Lincoln Electric RANGER SVM120-A, RANGER 10-LX Service Manual

SVM120-A

March 1999

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 READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before
you act and be careful.

SERVICE MANUAL

For use with machine code numbers 9815 and 9816

RANGER 10-LX

TM

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• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American W elding Society, P .O. Box 351040,
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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

1.e. 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
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle con­trol rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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FOR ENGINE
powered equipment.

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

1.d. Keep all equipment safety guards, covers

and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii ii

SAFETY

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.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS 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. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

vapors

to

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5.e. Also see item 1.b.

Mar ‘95

iii iii

SAFETY

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.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn 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 manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

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Mar ‘95

iv iv

SAFETY

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 suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

v v

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

RETURN TO MAIN INDEX

Safety .................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Installation Section Table of Contents........................................................................................A-1

Technical Specifications .............................................................................................................A-2

Safety Precautions ......................................................................................................................A-3

Location and Ventilation.............................................................................................................A-3

Pre-operation Engine Service.....................................................................................................A-4

Electrical Output Connections....................................................................................................A-5

Operation...............................................................................................................................Section B

Safety Instructions......................................................................................................................B-2

General Description....................................................................................................................B-2

Recommended Applications ......................................................................................................B-3

Design Features and Advantages...............................................................................................B-3

Welding Capability ......................................................................................................................B-3

Page

Limitations .................................................................................................................................B-3

Controls and Settings.................................................................................................................B-4

Engine Operation........................................................................................................................B-7

Welding Operation....................................................................................................................B-10

Summary of Welding Processes...............................................................................................B-13

Auxiliary Power.........................................................................................................................B-14

Accessories...........................................................................................................................Section C

Maintenance .........................................................................................................................Section D

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance ............................................................................................D-2

Major Component Locations....................................................................................................D-10

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair.................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manual.................................................................................................................................P-217

RANGER 10-LX

Section A-1 Section A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

Installation

Technical Specifications .............................................................................................................A-2

Safety Precautions ......................................................................................................................A-3

Location and Ventilation.............................................................................................................A-3

Storing .................................................................................................................................A-3

Stacking................................................................................................................................A-4

Tilting .................................................................................................................................A-4

Lifting .................................................................................................................................A-4

High Altitude Operation........................................................................................................A-4

Pre-operation Engine Service.....................................................................................................A-4

Oil ........................................................................................................................................A-4

Fuel.......................................................................................................................................A-4

Engine Coolant.....................................................................................................................A-4

Battery Connections.............................................................................................................A-4

Muffler Relocation ................................................................................................................A-5

Spark Arrester ......................................................................................................................A-5

Electrical Output Connections....................................................................................................A-5

Welding Cable Connections.................................................................................................A-6

Cable Size and Length............................................................................................A-6

Cable Installation.....................................................................................................A-6

Machine Grounding..............................................................................................................A-6

Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment .......................................A-7

Circuit Breakers ....................................................................................................................A-7

Premises Wiring....................................................................................................................A-7

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RANGER 10-LX

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 10-LX

INPUT - DIESEL ENGINE

Manufacturer Description Speed Displacement Ignition Capacities

KUBOTA 3 cyl., 3600 RPM 52.17 cu. in. Electric Fuel: 10 gal. (38 l)

DH850B-88 liquid-cooled Full load (855 cc)

diesel Oil: 3.9 qt. (3.7 l)
23 HP @ 3750 RPM
3600 RPM High idle

Cooling system:

2150 RPM 5.4 qts. (5.1 l)

Low idle

RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes

100% Duty Cycle 250 AC Constant Current 25
100% Duty Cycle 250 DC Constant Current 25
100% Duty Cycle 250 DC Constant Voltage 30

OUTPUT - WELDER AND GENERATOR

Auxiliary Power for

Welding Ranges Max. Open Circuit Voltage Auxiliary Power

45- 250 Amps 80 Volts RMS 10000 Continuous Watts 42V, 60 Hz, 8 Amps

@ 3700 RPM 87 Amps @ 115 V

43.5 Amps @ 230 V 115V, 60 Hz, 8 Amps

(1)

Wire Feeders

PHYSICAL DIMENSIONS

Height Width Depth Weight

37.4 in. 24.8 in. 60.5 in. 1100 lb.

949 mm 629 mm 1529 mm 499 kg

(1)

Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity.

When welding, available auxiliary power will be reduced.

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RANGER 10-LX

A-3 A-3

INSTALLATION

Read this entire installation section before you
start installation.

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.

• Insulate yourself from the work
and ground.

• Always wear dry insulating
gloves.

ENGINE EXHAUST can kill.

LOCATION AND VENTILATION

Whenever you use the RANGER 10-LX, be sure that
clean cooling air can flow through the machine’ s diesel
engine and the machine case. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.

The RANGER 10-LX may be used outdoors. Do not
set the machine in puddles or otherwise submerge it in
water. Such practices pose safety hazards and cause
improper operation and corrosion of parts.

Always operate the RANGER 10-LX with the case roof
on and all machine components completely assem­bled. This will protect you from the dangers of moving
parts, hot metal surfaces, and live electrical devices.

STORING

1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from con­struction activities, moving vehicles, and other
hazards.

• Use in open, well ventilated
areas or vent exhaust to the out­side.

• Do not stack anything on or near
the engine.

MOVING PARTS can injure.

• Do not operate this equipment
with any of its doors open or
guards off.

• Stop the engine before servicing
it.

• Keep away from moving parts.

Only qualified personnel should install, use, or ser­vice this equipment.

2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate
oil to all the parts. See the Maintenance section
of this manual for details on changing oil.

3. If you are storing the machine for more than 30

days, drain the coolant from the radiator. Open the
cock at the bottom of the radiator and remove the
pressure cap so that the coolant drains complete­ly. Attach a note that says “NO WATER” on the
radiator.

4. Remove the battery, recharge it, and adjust the

electrolyte level. Store the battery in a dry, dark
place.

5. If the engine is not used for a long period of time,

every two to three months fill the radiator and run
the engine for about five minutes to keep it free
from rust.

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RANGER 10-LX

A-4 A-4

INSTALLATION

STACKING

RANGER 10-LX machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenev­er you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.

The diesel engine is designed to run in a level position
for best performance. It can operate at an angle, but
this should never be more than 20 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level at the
FULL mark as it would be in its normal level condition.
Also, fuel capacity will be a little less at an angle.

LIFTING

The RANGER 10-LX weighs 1100 lbs/499 kg. A lift bail
is mounted to the machine frame and should always
be used when lifting the machine.

OIL

The RANGER 10-LX is shipped with the

engine filled with SAE 10W-30 oil (API class
CC/DO). CHECK THE OIL LEVEL BEFORE YOU
START THE ENGINE. This is an added precaution.
When full, the oil level should be up to but not over the
FULL mark on the dipstick. If it is not full, add enough
oil to fill it to the full mark.

For more oil fill and service information, see the
Maintenance section of this manual.

FUEL

Fill the fuel tank with clean, diesel fuel only.
The RANGER 10-LX has a 10 gallon (38 litre)

fuel tank with a top fill and fuel gauge

mounted on the control panel. See the
Operation and Maintenance sections of this manual
for more details about fuel.

ENGINE COOLANT

HIGH ALTITUDE OPERATION

It may be necessary to derate welder output at higher
altitudes. Derate the welder output 0.4% for every 100
ft (30 m) above 500 ft (150 m). Some engine adjust­ment may be required. Contact a Kubota Service
Representative.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the RANGER 10-LX.

WARNING

• Keep hands away from the engine muffler or HOT
engine parts.

• Stop the engine when fueling.

• Do not smoke when fueling.

• Remove the fuel cap slowly to release pressure.

• Do not overfill the fuel tank.

• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.

WARNING

HOT COOLANT can burn
skin.

• Do not remove cap if radiator is hot.

The welder is shipped with the engine and radiator
filled with a 50% mixture of ethylene glycol and water.
The recovery bottle should be partially filled. See the
Maintenance section and the engine Operator’s
Manual for more information on coolant.

BATTERY CONNECTIONS

–+

sure the Engine Switch is in the STOP position and
attach the disconnected cable securely to the battery
terminal. If the battery is discharged and won’t start
the engine, see the battery charging instructions in the
Maintenance section.

The RANGER 10-LX is shipped with the
negative battery cable disconnected.
Before you operate the machine, make

• Keep sparks and flame away from the fuel tank.

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RANGER 10-LX

A-5 A-5

INSTALLATION

FIGURE A.1 - RANGER 10-LX OUTPUT CONNECTIONS

2

1. 115/230 VOLT, 50 AMP RECEPTACLE

2. 115 VOLT, 20 AMP RECEPTACLES (2)

1

5

3. WELD OUTPUT TERMINALS (2)

4. GROUND STUD (LOCATION)

5. CIRCUIT BREAKERS (CSA machines only)

4

3

MUFFLER RELOCATION

WARNING

Shut off the machine and allow the muffler to cool
before touching the muffler.

The RANGER 10-LX is shipped with the exhaust
directed toward the rear. It can be changed to the right
side by loosening the clamp that holds the exhaust
deflector in place and rotating the deflector to the
desired direction.

SPARK ARRESTER

Diesel engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.

Standard mufflers and deflectors (like the ones includ­ed with the RANGER 10-LX) do not act as spark
arresters. When local laws require it, a spark arrester
must be installed on the machine and properly main­tained. An optional spark arrester kit (K903-1) is avail­able for your RANGER 10-LX. See the Accessories
section of this manual for more information.

CAUTION

An incorrect spark arrester may lead to damage to the
engine or reduce performance.

ELECTRICAL OUTPUT
CONNECTIONS

See Figure A.1 for the location of the 115 and 230 volt
receptacles, weld output terminals, circuit breakers
and ground stud.

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RANGER 10-LX

A-6 A-6

INSTALLATION

WELDING CABLE CONNECTIONS

CABLE SIZE AND LENGTH

Be sure to use welding cables that are large enough.
The correct size and length becomes especially impor­tant when you are welding at a distance from the
welder.

Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the

TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

Cable Size for 250 Amp Cable Size for 250 Amp

Cable Length 40% Duty Cycle 100% Duty Cycle

0-50 feet (0-15 meters) 2 AWG 1 AWG
50-100 feet (15-39 meters) 2 AWG 1 AWG
100-150 feet (30-46 meters) 1 AWG 1 AWG
150-200 feet (46-61 meters) 1 AWG 1 AWG
200-250 feet (61-76 meters) 1/0 AWG 1/0 AWG

CABLE INSTALLATION

Install the welding cables to your RANGER 10-LX as
follows. See Figure A.1 for the location of parts.

1. The diesel engine must be OFF to install welding

cables.

2. Remove the flanged nuts from the output termi-

nals.

3. Connect the electrode holder and work cables to

the weld output terminals. The terminals are iden­tified on the case front.

welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.

Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the Acces-
sories section of this manual for more information.

MACHINE GROUNDING

Because the RANGER 10-LX creates
its own power from its diesel-engine
driven generator, you do not need to
connect the machine frame to an earth

ground. However, for best protection
against electrical shock, connect a heavy gauge wire
(#8 AWG or larger) from the ground stud located on
the bottom of the output panel (see Figure A.1) to a
suitable earth ground such as a metal pipe driven into
the ground.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding
(the “work”) is properly connected to the work
clamp and cable.

6. Check and tighten the connections periodically.

CAUTION

• Loose connections will cause the output terminals to

overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output termi-

nal connection. Keep the cables isolated and sepa­rate from one another.

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WARNING

Do not ground the machine to a pipe that carries
explosive or combustible material.

RANGER 10-LX

A-7 A-7

INSTALLATION

When the RANGER 10-LX is mounted on
a truck or a trailer, the machine generator
ground stud MUST be securely connect­ed to the metal frame of the vehicle. See
Figure A.1. The ground stud is marked

with the ground symbol.
If the RANGER 10-LX is connected to premises wiring

such as a home or shop, it must be properly connect­ed to the system earth ground. See the Premises
Wiring section of this manual for details.

AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT

The control panel of the RANGER 10-LX features three
auxiliary power receptacles: See Figure A.1.

• Two 20 amp, 125 volt duplex (double outlet) recep-

tacles.

• One 50 amp 115/230 volt simplex (single outlet)

receptacle.

Through these receptacles the machine can supply up
to 10,000 rated continuous watts of single-phase, 60
Hz AC power. The machine output voltages fall within
± 10% of the rated voltage.

For further protection against electric shock, any elec­trical equipment connected to the generator recepta­cles must use a three-blade, grounded type plug or an
Underwriter’ s Laboratories (UL) appr oved double insu­lation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the Accessories section of this manual for details.

If you need ground fault protection for hand-held
equipment, refer to the Accessories section of this
manual for the K896-1 GFCI Receptacle kit.

