 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 RANGER 8 W ARNING FIELD CAP ACITOR AND/OR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln[...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 RANGER 8 FIELD CAP ACITOR AND/OR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .11 RECTIFIER BRIDGE LOCA TION AND DISCHAR[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 RANGER 8 FIELD CAP ACITOR AND/OR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) PROCEDURE - RECTIFIER BRIDGE REMOV AL AND REPLACEME[...]

  • Page 90

    NOTES F-50 F-50 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 RANGER 8 W ARNING PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory t[...]

  • Page 92

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 RANGER 8 PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .12 - PRINTED CIRCUIT BOARD LOCA TION In Line Connectors Curr[...]

  • Page 93

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 RANGER 8 Be sure to follow the r ecommended static- free methods for handling printed cir cuit boards. Failur e to do so can result in per[...]

  • Page 94

    NOTES F-54 F-54 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 95

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-55 F-55 RANGER 8 W ARNING OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory[...]

  • Page 96

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-56 F-56 RANGER 8 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .13 - OUTPUT RECTIFIER CONNECTIONS Mounting Screws with Ins[...]

  • Page 97

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-57 F-57 RANGER 8 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) 12. With the 3/8” wrench and slot head scr ew driver , remove the [...]

  • Page 98

    NOTES F-58 F-58 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 99

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-59 F-59 RANGER 8 W ARNING ENGINE/ROTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained pe[...]

  • Page 100

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-60 F-60 RANGER 8 ENGINE/ROTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .14 – COMPONENT LOCA TIONS, ENGINE/ROTOR REMOV AL 3 1 9 2 4 1 8 7 6 [...]

  • Page 101

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-61 F-61 RANGER 8 ENGINE/ROTOR REMOV AL AND REPLACEMENT (continued) ENGINE AND ROTOR REMOV AL PROCEDURE 1. Refer to Figure F .14 for component loca[...]

  • Page 102

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-62 F-62 RANGER 8 ROTOR REMOV AL PROCEDURE 1. T o remove the r otor , double check that the engine spark plug wires ar e disconnect- ed. Y ou will [...]

  • Page 103

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-63 F-63 RANGER 8 REASSEMBL Y PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace[...]

  • Page 104

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-64 F-64 RANGER 8 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that r equires you to r emove any mechanic[...]

  • Page 105

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section G-1 Section G-1 RANGER 8 Diagrams Section ............................................................................................................ Section G Dimension Print Ranger 8 (Onan) .................................................................[...]

  • Page 106

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return 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 9.29 9.31 30.00 UNDERCARRIAGE MOUNTING HOLES L 9.09 26.59 2.7[...]

  • Page 107

    L OF SHAFT 9.29 21.21 9.31 2.75 17.00 26.59 19.11 30.28 9.09 9.09 UNDERCARRIAGE MOUNTING HOLES 42.25 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 11.31 21.95 FOR OIL FILTER REMOVAL 30.00 8.80 30.00 42.00 C M17215-2 1-30-98E Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

  • Page 108

    DIAGRAMS G-4 G-4 RANGER 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF RANGER 8 TO LN-7 & K240 CONT ACTOR KIT W ARNING: T urn the power off when making connections. N.A. Use power source polarity switch to[...]

  • Page 109

    ELECTRICAL DIAGRAMS G-5 WIRING DIAGRAM - ONAN NON CSA MODEL 12 VOLT STARTER AM1 + - IDLER SOLENOID CR1 209 213 215 BATTERY S3 TO SPARK PLUGS IGNITION CONTROL 216A 212 212 (CAVITY #1) (NOTE CAVITY NUMBERS) LOCATING TAB 216 TERMINAL BLOCK CONNECTION + - AC AC B+ OIL PRESSURE SWITCH REGULATOR FLYWHEEL ALTERNATOR STARTER SOLENOID 209 208A 208B 208 (CAV[...]

  • Page 110

    ELECTRICAL DIAGRAMS G-6 WIRING DIAGRAM - ONAN CSA MODEL 12 VOLT STARTER IDLER SOLENOID CR1 209 213 215 BATTERY TO SPARK PLUGS IGNITION CONTROL 216A 212 (CAVITY #1) (NOTE CAVITY NUMBERS) LOCATING TAB TERMINAL BLOCK CONNECTION + - AC AC B+ OIL PRESSURE SWITCH REGULATOR FLYWHEEL ALTERNATOR STARTER SOLENOID 209 208 (CAVITY #3) CAPACITOR ELECTRICAL SYMB[...]

  • Page 111

    ELECTRICAL DIAGRAMS G-7 WIRING DIAGRAM - KOHLER NON CSA MODEL STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID 213 BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D S4 224B 224 213 "S4" SHOWN IN "AUTO" POSITION ENGINE COMPONENTS S3 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 LEAD COLOR CODE: B [...]

  • Page 112

    ELECTRICAL DIAGRAMS G-8 WIRING DIAGRAM - KOHLER CSA MODEL STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID 213 BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D S4 224B 224 213 "S4" SHOWN IN "AUTO" POSITION ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 LEAD COLOR CODE: B = BLACK[...]

  • Page 113

    ELECTRICAL DIAGRAMS G-9 WIRING DIAGRAM - HONDA CSA MODEL RA (CSA) - WIRING DIAGRAM K2160-1 NGER 8 HOND A M19988 A 25A CB7 208C R = RED OR PINK B = B LA CK OR GR AY 208B 210 221 5H BUTTON START S5 208A - + AM1 IN "RUN" "S3" SHOW N POSITION S3 N.A. GR OUNDI NG T HIS T ERMI NAL S T OP S T HE ENGI NE. ALL CAS E FRONT COM PON ENT S S[...]

  • Page 114

    ELECTRICAL DIAGRAMS G-10 SCHEMA TIC - IDLER/CONTROL PC BOARD 50V 0.1 C16 10.0K R74 1 6482 M COM + DIODES PROTECTION +10V +10V +10V COM +12V +10V COM COM COM C11 LM224 X3 4 11 4536B X4 16 8 5W 10V DZ6 C19 X2 1 3 LM2901 X1 3 12 NOTES : 75 S15128-11 NUMBER. ON ALL ANGLES IS + .5 OF A DEGREE ON 3 PLACE DECIMALS IS + .OO2 MATERIAL TOLERANCE ("t&quo[...]

  • Page 115

    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 . Lincoln Electric discourages board level troub[...]

  • Page 116

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional 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 troubleshooting chart, please share this information wi[...]