PREMISES WIRING

The RANGER 10-LX is suitable for temporary , standby,
or emergency power using the engine manufacturer’s
recommended maintenance schedule. With its three­wire grounded neutral generator, it can be permanent­ly installed as a standby power unit for 230 volt, three­wire, single phase 43 ampere service.

WARNING

Only a licensed, certified, trained electrician should
install the machine to a premises or residential electri­cal system. Be certain that:

• The installation complies with the National Electrical
Code and all other applicable electrical codes.

• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and local
laws require the premises to be isolated before the
generator is linked to the premises. Check your
state and local requirements.

• A double pole, double throw transfer switch in con­junction with the properly rated double throw circuit
breaker is connected between the generator power
and the utility meter.

The following information and the connection diagram,
Figure A.2, can be used as a guide by the electrician
for most applications to premises wiring.

1. Install a double pole, double throw switch between

the power company meter and the premises dis­connect. The switch rating must be the same as

or greater than the premises disconnect and
service overcurrent protection.

CIRCUIT BREAKERS

Canadian Standards Association
(CSA) versions of the RANGER 10-LX
are equipped with 50 amp circuit
breakers on the 115/230 V receptacle
and 15 amp circuit breakers on the 115 V receptacles
for overload protection. Under high heat a breaker
may tend to trip at lower loads than it would normally.

CAUTION

Never bypass the circuit breakers. Without overload
protection, the RANGER 10-LX could overheat and/or
cause damage to the equipment being used.

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2. Take the necessary steps to assure that the load is

limited to the capacity of the RANGER 10-LX by
installing a 45 amp 230 volt double pole circuit
breaker. Maximum rated load for the 230 volt aux­iliary is 43 amperes. Loading above 43 amperes
will reduce output voltage below the allowable
– 10% of rated voltage. This may damage appli­ances or other motor-driven equipment.

3. Install a 50 amp 115/230 volt plug (NEMA type 14-

50) to a double pole circuit breaker using No. 6, 4
conductor cable of the desired length. (The 50
amp 115/230 volt plug is available in the optional
power plug kit. See the Accessories section for
details.)

4. Plug this cable into the 50 amp 115/230 volt

receptacle on the RANGER 10-LX case front.

RANGER 10-LX

A-8 A-8

INSTALLATION

FIGURE A.2 - CONNECTION OF RANGER 10-LX TO PREMISES WIRING

230 VOLT

230 V olt

60 Hz.
3-Wire

Service

POWER

COMP ANY

METER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

115 VOLT

115 VOLT

GROUNDED CONDUCTOR

NEUTRAL
BUS

LOAD

50 AMP, 115/230

VOLT PLUG

NEMA TYPE 14-50

230 VOLTS

50 AMP, 115/230 VOLT

50 AMP, 115/230 VOLT

RECEPTACLE

RECEPTACLE

LOCATED ON

FRONT OF MACHINE

45 AMP

40 AMP

230 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

GND

PREMISES

SYSTEM

GROUND

EARTH
GROUND
PER THE U.S.
NATIONAL
ELECTRICAL
CODE

N

NOTE: No. 8 COPPER CONDUCTOR CABLE

NOTE: No. 6 COPPER 4 CONDUCTOR CABLE.

SEE NATIONAL ELECTRIC CODE FOR

SEE NATIONAL ELECTRIC CODE FOR

ALTERNATE WIRE SIZE RECOMMENDATIONS.

ALTERNATE WIRE SIZE RECOMMENDA TIONS .

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

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RANGER 10-LX

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

Operation...............................................................................................................................Section B

Safety Instructions......................................................................................................................B-2

General Description....................................................................................................................B-2

Recommended Applications ......................................................................................................B-3

Welder .................................................................................................................................B-3

Generator .............................................................................................................................B-3

Design Features and Advantages...............................................................................................B-3

Welding Capability ......................................................................................................................B-3

Limitations .................................................................................................................................B-3

Controls and Settings ................................................................................................................B-4

Welder/Generator Controls ..................................................................................................B-4

Diesel Engine Controls.........................................................................................................B-6

Engine Operation........................................................................................................................B-7

Before Starting the Engine ..................................................................................................B-7

Starting the Engine ..............................................................................................................B-8

Stopping the Engine ............................................................................................................B-8

Break-in Period ....................................................................................................................B-8

Welding Operation....................................................................................................................B-10

General Information............................................................................................................B-10

AC/DC Constant Current Stick Welding ......................................................................B-10

AC/DC TIG (Constant Current) Welding.......................................................................B-11

DC Wire Feed Welding.................................................................................................B-12

Summary of Welding Processes and Machine Settings ..........................................................B-13

Auxiliary Power.........................................................................................................................B-14

General Information............................................................................................................B-14

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RANGER 10-LX

B-2 B-2

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section before oper­ating your RANGER 10-LX.

SAFETY INSTRUCTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet cloth­ing.

• Insulate yourself from the work and
ground.

WARNING

ARC RAYS can burn.

• Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust to the outside.

• Do not stack anything on or near the
engine.

MOVING PARTS can injure.

• Do not operate this equipment with
any of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

• Always wear dry insulating gloves.

FUMES AND GASES can be dan­gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held
combustibles.

Only qualified personnel should install, use, or ser­vice this equipment.

GENERAL DESCRIPTION

The RANGER 10-LX is a diesel-engine driven, multi­process AC and DC arc welder and AC power genera­tor for commercial and residential applications. As a
generator it can supply up to 10,000 continuous watts
of 115/230 volt, 60 Hz, single-phase AC power to
operate AC power tools, battery chargers, and light­ing; it can also be used to provide standby power. As
a welder it provides 250 amps of AC current for weld­ing with AC stick electrodes or 250 amps of DC cur­rent for DC stick welding. The RANGER 10-LX can
also perform AC/DC TIG welding and DC semiauto­matic wire feed welding.

The RANGER 10-LX is powered by the Kubota
DH850B-88 water-cooled, three-cylinder diesel
engine.

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RANGER 10-LX

B-3 B-3

OPERATION

RECOMMENDED APPLICATIONS

WELDER

The RANGER 10-LX provides excellent constant cur­rent AC/DC welding output for stick (SMAW) welding
and for TIG welding, and it offers constant voltage out­put for DC semiautomatic wire feed welding. For more
details on using the machine as a welder, see Welding
Operation in the Operation section of this manual.

GENERATOR

The RANGER 10-LX gives AC generator output for
medium use demands. For more details on operat­ing the generator, see Auxiliary Power in the
Operation section of this manual.

DESIGN FEATURES AND
ADVANTAGES

• 10,000 watts of auxiliary power

• Enhanced constant voltage capability with low (9-19
volts), medium low (10-24 volts), medium high (15­29 volts) and high (22-40 volts) range settings for
greater control of wire feed applications.

• Built-in contactor with front panel selection of
“cold” or “hot” welding terminals.

• Constant current AC/DC Stick welding (SMAW)
process capability with output range from 45-250
amps (AC) or 45-250 amps (DC).

• Constant voltage DC Semiautomatic Wire Feed
Welding with output range from 45-250 amps.

• Constant current AC/DC TIG Welding with output
across the entire range of settings.

• Top-mounted 10 gallon (38.0 litre) fuel tank with
convenient top fil.

• Front-panel mounted fuel gauge.

• Quiet engine muffler and insonorized case for
extremely quiet operation.

• All copper alternator windings and high quality insu­lation for dependable long life.

• Automatic engine shutdown protection for low oil
pressure.

• Automatic engine idler goes to low idle 10 to 14
seconds after welding for greater fuel economy;
includes high idle switch.

• Standard Remote Control Receptacle provides
interface for Lincoln remote control accessories.
Both 6 pin and 14 pin amphenols are provided for
ease in hooking up wire feeders.

• Canadian Standard Association (CSA) approved
models available; include integrated generator out­put overload protection through circuit breakers.

WELDING CAPABILITY

The RANGER 10-LX is rated 250 amps, 25 volts con­stant current AC or 250 amps, 25 volts constant cur­rent DC (250 amps 30 volts constant voltage DC) at
100% duty cycle on a ten-minute basis.

The current is continuously variable from 45 to 250
amps AC or 45 to 250 amps DC. The RANGER 10-LX
can weld with all 3/32 and most 1/8 inch and 1/16
diameter Lincoln AC stick electrodes. Wire feed
processes using wire diameters from .030 to .068 inch
are possible, depending on the specific process and
wire feeder. (See LIMITATIONS.)

• Polarity switch for selecting DC+, DC-, or AC weld­ing output.

• Separate ground stud for safe connection of case to
earth ground.

• Single 50 amp, 230 volt, full 10 kVA auxiliary power
receptacle.

• Double duplex 20 amp, 125 volt auxiliary power
receptacles.

• Electric starting.

• Battery Charging Ammeter.

• Engine Hour Meter for determining periodic mainte­nance.

• 23 HP Kubota DH850B-88 diesel engine.

• Durable, heavy-gauge steel case.

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LIMITATIONS

• The RANGER 10-LX is not recommended for any
processes besides those that are normally per­formed using stick welding (SMAW), TIG welding
(GTAW), MIG (GMAW) welding and Innershield
(FCAW) welding. Specific limitations on using the
RANGER 10-LX for these processes are described
in the Welding Operation section of this manual.

• The RANGER 10-LX is not recommended for pipe
thawing.

• During welding, generator power is limited and out­put voltages can drop. Therefore, DO NOT OPER­ATE ANY SENSITIVE ELECTRICAL EQUIPMENT
WHILE YOU ARE WELDING. See Table B.4 for per-
missible simultaneous welding and auxiliary power
loads.

RANGER 10-LX

®

B-4 B-4

OPERATION

CONTROLS AND SETTINGS

All generator/welder controls are located on the
Output Control Panel of the machine case front.
Diesel engine glow plug, idler control, and start/stop

FIGURE B.1 – OUTPUT PANEL CONTROLS

1

2

7

8

controls are also on the case front. See Figur e B.1 and
the explanations that follow.

14

3

4

5

6

1. OUTPUT RANGE SELECTOR

2. FINE OUTPUT CONTROL

3. POLARITY SWITCH

4. CONTROL AT WELDER/REMOTE CONTROL SWITCH

5. WIRE FEEDER NO CONTROL CABLE/WIRE FEEDER
WITH CONTROL CABLE SWITCH

6 WIRE FEEDER POWER CIRCUIT BREAKER

7. 115 VOLT, 20 AMP RECEPTACLES (2)

8. 115/230 VOLT, 50 AMP RECEPTACLE

9. WELD OUTPUT TERMINAL (TO WORK)

10. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER)

11. GROUND STUD (LOCATION)

12. 14 PIN AMPHENOL

13. 6 PIN AMPHENOL

14. VOLTMETER

11

12

9

WELDER/GENERATOR CONTROLS

See Figure B.1 for the location of the following fea­tures:

1. OUTPUT RANGE SELECTOR: Selects continu-
ous current output for constant current stick or
TIG applications (blue settings) and constant volt­age wire feed applications (white settings). The
amperages on the dial correspond to the maxi­mum amperages for each corresponding range
setting. Never change the range switch setting

while welding since this could damage the
switch.

2. FINE OUTPUT CONTROL: Allows fine adjust-
ment of current or voltage within the selected out­put range.

3. POLARITY SWITCH: Selects DC+, DC- or AC
welding output. Color codings aid in the proper
selection of stick (blue) or wire feed (white) polari­ty setting. The color setting of the polarity switch
must match the color setting of the OUTPUT

RANGE SELECTOR. Never change the polarity

13

10

switch setting while welding since this could
damage the switch.

4. CONTROL AT WELDER/REMOTE CONTROL
SWITCH: Allows the operator to control welding

output at the welding control panel or at a remote
station. Remote connections are made at the 6 pin
or 14 pin amphenol connector.

5. WIRE FEEDER NO CONTROL CABLE/WIRE

FEEDER WITH CONTROL CABLE SWITCH:

Allows control of the RANGER 10-LX output con­tactor. In the “NO CONTROL CABLE” position, the
switch closes the output contactor, and welding
begins when an arc is struck between the electrode
and the workpiece. In the “WITH CONTROL
CABLE” position, the switch places control of the
contactor at the wire feeder. The contactor closes
when the wire feeder gun trigger or amptrol switch
closes and opens when it is released.

6. WIRE FEEDER POWER CIRUIT BREAKER:
Opens the wire feeder circuit and disables the
feeder if a fault is detected in the circuit.

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RANGER 10-LX

B-5 B-5

OPERATION

7. 20 AMP, 115 VOLT DUPLEX RECEPTACLES:
Connection point for supplying 115 volt power to

operate one or two electrical devices.

8. 50 AMP, 230/115 VOLT RECEPTACLE:

Connection point for supplying 230 volt power to
operate one electrical device.

9. WELD OUTPUT TERMINAL (TO WORK) WITH
FLANGE NUT: Provides the connection point for
the work cable.

10. WELD OUTPUT TERMINAL (TO ELECTRODE
HOLDER) WITH FLANGE NUT: Provides the
connection point for the electrode holder.

11. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.

12. 14 PIN AMPHENOL: For attaching wire feeder
control cables to the RANGER 10-LX. (Includes
contactor closure circuit, remote control circuit,
wire feeder 115/42 volt power source.)

13. 6 PIN AMPHENOL: For attaching optional remote
control equipment to the RANGER 10-LX.
(Includes contactor closure circuit & remote con­trol circuit.)

14. VOLTMETER – Displays actual voltage at the out-
put terminals when welding in CV-mode.

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RANGER 10-LX

B-6 B-6

OPERATION

FIGURE B.2 – ENGINE CONTROLS

8

1. ENGINE GLOW PLUG PUSHBUTTON

2. IDLER CONTROL SWITCH

3. START PUSHBUTTON

4. ENGINE HOUR METER

5. BATTERY CHARGER LIGHT

6. OIL PRESSURE LIGHT

7. WATER TEMPERATURE LIGHT

8. FUEL LEVEL GAUGE

9. ENGINE ON-OFF SWITCH

DIESEL ENGINE CONTROLS

See Figure B.2 for the location of the following fea­tures:

1. GLOW PLUG PUSHBUTTON: Acti-
vates glow plugs to preheat engine for
starting.

2. IDLER CONTROL SWITCH: Adjusts the running
speed of the engine. The switch has two posi­tions, HIGH and AUTO. In HIGH, the
engine runs continuously at high idle.
In AUTO, the idler control works as fol­lows:

Stick Welding; Wire Feeder switch in
“NO CONTROL CABLE” position:
The engine accelerates to high speed when the
electrode touches the work and strikes a welding
arc. The engine returns to low idle approximately
10-14 seconds after welding stops, as long as no
auxiliary power is being drawn.

Wire Welding; Wire Feeder switch in “WITH CON­TROL CABLE” position: The engine accelerates to
high speed when the electrode touches the work­piece. The engine returns to low idle approxi­mately 10-14 seconds after the gun trigger is
released and the welding stops, provided that no
auxiliary power is being drawn.

Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacles for
lights or tools. The engine returns to low idle
approximately 10-14 seconds after demand for
auxiliary power stops.

4

2

1

9

3

7

6

5

3. START PUSHBUTTON: When the
pushbutton is held, the starter motor
cranks over the engine – release the
button once the engine starts.

NOTE: If you press the START pushbutton when
the engine is running, you may damage the ring
gear or starter motor.

4. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to perform
required maintenance.

5. BATTERY LIGHT: Is off when battery charging
system is functioning normally. If light turns on
while the engine is running, the fan belt may be
broken or the alternator or the voltage regulator
may be defective.

WARNING

MOVING PARTS can injure.

• Have qualified personnel do mainte­nanace and troubleshooting work.

• If possible, turn the engine off and
disconnect the battery before work­ing inside the machine.

• Remove guards only when necessary to perform
maintenance, and replace them when the mainte­nance requiring their removal is complete.

• If fan guards are missing from a machine, obtain
replacements from a Lincoln Distributor. (See Parts
List.)

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RANGER 10-LX

B-7 B-7

OPERATION

6. OIL PRESSURE LIGHT: Remains off
with proper oil pressure. If light turns
on, the engine protection system will
stop the engine. The light will go on
when the “Engine” switch is switched to the “ON”
position with engine not running. It will go off after
one minute if the engine is not started.

7. WATER TEMPERATURE LIGHT:
Remains off under normal operating
temperatures. If light turns on, the
engine protection system will stop the
engine. The light will remain on when the engine is
over temperature and the “Engine” switch is in the
“ON” position (engine not running).

WARNING

HOT COOLANT can burn skin.

• Do not remove cap if radiator is hot.

BEFORE STARTING THE ENGINE

Check and fill the engine oil level:

1. Be sure the machine is on a level
surface.

2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick. See Figure D.1 in the
Maintenance section of this manual.

3. Add oil (if necessary) to bring the level up to the
full mark. Do not overfill.

Replace the dipstick.

Check and fill the engine fuel tank:

WARNING

DIESEL fuel can cause fire or
explosion.

• Stop engine when fueling.

• Do not smoke when fueling.

8. FUEL LEVEL GAUGE: Displays the level of diesel
fuel in the 10-gallon fuel tank.

9. ENGINE ON-OFF SWITCH: Energizes the fuel
solenoid in the ON position. In the STOP position,
stops fuel flow to the injection pump and stops the
engine.

ENGINE OPERATION

WARNING

DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.
The maximum allowable high idle speed for the
RANGER 10-LX is 3750 RPM, no load. Do NOT adjust
the governor screw on the engine. Severe personal
injury and damage to the machine can result if it is
operated at speeds above the maximum rated speed.

Read and understand all safety instructions included
in the Kubota instruction manual that is shipped with
your RANGER 10-LX.

Refer to Pre-Operation Engine Service in the
Installation section of this manual.

• Remove cap slowly to release pressure.

• Do not overfill tank.

• Wipe up spilled fuel and allow fumes to clear before
starting engine.

• Keep sparks and flame away from tank.

1. Remove the fuel tank cap.

2. Fill the tank approximately 4 inches (100 mm) from

the top of the filler neck to allow for fuel expansion
(observe the fuel gauge). DO NOT FILL THE TANK
TO THE POINT OF OVERFLOW.

3. Replace the fuel tank cap and tighten securely.

NOTE: DO NOT allow the RANGER 10-LX to run out
of fuel. If it does, you will have to bleed the injection
system.

NOTE: USE DIESEL FUEL ONLY.
NOTE: Purchase diesel fuel in quantities that will be

used within 30 days, to assure freshness.

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RANGER 10-LX

B-8 B-8

OPERATION

STARTING THE ENGINE

NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.

1. Open the engine compartment door and check
that the fuel shutoff valve located above the clear
plastic fuel filter housing is in the open position
(lever in the vertical position). See Figure B.3.

2. Check for proper level of coolant in the plastic
reserve overflow tank. The level should be
between the full and the low marks.

3. Check for proper oil level on the oil dipstick. Close
engine compartment door.

4. Set “IDLER” switch to “AUTO”.

5. Set the “ENGINE” switch to “ON”. Observe that
both the oil pressure light and battery charger light
are on. Check the fuel gauge to make sure that
there is an adequate fuel level (NEVER ALLOW
THE RANGER 10-LX TO RUN OUT OF FUEL).

6. Press the “GLOW PLUG” button for 15
seconds (30 seconds if below 0°C/32°F)
and then press the “START BUTTON”.

7. Release both buttons when the engine
starts.

8. Check that the indicator lights are off. If not,
immediately stop the engine and investigate the
indicated problem.

9. Allow the engine to warm up at low idle speed for
several minutes before applying a load and/or
switching to high idle. Allow a longer warm up
time in cold weather.

NOTE: If the engine fails to start in 60 seconds or
stops running, the “ENGINE” switch must be switched
to “OFF” and then switched back to “ON” before
attempting to restart the engine. This resets the
engine protection circuit.

If the engine will not start, see the Trouble-
shooting section of this manual.

STOPPING THE ENGINE

1. Remove all welding and generator
power loads and let the engine cool by
running it for several minutes at low idle.

2. Stop the engine by placing the Engine Switch in
the OFF position. This turns off the fuel solenoid.
You can also stop the engine by turning off the fuel
valve located on the fuel filter housing.

BREAK-IN PERIOD

Any engine will use a small amount of oil during its
“break-in” period. For the diesel engine on the
RANGER 10-LX, break-in is about 50 running hours.

Check the oil every four hours during break-in.
Change the oil after the first 50 hours of operation,
every 100 hours thereafter. Change the oil filter at the
second oil change. For more details, see the
Maintenance section of this manual.

CAUTION

During break-in, subject the RANGER 10-LX to mod­erate loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow the
engine to cool several minutes.

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FIGURE B.3 – FUEL SHUTOFF VALVE

RANGER 10-LX

B-9 B-9

OPERATION

TABLE B.1

TYPICAL RANGER 10-LX FUEL CONSUMPTION

KUBOTA DH850-B-88

Low Idle – No Load, 2150 RPM .30 Gallons/hour (1.0 liters/hour)
High Idle – No Load, 3750 RPM .60 Gallons/hour (2.2 liters/hour)
AC CC Weld Output, 250 Amps @ 25 Volts 1.1 Gallons/hour (4.2 liters/hour)
DC CC Weld Output, 250 Amps @ 25 Volts 1.2 Gallons/hour (4.6 liters/hour)
DC CV Weld Output, 250 Amps @ 30 Volts .90 Gallons/hour (3.6 liters/hour)
Auxiliary Power, 10,000 kVA 1.3 Gallons/hour (4.9 liters/hour)

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RANGER 10-LX

B-10 B-10

OPERATION

WELDING OPERATION

GENERAL INFORMATION

WARNING

• Do not touch electrically live parts or elec­trodes with your skin or wet clothing.

• Do not breathe welding fumes or gases.

• Use ventilation or exhaust to remove
welding fumes from the breathing area.

• Keep flammable material away.

• Wear eye, ear, and body protection.

The RANGER 10-LX can deliver from 45 to 250 amps
of constant current for AC/DC stick welding or from 45
to 250 amps of constant voltage current for DC semi­automatic wire feed welding. AC/DC TIG welding is
possible across the entire range from 45 to to maxi­mum rated output. Output can be adjusted by setting
the POLARITY SWITCH, the OUTPUT RANGE dial,
and the FINE CONTROL dial on the output control
panel to the settings that are best for your selected
welding process.

To use the RANGER 10-LX for AC/DC
Constant Current Stick Welding:

1. Remove the flange nuts from output terminals and
place the work and electrode welding cables over
the terminals. See Figure B.4. Replace and tight­en the flange nuts securely. Be sure the connec­tions are tight.

2. Select the appropriate electrode. See “Welding
Tips 1” included with your RANGER 10-LX.

3. Attach the work clamp securely to the work you
are welding.

4. Insert the electrode into the electrode holder.

5. Set the IDLER CONTROL to AUTO and start the
diesel engine. See Engine Operation in this sec­tion of the manual.

6. Set the OUTPUT RANGE dial to a setting equal to
or slightly higher than the welding current recom­mended for the electrode being used.

7. Set the POLARITY SWITCH to the desired polarity.

8. Set the FINE OUTPUT CONTROL. Use a setting
that results in the highest output at the lowest set­ting of the RANGE switch for the application.

9. Strike an arc and begin welding.

After you finish welding:

1. Stop the diesel engine. See Engine Operation in
this section of the manual.

2. Allow the electrode and work to cool completely.

3. Remove the work clamp from the work.

4. Remove any remaining piece of electrode fr om the
electrode holder.

5. If you are finished using the RANGER 10-LX for
welding, disconnect the welding cables from the
weld output terminals. Reattach the flange nuts
and leave them on the terminals.

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FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING

1. OUTPUT CONTROL PANEL

2. ELECTRODE CABLE

3. ELECTRODE HOLDER

4. ELECTRODE

5. OUTPUT TERMINALS

6. WORK

7. WORK CLAMP

8. WORK CABLE

RANGER 10-LX

B-11 B-11

OPERATION

To Use the RANGER 10-LX for AC/DC TIG
(Constant Current) Welding:

1. Connect the K930-1 TIG Module to the RANGER
10-LX. Follow the installation instructions provid­ed with the kit. Also be sure to follow the special
machine grounding instructions given in the man­ual.

2. Refer to the instruction manual with the TIG mod­ule (IM 528) for operation with a RANGER 10-LX
and proper machine settings.

3. Set the OUTPUT RANGE dial to the appropriate
setting for the electrode you are using. Refer to
IM -528 with the TIG module or refer to Table B.2
for AC TIG welding.

4. Set the POLARITY SWITCH to the desired polarity.

5. Do not AC TIG weld on the 250 AC range setting.
The output current may exceed the rating of the
RANGER 10-LX.

6. Start the arc and begin welding.

NOTE: When using the RANGER 10-LX for AC TIG

welding of aluminum, the TIG Module is to be
set for CONTINUOUS HF.

After you finish welding:

1. Stop the diesel engine. See Engine Operation in
this section of the manual.

2. Allow the electrode and work to cool completely.

3. Remove the work clamp from the work.

TABLE B.2 - AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS

Settings for Pure Tungsten

Tungsten Diameter (inches) Range Switch Settings Appropriate Current Range

1/8 65, 90 or 120

(1)

100 - 200 Amps
3/32 45, 65 or 90 50 - 100 Amps
1/16 45, 65 or 90 45 - 150 Amps

Settings for 1% Thoriated Tungsten

Tungsten Diameter (inches) Range Switch Settings Appropriate Current Range

1/8 90, 120, or 160 160 - 250 Amps
3/32 45, 90, or 120 100 - 180 Amps
1/16 45 or 90 60 - 120 Amps

(1)

The welding current will be approximately 200 amps with the range switch set at 120 and the OUTPUT CON­TROL set at 10. Do not use a range setting higher than 120 for AC TIG welding.

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RANGER 10-LX

B-12 B-12

OPERATION

To Use the RANGER 10-LX for DC Wire
Feed Welding (Constant Voltage):

1. Connect one of the following: the LN-25, LN-7 or
LN-8 Wire Feeder. Follow the installation instruc­tions in the Accessories section of this manual.

2. Some recommended Innershield electrodes are:
NR-211MP, NR-311, NR-203 series, as well as
Lincore®33 and 55 hardfacing electrodes.
Diameters from .035 (0.9mm) up to and including
5/64” (2.0mm) can be used. 5/64” (2.0mm) NS­3M can be used in limited applications. Cable
length and other conditions can affect the ultimate
results of this application. Request Lincoln publi­cation N-675 for additional information.

Recommended Outershield electrodes are .045
(1.1 mm), .052 (1.3 mm), and 1/16 (1.6 mm)
Outershield 71 and 1/16 (1.6 mm) Outershield 70.
Request Lincoln publication GS-200 for additional
information.

For MIG welding, the recommended electrodes
are .030 (0.8 mm), .035 (0.9 mm) and .045
(1.1 mm) L-50 and L-56. You must use a blended
shielding gas such as C25 (75% Argon, 25% CO2).
Request Lincoln publication GS-100 for additional
information.

4. Set the OUTPUT RANGE dial to either HIGH,
MEDIUM HIGH, MEDIUM LOW, or LOW depend­ing on your wire size and speed.

5. Set the POLARITY SWITCH to either WIRE FEED
DC+ or WIRE FEED DC- (white), depending on the
electrode.

6. Set the FINE OUTPUT CONTROL to a setting that
gives the most stable arc for the application.

7. Strike an arc and begin welding.

After you finish welding:

1. Stop the engine. See Engine Operation in this
section of the manual.

2. Allow the work to cool completely. The wire gun
and wire are “cold.”

3. Remove the work clamp from the work.

3. Set the IDLER CONTROL to “AUTO” for the LN-25
“HIGH” for the LN-7 or LN-8 and start the diesel
engine. See Engine Operation in this section of
the manual.

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RANGER 10-LX

B-13 B-13

OPERATION

SUMMARY OF WELDING
PROCESSES AND MACHINE
SETTINGS

Table B.3 summarizes the requirements for various
welding processes you can perform with the
RANGER 10-LX.

TABLE B.3 - SUMMARY OF WELDING PROCESSES

Process Control Idle Output Wire Electrode To Start Welding

Cable Mode Control Feeder State When
Used Switch Switch Not Welding

Stick – CC No Auto At Welder No Hot Touch electrode to work.

Control Welding starts immed­Cable ately and engine goes to

high idle.

TIG - CC Yes Auto Remote With Cold Press Amptrol. Welding
K930-1/K936-1 Control starts immediately.
(With Amptrol) Cable

Wire Feed - CV, Yes Auto Remote With Cold Press gun trigger,
LN-25 with 42V Control RANGER 10-LX contactor
Remote Control Kit Cable closes. Welding starts

immediately and engine
goes to high idle.

Wire Feed - CV No Auto At Welder No Cold Press gun trigger, LN-25
LN-25 with internal Control contactor closes. Weld­contactor Cable ing starts immediately

and engine goes to high
idle.

Wire Feed - CV, Yes High Remote With Cold Press gun trigger,

LN-7 or LN-8 Control RANGER 10-LX contactor

Cable closes. Welding starts

immediately.

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RANGER 10-LX

B-14 B-14

OPERATION

AUXILIARY POWER

WARNING

Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a
±10% voltage and a ±3% frequency variation.

GENERAL INFORMATION

The RANGER 10-LX generator is rated at 10,000 con­tinuous watts. It provides both 115 volt and 230 volt
power . You can draw up to 87 amps total, but no more
than 20 amps (15 amps CSA) from each 115V recep­tacle at once. Up to 43.5 amps can be drawn from the
single 230 volt receptacle.

The current rating of any plug used must be at least
equal to the current load being drawn from the recep­tacle. Do not try to connect the receptacles in paral­lel.

Electrical loads in watts are calculated by multiplying
the voltage rating of the load by the number of amps it
draws. (This information is given on the load device
nameplate.) For example, a device rated 115 volts, 2
amps will need 230 watts of power (115 x 2 = 230).

You can use Table B.5, GENERATOR POWER APPLI­CATIONS, to determine the wattage requirements of
some common types of loads you can power with the
RANGER 10-LX. Be sure to read the notes at the bot­tom of the table.

Powering Motors

You can start most 1.5 HP, single-phase electric
motors if there is no load on the motor or other load
connected to the RANGER 10-LX. After starting, the
motor may be run at full load. Larger motors (up to 2
HP) may be started and run as long as you don’t
exceed the current rating of the receptacle. This may
mean that only 230 volt motors of this size may be
operated.

Using Auxiliary Power and Welding at the
Same Time

It is possible to weld and use the RANGER 10-LX for
auxiliary power at the same time. However, the size of
the loads you can power is reduced when you weld.
See Table B.4 in this section of the manual for a list of
permissible simultaneous welding and load ratings.
The table assumes that power is being drawn from
either a 115 volt or the 230 volt receptacle, but not
both at the same time.

NOTE: For simultaneous welding and power, set the
OUTPUT CONTROL at “10” for maximum auxiliary
power. At settings below “10,” only incandescent
loads should be connected to the auxiliary recepta­cles.

To use the generator as an auxiliary power supply:

1. Start the engine. See Engine Operation in this
section of the manual.

2. Set the IDLER CONTROL to the desired operating
mode, HIGH or AUTO. Set the OUTPUT CON­TROL to “10.” See Figure B.1.

3. Plug the load(s) into the appropriate 115 volt or
230 volt power receptacle.

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NOTE: The 115 volt auxillary power receptacles

should only be used with three-wire grounded
type plugs or approved double insulated
devices with two-wire plugs.

RANGER 10-LX

B-15 B-15

OPERATION

TABLE B.4 - SIMULTANEOUS WELDING AND AUXILIARY POWER

Output Selector Welding Permissible Power in Watts Permissible Auxiliary Current
Setting Output (Unity Power Factor) in Amperes

@ 115V @230V

250 250 None — —
200 200 3000 26 13

160 160 3500 30 15
120 120 5500 48 24

90 90 6500 56 28
65 65 7500 65 32.5
45 45 8500 74 37

CV Low 200 7000 60 30

40 9500 82 41

CV Medium Low 250 5500 48 24

60 8500 74 37

CV Medium High 250 3500 30 15

80 7000 60 30

CV High 250 1500 13 6.5

100 6000 52 26

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RANGER 10-LX

B-16 B-16

OPERATION

TABLE B.5

TYPICAL GENERATOR POWER APPLICATIONS

Suggested Power Applications Running Watts *Start-up Watts

*Air Compressor - 3/4 HP 1,250 3,100 - 5,000
*Airless Sprayer - 1/3 HP 600 1,500 - 2,400
Chain Saw 1,200
Circular Saw 1,200
Coffee Maker 1,000
*Deep Freezer 500 750 - 2,000
*Electric Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 100 or 125 Amp Wire Feeder/Welder 4,000

NOTES:

Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in the

table, multiply RUNNING WATTS by 2.
Multiple loads can be used as long as the total load does not exceed 10,000 watts. Be sure to start the

largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may
require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to
start.

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RANGER 10-LX

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES -

Accessories...........................................................................................................................Section C

Options/Accessories...................................................................................................................C-2

TIG Welding..........................................................................................................................C-3

Semiautomatic FCAW and MIG Welding.............................................................................C-3

Connection of Lincoln Electric Wire Feeders.......................................................................C-4

Connection of the K867 Universal Adapter...................................................................C-4

Connection of the LN-25 “Across the Arc”...................................................................C-5

Connection of the LN-7 Using the K584 Input Cable Assembly...................................C-6

Connection of the LN-7 Using the K867 Universal Adapter .........................................C-7

Connection of the LN-8 .................................................................................................C-8

Connection of the K488 SG Control Module and the K487 Magnum Spool Gun........C-9

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RANGER 10-LX

C-2 C-2

ACCESSORIES

OPTIONS/ACCESSORIES

The following options/accessories are available for
your RANGER 10-LX from your local Lincoln
Distributor.

Two-Wheel Trailer (K768) – For in-plant or yard tow­ing of the RANGER 10-LX. (Not intended for highway
towing as equipped. For highway use of this trailer,
consult applicable federal, state, and local laws about
possible requirements for brakes, lights, fenders, etc.)

Power Plug Kit (K802-N) – Provides four 20 amp, 115
volt plugs and one 50 amp, dual voltage (115/230V),
full kVA plug. NOTE: For CSA machines and
machines with GFCI receptacles, use Power Plug Kit
K802-R.)

Power Plug Kit (K802-R) –Provides four 15 amp, 115
volt plugs and one 50 amp, dual voltage (115/230V),
full kVA plug.

Accessory Kit (K702) – Includes the following:

• Thirty-five feet (10.5 meters) of #2 AWG electrode
cable

• Thirty feet (9.1 meters) of #2 AWG work cable

• Headshield with No. 12 filter.

• GC300 work clamp

• Cooltong®300 insulated electrode holder

The cables are rated at 250 amps, 40% duty cycle.

Spark Arrester Kit (K903-1) – A field-installed kit for
the RANGER 10-LX engine muffler exhaust pipe (either
engine option). Includes a heavy-gauge steel,
approved spark arrester, mounting clamp and adapter .

Remote Control (K857) – Includes a control box with
25 feet (7.5 meters) of 4-conductor cable. Allows out­put voltage to be controlled remotely.

GFCI Receptacle Kit (K896-1) – Includes two UL
approved 115 volt ground fault circuit interrupter
receptacles (duplex type) with covers and installation
instructions. Each receptacle is rated 15 amps, but
the maximum total current from each GFCI duplex is
limited to 20 amps. The GFCI receptacles replace the
two factory installed 115 volt duplex receptacles.

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RANGER 10-LX

C-3 C-3

ACCESSORIES

TIG WELDING
TIG Module (K930-1) - The TIG Module is an acces-

sory that provides high frequency and shielding gas
control for AC and DC GTAW (TIG) welding applica­tions. It provides contactor control of constant current
welding power sources having an internal contactor.

The K930-1 TIG Module is supplied without accessories.
Arc Start switches, Amptrols, cables, torches and
mounting brackets must be purchased separately.

Docking Kit (K939-1) - For mounting the K930-1 TIG
Module on top of the RANGER 10-LX.

Control Cable (K936-1) - Control cable for connecting
the K930-1 TIG Module to a RANGER 10-LX 9-Socket
(at the TIG Module) to 14-pin (at RANGER 10-LX).
(Contains circuits 2, 4, 31, 32, 75, 76, 77 and ground.)

Arc Start Switch (K814) - A remote start switch used
in conjunction with the K930-1 TIG Module to energize
the output terminals via the TIG Module.

K812 – Hand Amptrol.
K870 – Foot Amptrol.
NOTE: TIG welding requires a Magnum™ TIG Gun,

appropriate Magnum Parts Kit and argon gas.

SEMIAUTOMATIC FCAW AND MIG WELDING
LN-25 Wire Feeder – This portable unit provides

CC/CV for flux-cored arc welding (FCAW) and metal
inert gas welding (MIG).

LN-7 or LN-8 Wire Feeder – Semiautomatic, con­stant speed wire feeders.

NOTE: Gas-shielded welding requires a Magnum
Gun. Gasless welding requires an Innershield Gun.

Magnum Spool Gun (K487-25) – A lightweight, semi­automatic wire feeder for aluminum welding with
argon gas. Has built-in remote wire speed control in
the handle. Requires the K488 SG Control Module.
Includes 50 feet (15.2 meters) of power cable.

SG Control Module (K488) – Controls wire speed and
gas flow. Provides the required control interface
between the RANGER 10-LX and the K487-25
Magnum Spool Gun.

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RANGER 10-LX

C-4 C-4

ACCESSORIES

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

WARNING

ELECTRIC SHOCK can kill.

• Do not operate with panels open.

• Disconnect NEGATIVE (-) BATTERY
LEAD before servicing.

• Do not touch electrically live parts.

MOVING PARTS can injure.

• Keep guards in place.

• Keep away from moving parts.

• Only qualified personnel should install,
use or service this equipment.

CONNECTION OF THE RANGER 10-LX TO
WIRE FEEDERS USING K867 UNIVERSAL
ADAPTER (SEE FIGURE C.1)

NOTE: When you use the RANGER 10-LX with

non-Lincoln Electric wire feeders or with
certain earlier models of Lincoln wire feed­ers, you will require the K867 Univeral
Adapter. The following discussion and
connection diagram explain in general
how to make the proper connections.

1. Shut the welder off.

2. Connect the electrode cable from the wire feeder to
the “ELECTRODE” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.

NOTE: Welding cable must be sized for current

and duty cycle of application.

3. Connect the K867 Universal Adapter to the 14 pin
amphenol of the RANGER 10-LX as shown in
Figure C.1. Make the proper connections for local
or remote control according to Figure C.1 and the
following NOTES, indicated on the figure:

A. These leads are not used for the RANGER

10-LX. Insulate each unused lead individually.

B. For wire feeders

that return a signal
for welding output,
use an isolation relay to close leads 2 and 4.

C. Refer to the Operation section of this manual

for maximum auxiliary current draw.

4. Set the welder “polarity” switch to the desired
polarity, either DC (-) or DC (+).

5. Set the “RANGE” switch to the “WIRE FEED” posi­tion.

6. Place the “IDLER” switch in the “HIGH” position.

CAUTION

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set­ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.

FIGURE C.1 – RANGER 10-LX/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM

14 PIN
AMPHENOL

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A

B

C

RANGER 10-LX

C-5 C-5

ACCESSORIES

7. Place the WIRE FEEDER switch in the “WITH CON­TROL CABLE” position.

8. Adjust wire feed speed at the wire feeder and set
the welding voltage with the output “CONTROL” to
a CV (constant voltage) position at the welder.

NOTE: If optional remote control is used, place

the output control switch in the “CON­TROL REMOTE” position.

CONNECTION OF THE LN-25 TO THE
RANGER 10-LX “ACROSS THE ARC”
(SEE FIGURE C.2.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the
“ELECTRODE” terminal of the welder. Connect the
work cable to the “TO WORK” terminal of the
welder.

NOTE: Welding cable must be sized for current

and duty cycle of application.

3. Set the welder “polarity” switch to the desired
polarity, either DC (-) or DC (+).

6. Place the “IDLER” switch in the “AUTO” position.

7. Place the WIRE FEEDER switch in the “NO CON­TROL CABLE” position.

8. Adjust wire feed speed at the LN-25 and adjust the
welding voltage with the output “CONTROL” at the
welder.

NOTE: If optional remote control is used, place

the output control switch in the “CON­TROL REMOTE” position.

4. Set the “RANGE” switch to the “WIRE FEED” posi­tion.

5. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead. This is only a control lead — it carries no
welding current.

FIGURE C.2 – RANGER 10-LX/LN-25 ACROSS THE ARC CONNECTION DIAGRAM

K857

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RANGER 10-LX

C-6 C-6

ACCESSORIES

CONNECTION OF THE LN-7 TO THE
RANGER 10-LX USING K584 INPUT
CABLE ASSEMBLY (SEE FIGURE C.3.)

NOTE: If your LN-7 comes equipped with a K291 or

K404 Input cable, refer to Connection of the
LN-7 Using K867 Universal Adapter, rather
than this discussion, to connect your
RANGER 10-LX for wire feed welding.

1. Shut the welder off.

2. Connect the electrode cable from the K584-XX
Input Cable Assembly to the “ELECTRODE” termi­nal of the welder and to the LN-7 wire feeder.
Connect the work cable to the “TO WORK” termi­nal of the welder.

NOTE: Welding cable must be sized for current and

duty cycle of application.

3. Connect the input cable from the K584-XX Input
Cable Assembly to the 14 pin amphenol on the
RANGER 10-LX and the input cable plug on the
LN-7.

4. Set the welder “polarity” switch to the desired
polarity, either DC (-) or DC (+).

CAUTION

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set­ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.

7. Place the WIRE FEEDER switch in the “WITH CON­TROL CABLE” position.

8. Adjust wire feed speed at the LN-7 and set the
welding voltage with the output “CONTROL” at a
CV (constant voltage) position at the welder.

NOTE: If optional remote control is used, place the

output control switch in the “CONTROL
REMOTE” position.

5. Set the “RANGE” switch to the “WIRE FEED” posi­tion.

6. Place the “IDLER” switch in the “HIGH” position.

FIGURE C.3

RANGER 10-LX/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

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RANGER 10-LX

C-7 C-7

ACCESSORIES

CONNECTION OF THE LN-7 TO THE
RANGER 10-LX USING K867 UNIVERSAL
ADAPTER (SEE FIGURE C.4.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-7 to the
“ELECTRODE” terminal of the welder. Connect the
work cable to the “TO WORK” terminal of the
welder.

NOTE: Welding cable must be sized for current and

duty cycle of application.

3. Connect the K867 Universal Adapter to the LN-7
wire feeder and the 14 pin amphenol of the
RANGER 10-LX as indicated in Figure C.4. Make
the proper connections for local or remote control
according Figure C.4 and the following NOTES,
indicated on the figure.

4. Set the welder “polarity” switch to the desired
polarity, either DC (-) or DC (+).

5. Set the “RANGE” switch to the “WIRE FEED” posi­tion.

6. Place the “IDLER” switch in the “HIGH” position.

CAUTION

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set­ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.

7. Place the WIRE FEEDER switch in the “WITH CON­TROL CABLE” position.

8. Adjust wire feed speed at the LN-7 and set the
welding voltage with the output “CONTROL” to a
CV (constant voltage) position at the welder.

NOTE: If optional remote control is used, place the

output control switch in the “CONTROL
REMOTE” position.

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FIGURE C.4

RANGER 10-LX/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM

Insulate each unused lead

A

individually.

B

Splice the leads and insulate.

RANGER 10-LX

C-8 C-8

ACCESSORIES

CONNECTION OF THE LN-8 TO THE
RANGER 10-LX (SEE FIGURE C.5.)

CAUTION

1. Shut the welder off.

2. Connect the electrode cable from the LN-8 to the
“ELECTRODE” terminal of the welder. Connect the
work cable to the “TO WORK” terminal of the
welder.

NOTE: Welding cable must be sized for current and

duty cycle of application.

3. Connect the K867 Universal adapter to the LN-8
wire feeder and the 14 pin amphenol of the
RANGER 10-LX as indicated in Figure C.5. Make
the proper connections for local or remote control
according to Figure C.5 and the following NOTES,
indicated on the figure.

NOTE: If K595 control cable assembly is available,

K867 universal adapter is not required.

4. Set the welder “polarity” switch to the desired
polarity, either DC (-) or DC (+).

5. Set the “RANGE” switch to the “WIRE FEED” posi­tion.

6. Place the “IDLER” switch in the “˙HIGH” position.

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set­ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.

7. Place the WIRE FEEDER switch in the “WITH CON­TROL CABLE” position.

8. Adjust wire feed speed at the LN-8 and set the
welding voltage with the output “CONTROL” to a
CV (constant voltage) position at the welder.

NOTE: If optional remote control is used, place the

output control switch in the “CONTROL
REMOTE” position.

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FIGURE C.5

RANGER 10-LX/LN-8 CONNECTION DIAGRAM

Insulate each unused lead

A

individually.

B

Splice the leads and insulate.

RANGER 10-LX

C-9 C-9

ACCESSORIES

CONNECTION OF THE K488 SG CON­TROL MODULE AND K487 MAGNUM
SPOOL GUN TO THE RANGER 10-LX
(SEE FIGURE C6.)

1. Shut the welder off.

2. Connect the electrode cable from the SG Control
Module to the “ELECTRODE” terminal of the
welder . Connect the work cable to the “TO WORK”
terminal of the welder.

NOTE: Welding cable must be sized for current and

duty cycle of application.

3. Connect the K691-10 Input Cable to the SG
Control Module and the 14 pin amphenol of the
RANGER 10-LX as indicated in Figure C.6.

4. Set the slide switch on the SG Control Module to
the “Lincoln” position.

CAUTION

Be sure this switch is set to the “Lincoln” (contact clo­sure) position before attempting to operate the SG
Control Module. Incorrect switch position could result
in damage to the SG Control Module and/or the
RANGER 10-LX.

5. Set the welder “polarity” switch to the desired
polarity, either DC (-) or DC (+).

6. Set the “RANGE” switch to the “WIRE FEED” posi­tion.

7. Place the “IDLER” switch in the “HIGH” position.

CAUTION

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor set­ting is preset at the factory — do not adjust above
RPM specifications listed in this manual.

8. Place the WIRE FEEDER switch in the “WITH CON­TROL CABLE” position.

9. Adjust wire feed speed at the SG Control Module
and set the welding voltage with the output “CON­TROL” to a CV (constant voltage) position at the
welder.

NOTE: If optional remote control is used, place the

output control switch in the “CONTROL
REMOTE” position.

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RANGER 10LX/K691-10/K488/K487 SPOOL GUN CONNECTION DIAGRAM

115VRECEPTACLE

14 PIN WIRE FEEDER
RECEPTACLE

ELECTRODE

TO WORK

TO WORK

6 PIN REMOTE
RECEPTACLE

ELECTRODE CABLE
TO CONTROL MODULE

FIGURE C.6

RANGER 10-LX

K488 SG
CONTROL MODULE

K691-10
INPUT CABLE

K487-25
SPOOL GUN

Section D-1 Section D-1

TABLE OF CONTENTS

-MAINTENANCE-

Maintenance .........................................................................................................................Section D

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance ............................................................................................D-2

Engine Maintenance.............................................................................................................D-2

Change the Oil...............................................................................................................D-2

Change the Oil Filter......................................................................................................D-3

Fuel.................................................................................................................................D-3

Fuel Filter........................................................................................................................D-3

Bleeding the Fuel System..............................................................................................D-4

Air Cleaner......................................................................................................................D-5

Tightening the Fan Belt ..................................................................................................D-5

Checking/Adding/Draining Radiator Coolant.................................................................D-6

Clean Spark Arrester Screen .........................................................................................D-6

Engine Maintenance Schedule ......................................................................................D-7

Battery Maintenance............................................................................................................D-8

Cleaning the Battery ......................................................................................................D-8

Checking Electrolyte Level.............................................................................................D-8

Charging the Battery......................................................................................................D-8

Welder/Generator Maintenance...........................................................................................D-8

Storage...........................................................................................................................D-8

Cleaning.........................................................................................................................D-8

Brush Removal and Replacement.................................................................................D-8

Receptacles ...................................................................................................................D-9

Cable Connections.........................................................................................................D-9

Major Component Locations .............................................................................................D-10

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RANGER 10-LX

D-2 D-2

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance and
troubleshooting work.

• Turn the engine off before working inside the
machine.

• Remove covers or guards only when necessary to
perform maintenance and replace them when the
maintenance requiring their removal is complete.

• If covers or guards are missing from the machine,
get replacements from a Lincoln Distributor. See
the Parts List at the back of this manual.

Read the Safety Precautions in the front of this manu­al and in the instruction manual for the Kubota diesel
engine used with your machine before working on the
RANGER 10-LX.

Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep your hands, hair,
clothing, and tools away from the fans, and all other
moving parts when starting, operating, or repairing this
machine.

OIL: Check the oil level before starting
engine or daily. BE SURE TO MAIN-

TAIN THE OIL LEVEL. Change the oil
the first time after 50 hours of operation. Then, under
normal operating conditions, change the oil as speci­fied in Table D.1. If the engine is operated under
heavy load or in high ambient temperatures, change
the oil more frequently.

CHANGE THE OIL

Change the oil, while the engine is still warm, as fol­lows:

1. Drain the oil from the drain plug located on the

engine bottom, as shown in Figure D.1.

2. Replace the plug and tighten it securely.

3. Remove the oil fill cap and add oil until the level

reaches the full mark on the dipstick. Use high
quality detergent oil of API service class
CC/CD/CE, oil viscosity grade 10W30. Always
check the level with the dipstick before adding
more oil.

4. Reinstall the oil fill cap and the dipstick.

ROUTINE AND PERIODIC
MAINTENANCE

ENGINE MAINTENANCE

CAUTION

To prevent the engine from accidentally starting, dis­connect the positive battery cable before servicing the
engine.

See Table D.1 for a summary of maintenance intervals
for the items listed below. Follow either the hourly or
the calendar intervals, whichever come first. More fre­quent service may be required, depending on your
specific application and operating conditions.

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RANGER 10-LX

D-3 D-3

MAINTENANCE

FIGURE D.1 – OIL DRAIN AND REFILL LOCATION

4

1

3

2

1. DIPSTICK

2. OIL DRAIN PLUG

CHANGE THE OIL FILTER

Change the oil filter the first time after 50 hours of
operation. Then, under normal operating conditions,
change the oil filter after every 200 hours of operation.
If the engine is operated under heavy load or in high
ambient temperatures, change the oil filter more fre­quently. See Table D.1 for recommended mainte-
nance intervals.

Change the oil filter as follows:

1. Drain the oil from the engine and allow the oil filter
to drain.

2. Remove the old filter (spin it off) and discard it.
Wipe off the filter mounting surface and adapter.

3. Apply a thin coat of new oil to the rubber gasket on
the new oil filter.

4. Spin the new filter onto the mounting adapter until
the gasket just touches the mounting surface, then
turn it down another 1/2 to 3/4 turn. Do not over­tighten the new filter.

5. Refill the engine with the proper amount and type of
oil as described in the Change the Oil section,
above. Start the engine and check for leaks around
the filter element. Correct any leaks (usually by
retightening the filter, but only enough to stop leaks)
before placing the RANGER 10-LX back in service.

3. OIL FILTER

4. OIL FILL CAP

6. If there are no leaks, stop the engine and recheck
the oil level. If necessary, add oil to bring the level
up to the FULL mark, but do not overfill.

FUEL: At the end of each day’s use, refill the
fuel tank to minimize moisture condensation
and dirt contamination in the fuel line. Do
not overfill; leave room for the fuel to
expand.

Use only fresh, No.2 grade DIESEL fuel oil. Do not use
kerosene.

FUEL FILTER: Clean the fuel filter every 100 hours of
operation. Be sure to clean the fuel filter regularly.
Dust and dirt in the fuel system can cause the injection
pump and injection nozzle to wear quickly. Clean the
fuel filter as follows (See Figure D.2.):

1. Close the fuel filter cock.

2. Loosen the ring screw on the top of the filter pot,
remove the pot and remove the element from inside
the pot. Clean the inside of the pot with clean
diesel fuel.

3. Rinse the element with clean diesel fuel.

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RANGER 10-LX

D-4 D-4

MAINTENANCE

FIGURE D.2 – FUEL FILTER

5

1. COCK - CLOSED

2. COCK - OPEN POSITION

3. RING SCREW

4. FILTER POT (ELEMENT INSIDE)

5. VENT PLUGS

1

3

2

4

4. Carefully place the element back into the fuel pot.
Be careful not to allow any dirt to stick to the ele­ment.

5. Reassemble the filter pot and tighten the ring screw
at the top.

6. Open the fuel cock and loosen the two air vent
plugs a few turns. When bubbles no longer appear
around the plugs, screw them back in.

7. Bleed the fuel injection pump. (See the next sec­tion.)

BLEEDING THE FUEL SYSTEM: You will need to
bleed air from the fuel system any time the fuel filter or
fuel lines have been detached and refitted; after the
fuel tank has been run out of fuel; or before using the
engine after long storage. Bleed the fuel system as
follows:

CAUTION

To avoid personal injury, do not bleed a hot engine.
This could cause fuel to spill onto a hot exhaust man­ifold, creating a danger of fire.

1. Fill the fuel tank. Open the fuel cock.

2. Loosen the fuel filter air vent plugs a few turns. See
Figure D.2. When bubbles no longer appear, tight­en the plugs.

3. Open the air vent cock on the top of the fuel injec­tion pump. See Figure D.3.

4. Move the fuel feed pump lever by hand.

5. When bubbles no longer appear around the air vent
cock on the injection pump, close the cock.

NOTE: Always keep the air vent cock on the fuel
injection pump closed except when air is vented.
Opening the air vent cock may cause the engine to
stop.

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RANGER 10-LX

D-5 D-5

MAINTENANCE

FIGURE D.3 – FUEL SYSTEM BLEEDING

1. AIR VENT COCK

2. FUEL FEED
PUMP LEVER

1

2

AIR CLEANER: The Kubota diesel engine is equipped
with a dry type air filter. Never apply oil to it. Service
the air cleaner as follows:

1. Remove the dust cup from the bottom of the air
cleaner housing. Clean out any accumulated dust.

2. If dust is sticking to the element, blow compressed
air through the element from the inside out. Turn
the element as you apply air. Air pressure should
be under 686 kPa (7 kgf/cm2, 99 psi).

3. If carbon or oil sticks to the element, soak it in
detergent for 15 minutes. Then wash the element
in water, rinse it with clean water and let it air dry.
Check the element for damage before reassem­bling the air cleaner.

4. Replace the element at least every year or every six
cleanings.

TIGHTENING THE FAN BELT: If the fan belt is loose,
the engine can overheat and the battery lose its
charge. Check tightness by pressing on the belt mid­way between the pulleys. It should deflect about 7 to
9 mm (0.28 to 0.35 in.) under a load of 10 kgf (22.1
lbs.).

Refer to the Kubota Operator’s Manual for the adjust­ment procedure.

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RANGER 10-LX

D-6 D-6

MAINTENANCE

FIGURE D.4 – COOLING SYSTEM

RADIATOR CAP

RESERVE TANK

CHECKING/ADDING/DRAINING RADIATOR COOL­ANT: Check the level of coolant in the reserve tank.

The level is sufficient if it is between the “FULL” and
the “LOW” marks. If the level is below the “LOW”
mark, add fresh, water/antifreeze mixture to the
“FULL” mark. Check the two drain cocks for tightness
(one at the bottom side of the radiator, one on the side
of the engine). See Figure D.4.

WARNING

To avoid personal injury, never remove the radiator
pressure cap nor the reserve tank cap while the engine
is running under heavy load or immediately after it has
stopped. Hot water may gush out, which can scald
people nearby.

To drain the cooling system, open both the radiator
and the engine drain cocks (Figure D.4). Also open the
radiator cap. Tighten both cocks and refill the radiator
with fresh coolant. A 50/50 antifreeze/water solution
should be used year round.

RADIATOR DRAIN COCK

CLEAN SPARK ARRESTER SCREEN: If the muffler
has the optional spark arrester, remove it every 50
hours or once a year, whichever comes first, and
inspect it. Clean the arrester. Replace it if you find any
damage.

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RANGER 10-LX

D-7 D-7

MAINTENANCE

TABLE D.1

KUBOTA ENGINE MAINTENANCE SCHEDULE

FREQUENCY MAINTENANCE REQUIRED
Daily or Before

Starting Engine • Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose, or damaged parts.

• Check air intake and cooling areas, clean as necessary.

Every 50 Hours • Check fuel lines and clamps.
Every 100 Hours • Clean air filter element.

• Clean fuel filter.

• Change engine oil.

• Check battery electrolyte level.

• Check fan belt tightness.

Every 200 Hours • Check radiator hoses.

• Replace oil filter cartridge.

Every 400 Hours • Replace fuel filter element.

Refer to your Kubota engine Owner’s Manual for periodic maintenance at 500 hours and beyond.

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RANGER 10-LX

D-8 D-8

MAINTENANCE

BATTERY MAINTENANCE

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame, and cigarettes
away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - Disconnect the
negative cable from the old battery first and connect
to the new battery last.

• CONNECTING A BATTERY CHARGER ­Remove the battery from the welder by
disconnecting the negative cable first,
then the positive cable and battery
clamp. When reinstalling, connect the
negative cable last. Keep the area well
ventilated.

• USING A BOOSTER - Connect the positive lead to
the battery first, then connect the negative lead to
the engine foot.

CHECKING ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is
low, check for leaks.

The battery is a group 45, 495 amps cold cranking.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect
battery cables to the battery, be sure the polarity is
correct. Improper polarity can damage the charging
circuit. The RANGER 10-LX positive (+) battery termi­nal has a red terminal cover.

If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.

Follow the instructions of the battery charger manu­facturer for proper charger settings and charging time.

BATTERY ACID CAN BURN EYES AND
SKIN.

• Wear gloves and eye protection and be
careful when working near a battery.
Follow the instructions printed on the
battery.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon­nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.113 kg)
of baking soda and 1 quart (0.946 l) of water. Be sure
the battery vent plugs (if equipped) are tight so that
none of the solution enters the cells.

After cleaning, flush the outside of the battery , the bat­tery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petrole­um jelly or a non-conductive grease to retard corro­sion.

Keep the battery clean and dry. Moisture accumula­tion on the battery can lead to more rapid discharge
and early battery failure.

WELDER/GENERATOR
MAINTENANCE

STORAGE: Store the RANGER 10-LX in clean, dry,

protected areas.
CLEANING: Blow out the generator and controls peri-

odically with low pressure air. Do this at least once a
week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: It’s normal
for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over­haul is necessary. Remove the brushes and clean the
slip rings with fine emery paper. Refer to the “Brush
Removal and Replacement” procedure in the Trouble-
shooting and Repair section of this manual.

CAUTION

Do not attempt to polish slip rings while the engine is
running.

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RANGER 10-LX

D-9 D-9

MAINTENANCE

To reinstall the brushes, press them upward and slide
a cable tie or wooden stick through the brush holder
tabs. See Figure D.5. Install the brush holder into
position and secure with the screws previously
removed. Remove the cable tie or wooden stick and
the brushes will seat onto the slip rings.

FIGURE D.5 - BRUSH REMOVAL AND REPLACEMENT

RECEPTACLES: Keep the electrical receptacles in

good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.

CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always tight.

1. BRUSHES

2. CABLE TIE

3. RETAINER CLIP

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RANGER 10-LX

D-10 D-10

MAINTENANCE

FIGURE D.6 - MAJOR COMPONENT LOCATIONS

1. OUTPUT TERMINALS (LOCATION)

2. ENGINE CONTROLS (on Control Panel)

3. AUXILIARY POWER RECEPTACLES

4. OUTPUT CONTROL PANEL

5. REACTOR ASSEMBLY

6. FUEL TANK

7. DIESEL ENGINE

8. ROTOR/STATOR ASSEMBLY

9. BATTERY (not shown)

10. BASE WELDED ASSEMBLY

6

11. P.C. BOARD COVER

12. CAPACITOR BANK

13. RADIATOR ASSEMBLY

14. CHOKE ASSEMBLY

15. LIFT BAIL WELDED ASSEMBLY

16. CASE BACK ASSEMBLY

17. FIELD CAPACITOR

18. RECTIFIER BRIDGE (on fuel tank rail)

19. CONTACTOR

20. SHUTOFF & IDLER ASSEMBLY

20

7

11

8

19

16

15

13

5

3

14

10

17

12

4

1

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RANGER 10-LX

5/96

Section E-1 Section E-1

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

Theory of Operation .............................................................................................................Section E

Battery, Starter, Engine, Glow Plugs, Engine Protection, Rotor, Stator, and

Idler Solenoid.........................................................................................................................E-2

Rotor Field Feedback, Auxiliary and Wire Feeder Power .....................................................E-3

Weld Winding, Reactor, and Range Switch...........................................................................E-4

Output Bridge, Choke, Polarity Switch, CV Contactor, and Output Terminals .....................E-5

RANGE

SWITCH

ENGINE

PROTECTION

RELAY

BY-PASS

BOARD

SHUTDOWN

SOLENOID

STARTER

MOTOR

CONTACTOR CLOSURE

GLOW PLUGS

ALTERNATOR

BATTERY

ENGINE

REGULATOR

IDLER

SOLENOID

REACTOR

MECHANICAL

ROTATION

ROTOR

SLIP

RINGS

PRINTED
CIRCUIT
BOARD

BRIDGE

FIELD

CAPACITOR

STATOR

ROTOR

FIELD

AC

AC

OUTPUT

RECTIFIER

BRIDGE

PART OF

RANGE

SWITCH

CAPACITORS

115 & 230VAC
RECEPTACLES

CHOKE

CONTACTOR CLOSURE

SWITCH

POLARITY

cv

output

contactor

WORK

TERMINAL

ELECTRODE

TERMINAL

OUTPUT

6 PIN

AMPHENOL

14 PIN

AMPHENOL

CONTROL

42VAC

115VAC

REMOTE
SWITCH

FIGURE E.1 – RANGER 10-LX BLOCK LOGIC DIAGRAM

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E-2 E-2

THEORY OF OPERATION

FIGURE E.2 – BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION,

ROTOR, STATOR AND IDLER SOLENOID

RANGE

SWITCH

6 PIN

AMPHENOL

14 PIN

AMPHENOL

ENGINE

PROTECTION

RELAY

BY-PASS

BOARD

SHUTDOWN

SOLENOID

CONTACTOR CLOSURE

OUTPUT

CONTROL

42VAC

115VAC

STARTER

MOTOR

GLOW PLUGS

ALTERNATOR

BATTERY

REMOTE
SWITCH

ENGINE

REGULATOR

IDLER

SOLENOID

REACTOR

MECHANICAL

ROTATION

ROTOR

SLIP

RINGS

PRINTED
CIRCUIT
BOARD

BRIDGE

FIELD

CAPACITOR

STATOR

ROTOR

FIELD

AC

AC

OUTPUT

RECTIFIER

BRIDGE

PART OF

RANGE

SWITCH

CAPACITORS

115 & 230VAC
RECEPTACLES

CHOKE

CONTACTOR CLOSURE

SWITCH

POLARITY

cv

output

contactor

WORK

TERMINAL

ELECTRODE

TERMINAL

BATTERY, STARTER, ENGINE,
GLOW PLUGS, ENGINE
PROTECTION, ROTOR, STATOR
AND IDLER SOLENOID

The 12VDC battery powers the starter motor and glow
plugs. The glow plugs are used to preheat the diesel
engine to enhance starting., 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 configuration.
This excitation (“flashing”) voltage magnetizes the
rotor lamination. The rotor is mechanically coupled to
the engine. This rotating magnet induces a voltage in
the stationary windings of the main alternator (stator).,
There are four separate and isolated windings incorpo­rated in the stator lamination assembly. Each set has
a different number of turns producing different magni­tudes of AC output voltages. These four windings are
the weld winding, the auxiliary power winding, the field
feedback winding and the auxiliary power winding for

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wire feeders. The field feedback winding provides
rotor current during machine operation. The output of
the Ranger 10-LX is dependent on two criteria, the
engine RPM and the amount of current in the rotor
winding.

The engine alternator and regulator supply “charging”
current for the battery circuit., The battery circuit pro­vides power for the printed circuit board and also for
the idler solenoid. The idler solenoid is mechanically
connected to the engine’s throttle linkage. If no weld­ing or auxiliary current is being drawn from the Ranger
10-LX the printed circuit board activates the idler sole­noid, which then brings the engine to a low idle state.
When output current is sensed, either weld or auxiliary,
the printed circuit board deactivates the idler solenoid,
and the engine returns to high RPM.

The engine protection circuit shuts the engine off in the
event of low oil pressure or over temperature of engine
coolant.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGER 10-LX

E-3 E-3

THEORY OF OPERATION

FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER

RANGE

SWITCH

6 PIN

AMPHENOL

14 PIN

AMPHENOL

ENGINE

PROTECTION

RELAY

BY-PASS

BOARD

SHUTDOWN

SOLENOID

CONTROL CLOSURE

CONTACTOR CLOSURE

OUTPUT

CONTROL

42VAC

115VAC

STARTER

MOTOR

GLOW PLUGS

ALTERNATOR

BATTERY

REMOTE
SWITCH

ENGINE

REGULATOR

IDLER

SOLENOID

REACTOR

MECHANICAL

ROTATION

ROTOR

SLIP

RINGS

PRINTED
CIRCUIT
BOARD

FIELD

CAPACITOR

FIELD

BRIDGE

STATOR

ROTOR

AC

AC

OUTPUT

RECTIFIER

BRIDGE

PART OF

SWITCH

CAPACITORS

115 & 230VAC

RECEPTACLES

CHOKE

RANGE

CONTACTOR CLOSURE

SWITCH

POLARITY

cv

output

contactor

WORK

TERMINAL

ELECTRODE

TERMINAL

ROTOR FIELD FEEDBACK,
AUXILIARY, AND WIRE FEEDER
POWER

The AC voltage developed in the field winding is fed to
the full wave field bridge. The DC output of the field
bridge is filtered by the field capacitor and controlled
by the printed circuit board according to the output or
remote control setting. This filtered and controlled
voltage is fed to the rotor winding via the brush and
slip ring configuration. As the feedback voltage is
increased or decreased, the outputs of the weld and
auxiliary windings are increased or decreased.

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When full field voltage is applied to the rotor and the
engine is running at high speed (3700 RPM), a 230AC
voltage is developed in the stator auxiliary winding.
This winding is tapped to provide 115 VAC. The two
voltages (115VAC and 230VAC), are connected to the
appropriate receptacles and offer 10,000 watts (total)
of AC power.

The auxiliary wire feeder winding offers 115VAC and is
tapped to also provide 42VAC. The current draw from
this winding should be limited to 8 amps. These volt­ages and remote control signals are fed through the
bypass (filter) board to the amphenol receptacles.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGER 10-LX

E-4 E-4

THEORY OF OPERATION

FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH

RANGE

SWITCH

6 PIN

AMPHENOL

14 PIN

AMPHENOL

ENGINE

PROTECTION

RELAY

BY-PASS

BOARD

SHUTDOWN

SOLENOID

CONTACTOR CLOSURE

OUTPUT

CONTROL

42VAC

115VAC

STARTER

MOTOR

GLOW PLUGS

ALTERNATOR

BATTERY

REMOTE
SWITCH

ENGINE

REGULATOR

IDLER

SOLENOID

REACTOR

MECHANICAL

ROTATION

ROTOR

SLIP

RINGS

PRINTED
CIRCUIT
BOARD

BRIDGE

FIELD

CAPACITOR

STATOR

ROTOR

FIELD

AC

AC

OUTPUT

RECTIFIER

BRIDGE

PART OF

RANGE

SWITCH

CAPACITORS

115 & 230VAC
RECEPTACLES

CHOKE

CONTACTOR CLOSURE

SWITCH

POLARITY

cv

output

contactor

WORK

TERMINAL

ELECTRODE

TERMINAL

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. The reactor coil is
tapped at various points. As the range switch is ro­tated, different amounts of reactor coil ar e brought into
the current path. As more turns of reactor are brought
into the circuit, the more impedance there is to current
flow. Simply stated, the mor e r eactor in the circuit, the
lower the welding current.

If a constant voltage is desired for wire feeding, then
the reactor is bypassed and the range switch is con­nected to one of four taps on the stator weld winding
to provide a lower but “stiffer” output voltage.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGER 10-LX

E-5 E-5

THEORY OF OPERATION

FIGURE E.5 – OUTPUT BRIDGE, CAPACITOR, CHOKE, POLARITY SWITCH, CV CONTACTOR AND

OUTPUT TERMINALS

RANGE

SWITCH

6 PIN

AMPHENOL

14 PIN

AMPHENOL

ENGINE

PROTECTION

RELAY

BY-PASS
BOARD

SHUTDOWN

SOLENOID

CONTACTOR CLOSURE

OUTPUT

CONTROL

42VAC

115VAC

STARTER

MOTOR

GLOW PLUGS

ALTERNATOR

BATTERY

REMOTE

SWITCH

ENGINE

REGULATOR

IDLER

SOLENOID

REACTOR

MECHANICAL

ROTATION

ROTOR

SLIP

RINGS

PRINTED
CIRCUIT
BOARD

BRIDGE

FIELD

CAPACITOR

STATOR

ROTOR

FIELD

AC

AC

OUTPUT

RECTIFIER

BRIDGE

PART OF

SWITCH

CAPACITORS

115 & 230VAC

RECEPTACLES

CHOKE

RANGE

CONTACTOR CLOSURE

SWITCH

POLARITY

cv

output

contactor

WORK

TERMINAL

ELECTRODE

TERMINAL

OUTPUT BRIDGE, CHOKE,
POLARITY SWITCH, CV
CONTACTOR 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. Depending
upon the setting of the polarity switch, either AC volt­age or DC voltage is delivered to the output terminals.
If AC output is selected, then the current path is from
the stator weld winding through the reactor, range
switch, and polarity switch to the output terminals. If
a DC output is called for, then the current path is
through the output rectifier bridge, where the AC volt­age is rectified to a DC voltage, and then to the choke,
where the DC output is filtered. The filtered DC current
path is through the polarity switch to the output termi­nals.

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When a CV (constant voltage) is desired, the reactor is
passed by. The range switch applies a lower AC volt­age to the rectifier bridge. The DC output of the bridge
is filtered and “stiffened” by the capacitors. This lower
but “stiffer” DC output is passed through the choke,
polarity switch, and CV output contactor to the output
terminals. The CV output contactor provides for an
electrically “cold” electrode when in the constant volt­age mode.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGER 10-LX

Section F-1 Section F-1

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section.................................................................................Section F

How to Use Troubleshooting Guide ......................................................................................F-2

PC Board Troubleshooting Procedures.................................................................................F-3

Troubleshooting Guide.................................................................................................F4 - F-20

Test Procedures

Rotor Voltage Test.........................................................................................................F-21

Rotor Resistance Test ...................................................................................................F-23

Auxiliary and Field Winding Test ...................................................................................F-25

Output Rectifier Bridge Test..........................................................................................F-29

Charging Circuit Test.....................................................................................................F-31

Protection Relay (CR1) Test ..........................................................................................F-33

Engine Throttle Adjustment Test...................................................................................F-35

Oscilloscope Waveforms.....................................................................................................F-39

Normal Open Circuit Voltage Waveform (115 VAC Supply)..........................................F-39

Typical DC Weld Output Waveform (CV Mode) – Machine Loaded..............................F-40

Typical DC Weld Output Waveform – Machine Loaded................................................F-41

Typical AC Weld Output Waveform – Machine Loaded................................................F-42

Abnormal Open Circuit Weld Voltage Waveform (one diode open)..............................F-43

Abnormal Open Circuit DC Weld Voltage Waveform

(High CV Mode) – Output Capacitor Bank not Functioning ...................................F-44

Normal Open Circuit Weld Voltage Waveform (High CV Mode) ...................................F-45

Normal Open Circuit DC Weld Voltage Waveform........................................................F-46

Normal Open Circuit AC Weld Voltage Waveform ........................................................F-47

Replacement Procedures....................................................................................................F-48

Brush Removal and Replacement ................................................................................F-48

Field Capacitor and Rectifier Bridge Removal and Replacement................................F-51

Control Board Removal and Replacement...................................................................F-54

Output Rectifier Bridge Removal and Replacement.....................................................F-57

Output Capacitor Removal and Replacement..............................................................F-60

Output Contactor Removal and Replacement..............................................................F-62

Stator and/or Rotor Removal and Replacement (Kit S20788)......................................F-65

Retest After Repair ..............................................................................................................F-70

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RANGER 10-LX

F-2 F-2

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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.

This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc­tions. Simply follow the three-step procedure
listed below.

Step 1. LOCA TE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMP­TOMS). This column describes possible symp­toms that the machine may exhibit. Find the list­ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into three main categories: Output Problems,
Engine Problems, and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con­ducted without removing the case wrap-around
cover.

Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub­ject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.

All of the referenced test procedur es referr ed to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec­trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

Have an electrician install and service
this equipment. Tur n the machine OFF
before working on equipment. Do not
touch electrically hot parts.

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability that
the PC board is the most likely component caus­ing the failure symptom.

2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read the
warning inside the static resistant bag and perform
the following procedures:

PC Board can be damaged by
static electricity.

• Remove your body’s static charge
before opening the static-shield­ing bag. Wear an anti-static wrist

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

Reusable
Container
Do Not Destroy

strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.

• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to pre­vent static build-up. Be sure not
to touch any electrically live parts
at the same time.

• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set
the PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately, put it back in the static­shielding bag.

• 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
proper failure analysis.

4. Test the machine to determine if the failure symp-

tom has been corrected by the replacement PC
board.

NOTE: Allow the machine to heat up so that all elec-

trical components can reach their operating
temperature.

5. Remove the replacement PC board and substitute

it with the original PC board to recreate the original
problem.

a. If the original problem does not reappear

by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and termi­nal strips.

b. If the original problem is recreated by the

substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the
machine.

6. Always indicate that this procedure was followed

when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the

warranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help
avoid denial of legitimate PC board warranty
claims.

• T ools which come in contact with the PC Boar d must
be either conductive, anti-static or static-dissipative.

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RANGER 10-LX

F-4 F-4

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Major physical or electrical dam­age is evident.

No weld output and no auxiliary
power. Engine operates normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local Lincoln
Authorized Field Service
Facility.

1. Make sure the REMOTE switch
(S7) is in the proper position –
“MACHINE CONTROL” if a
remote control unit is NOT con­nected to the machine.

2. Check the brushes for wear and
proper contact to the rotor slip
rings.

RECOMMENDED
COURSE OF ACTION

1. Contact The Lincoln Electric
Service Dept. [phone] or
1-800-833-9353 (WELD).

1. Perform the Rotor Voltage
Test.

2. If the Rotor Voltage Test is nor­mal, then perform the Rotor
Resistance Test.

3. If the Rotor Voltage Test is NOT
normal, perform the Auxiliary

and Field Winding Voltage
Test. Then check the field

diode bridge (D2), the field
capacitor (C2), and the Output
Control (R1). Replace if neces­sary.

4. The control board may be
faulty. Replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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RANGER 10-LX

F-5 F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

No weld output, the auxiliary
power (230-115VAC) is operating
normally. Engine operates normal­ly.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. If the Polarity mode switch (S1)
is in a constant voltage (CV)
position, make sure the CV out­put contactor is activating.

2. With the Polarity mode switch
(S1) is in a constant current
(CC) position, check the open
circuit voltage at the welder
output terminals. Normal AC is
70 to 76VAC. Normal DC is 61
to 68VDC. If the OCV is OK,
proceed to Step #2., If the OCV
is NOT present at the welder
output terminals, contact your
local Lincoln Authorized Field
Service Facility.

3. Check the welding cables,
clamps, and electrode holder
for loose or broken connec­tions.

RECOMMENDED
COURSE OF ACTION

1. If OCV is present in the CC
mode but NOT in the CV mode,
check the CV output contactor
and also the Polarity mode
switch (S1).

2. If OCV is absent in both modes
(CV and CC), disconnect lead
W1 from the output bridge (D1).
With the engine at high idle and
the output control at maximum,
check for 70 to 76VAC from
lead W1 to lead W2 on the main
transformer. See Wiring
Diagram. If the AC voltage is
NOT present, the winding may
be faulty . Check the winding for
continuity and test to be sure it
is NOT grounded to the stator
iron. Replace if necessary. If
the correct voltage is present,
proceed to step #3.

3. Check the reactor, Range
switch (S2), and associated
wires for loose or faulty connec­tions. Check the reactor wind­ing for continuity and test to be
sure it is NOT grounded to the
reactor iron.

4. Check the choke (L1), Polarity
mode switch (S1), and associ­ated wires for loose or faulty
connections. Check the choke
winding for continuity and test
to be sure it is NOT grounded to
the choke iron.

5. Check the weld output termi­nals and associated wires for
loose or faulty connections.

6. Perform the Output Rectifier

Bridge Test.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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RANGER 10-LX

F-6 F-6

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

No auxiliary power at receptacles –
welding output is normal – engine
runs normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. If the machine is equipped with
circuit breakers, check circuit
breakers. Reset if tripped.

2. Make sure the output control
(R1) is set at the maximum
position.

3. Check for loose or faulty plug(s)
at the power receptacles.

RECOMMENDED
COURSE OF ACTION

1. Check the auxiliary power
receptacles and associated
wires for loose or faulty con­nections.

2. Perform the Auxiliary and

Field Winding Voltage Test.

If for any reason you do not understand the test procedures or ar e unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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CAUTION

RANGER 10-LX

F-7 F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Machine has low welding output
and low auxiliary output.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. If a remote control unit is NOT
connected to the machine,
make sure the REMOTE switch
is in the proper position –
“MACHINE CONTROL.”

2. The brushes may be worn.
Contact your local Lincoln
Authorized Field Service
Facility.

3. The Engine RPM may be low.

RECOMMENDED
COURSE OF ACTION

1. If the engine high idle RPM is
low, perform the Throttle

Adjustment Test.

2. Perform the Rotor Voltage
Test.

3. If the rotor voltage is low, the
field capacitor (C1) or the field
bridge (D2) may be faulty. Test
and replace if necessary.

4. Check the output control
potentiometer (R1). Normal
resistance is 10,000 ohms.
Also check associated wiring
for loose or faulty connections.

5. The rotor may be faulty.
Perform the Rotor Resistance

Test.

6. The control board may be
faulty. Replace.

7. If the engine high idle RPM is
OK, then the engine may have
lost horsepower and be in need
of major repair.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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CAUTION

RANGER 10-LX

F-8 F-8

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

No DC welding output. AC welding
output and auxiliary power are nor­mal.

No AC welding output. DC weld­ing output and auxiliary power are
normal.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the Polarity mode
switch (S1) is in the proper posi­tion and is “seated” correctly.

2. Make sure the electrode and
polarity are correct for the
process being used.

1. Make sure the Polarity mode
switch (S1) is in the proper
position and is “seated” cor­rectly.

2. Make sure the electrode is cor­rect for the process being used.

3. Make sure the welding cables
are not coiled or too long.

RECOMMENDED
COURSE OF ACTION

1. Perform the Output Rectifier

Bridge Test.

2. Check the choke (L1), the
Polarity switch (S1), and associ­ated wires for loose or faulty
connections. Check the choke
winding for continuity and test
to be sure it is NOT grounded to
the choke iron.

1. Check the operation of the
Polarity mode switch (S1). Also
check the associated wires for
loose or faulty connections.
See Wiring Diagram.

2. Check for continuity from lead
“S2” to lead “E” located in the
main stator. See Wiring Dia­gram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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CAUTION

RANGER 10-LX

F-9 F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

No constant voltage (CV) welding
output. Constant current (CC) and
the auxiliary power are operating
normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the Range switch
(S2) is in the proper position
and “seated” correctly.

2. Put the control cable switch
(S8) in the “No control cable”
position. If CV output is
restored, the output contactor
is functioning correctly. Place a
jumper wire from pin “D” to Pin
“C” in the 14 pin amphenol. If
CV output is restored, the prob­lem is in the control cable or
wire feeder. If CV output is NOT
restored, check the continuity
of leads #2 and #4 within the
wiring harness. See Wiring
Diagram.

3. Make sure the wire feeder and
welding cables are connected
correctly.

RECOMMENDED
COURSE OF ACTION

1. Check the operation of the CV
output contactor. Make certain
it is “closing” and the contacts
have continuity when contactor
is activated. See Wiring
Diagram.

2. Check the operation of the
Range swtich (S2), and check
the associated wires for loose
or faulty connections. See
Wiring Diagram.

3. Check the continuity from leads
C1, C2, C3, and C4 to lead W1
located in the main stator. See
Wiring Diagram.

The constant voltage (CV) welding
output is low or unstable.
Constant current (CC) and auxiliary
power are operating normally.

1. Make sure the Range switch
(S2) is in the proper position
(CV) and “seated” correctly.

2. Make sure the wire feeder and
welding cables are connected
correctly.

1. Check the operation of the CV
output contactor. Make sure it
is “closing” and the contacts
have continuity when the con­tactor is activated. See Wiring
Diagram.

2. Check the operation of the
Range switch (S2), and check
the associated wires for loose
or faulty connections. See
Wiring Diagram.

3. The capacitor bank (C6, C7, C8,
and C9) may be faulty. Check
or replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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RANGER 10-LX

F-10 F-10

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Engine will not idle down to low
speed. Machine has normal weld
output and auxiliary power.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure the Idler switch (S5)
is in the “Auto” position.

2. Make sure there is NOT an
external load on the weld termi­nals nor the auxiliary power
receptacles.

3. Check circuit breaker CB1.
Reset breaker if “tripped.”

RECOMMENDED
COURSE OF ACTION

1. With the Idler switch (S5) in the
“AUTO” position and the engine
running, check for the presence
of 12VDC at leads #222F to
#214, located at the Idler sole­noid. If 12VDC is present and
the idler solenoid is not activat­ing, then the solenoid may be
faulty or there is a mechanical
restriction preventing it from
functioning.

2. If there is NOT 12VDC at leads
#222F to #214, check the CB1
circuit breaker. Also check for
12VDC from lead #222F to lead
#5 (ground). If 12VDC is pre­sent, then check lead #214 for
continuity (zero Ohms) from the
idler solenoid to the printed cir­cuit board plug 5J1. Also check
the Idler switch (S5) and associ­ated leads. See Wiring
Diagram. If the above are OK,
then the control board may be
faulty. Replace.

If for any reason you do not understand the test procedures or ar e unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-11 F-11

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Engine will not go to high idle when
attempting to weld. Welding out­put is normal when Idler switch is
in “HIGH” position. Automatic idle
function works properly when the
auxiliary power is loaded.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure the welding cables
and connections are tight.

RECOMMENDED
COURSE OF ACTION

1. Check for broken or faulty con­nections in the sensing leads
(#254 and #254A, #241 for CV
mode). Make sure their con­nections are tight at the work
output terminal, Polarity mode
switch, and CV output contac­tor. See Wiring Diagram.

2. Make sure leads #254 and
#254A are looped three times
through the current sensor on
the control board. For CV oper­ation, make sure leads #240,
#241, and #242 have continuity
(zero ohms) from their connec­tion points to the control board
plug J2. See Wiring Diagram.

3. If the automatic idle function
works correctly in the constant
current (CC) mode but NOT in
the constant voltage (CV)
mode, the control board may
be faulty. Replace.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-12 F-12

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The engine will not go to high idle
when attempting to weld or when
the auxiliary power is loaded.
Welding output and auxiliary power
output are normal when idler
switch is in the “HIGH” position.

The engine will not crank or cranks
very slowly.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure the welding cables
and auxiliary power lead con­nections are tight.

2. Automatic idler may not func­tion if the auxiliary power is
loaded to less than 150 watts.

3. If using the 115/230 volt recep­tacle for 115 volts, try using the
“other side” of the receptacle.
The internal load sensing is only
on one side of the receptacle.

1. Check for loose or faulty battery
cable connections.

2. The battery may be faulty.

RECOMMENDED
COURSE OF ACTION

1. Check for broken or faulty con­nections in the sensing leads
(#254, 254A and lead #3).
Make sure lead #3 is looped
through the current sensor on
the control board.

2. The control board may be
faulty. Replace.

1. If the battery is replaced or tests
good, then the charging circuit
may be faulty. Perform the

Charging Circuit Test.

2. The starter motor or starter
solenoid may be faulty.

3. The engine may be hard to
crank due to a mechanical fail­ure in the engine.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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RANGER 10-LX

F-13 F-13

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The engine cranks but will not
start.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. The engine may be low on or
out of fuel.

2. The oil level or pressure may be
low, causing the engine protec­tion system to shut off fuel flow
to the engine. Check the oil
pressure light.

3. The engine coolant may be
overheated, causing the engine
protection system to shut off
fuel flow to the engine. Check
the water temperature light.

4. The engine “glow” plugs may
not be operating correctly.

RECOMMENDED
COURSE OF ACTION

1. The fuel solenoid may be faulty.
Check or replace.

2. The engine protection relay
(CR1) may be faulty. Perform
the Protection Relay (CR1)

Test.

3. The engine may be faulty.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-14 F-14

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The engine goes to low idle but
does not stay in low idle.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure there is NOT an
external load (auxiliary or weld)
connected to the RANGER 10­LX.

RECOMMENDED
COURSE OF ACTION

1. The idler solenoid linkage may
be misadjusted or damaged.

2. The idler solenoid (L2) hold-in
circuitry may be faulty. Check
lead #214 for continuity (zero
ohms) from the solenoid to the
control board plug 5J1. See
Wiring Diagram. With the
Ranger 10-LX in the low idle
mode, check for 10 to 12VDC
from lead #222F to lead #214.
If the correct DC voltage is pre­sent, the idler solenoid (L2) may
be faulty. If the correct DC volt­age is NOT present, the control
board may be faulty.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

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TROUBLESHOOTING & REPAIR

F-15 F-15

RANGER 10-LX

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS

Output control on welder not func­tioning.

1. Make sure the Remote switch
(S7) is in the “MACHINE CON­TROL” position.

2. The Output Control (R1) may be
defective.

1. Check the Output Control (R1).
Normal resistance is 10,000
ohms. Replace if defective.

2. Check the Remote switch (S7)
and associated wiring. See
Wiring Diagram (leads #75, #76,
and #77).

3. The control board may be
faulty. Replace.

Remote output control not func­tioning.

1. Make sure the Remote switch
(S7) is in the “REMOTE” posi­tion.

2. The remote control unit may be
faulty. Repair or replace.

1. Check the Remote switch (S7)
and associated wiring. See
Wiring Diagram (leads #75, #76,
and #77).

2. The RF bypass board may be
defective. Check or replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

F-16 F-16

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The wire feeder does not work
when connected to the welder
amphenol.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Check circuit breaker CB2.
Reset if tripped.

2. The wire feeder control cable
may be faulty. Check or
replace.

3. The wire feeder may be faulty.
Check or replace.

RECOMMENDED
COURSE OF ACTION

1. Check for the presence of
115VAC at leads #31A and #32.
See Wiring Diagram.

2. Check for the presence of
42VAC at leads #31B to #42.
See Wiring Diagram.

3. If any of the above voltages are
missing or low, then check the
circuit breaker CB2 for proper
operation.

4. The RF bypass board may be
faulty. Check or replace.

5. Perform the Auxiliary and Field

Winding Test.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-17 F-17

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The CV output contactor does not
pull in when using a wire feeder
with a control cable connected to
the RANGER 10-LX amphenol.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the Wire Feeder
switch (S8) is in the “WITH
CONTROL CABLE” position.

2. Install a jumper wire from pins
“D” to “C” on the 14 pin amphe­nol. If the output contactor acti­vates, the problem is external to
the RANGER 10-LX. The wire
feeder or control cable may be
faulty.

RECOMMENDED
COURSE OF ACTION

1. With the jumper installed in pins
“D” and “C” in the 14 pin
amphenol, check for 12VDC
from leads #224F(+) to #2C(-) at
the CV output contactor. If
12VDC is present and the con­tactor does NOT activate, then
the contactor may be defective.

2. If the correct voltage is NOT
present in Step #1, check from
lead #224F to ground (lead #5)
for the presence of 12VDC. If
12VDC is present, then check
the continuity of lead 2C
through the RF bypass board to
the 14 pin amphenol. See
Wiring Diagram.

3. If 12VDC is NOT present from
lead #224F to ground (lead #5),
then check the #224F lead for
an open circuit. See Wiring
Diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-18 F-18

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The CV output contactor does not
pull in when the wire feeder switch
(S8) is in the NO CONTROL CABLE
position.

The CV output contactor does not
deactivate (drop out) when a wire
feeder with a control cable is con­nected to the RANGER 10-LX.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the wire feeder is
connected correctly to the
RANGER 10-LX.

1. Make certain the Wire Feeder
switch (S8) is in the “WITH
CONTROL CABLE” position.

2. The Wire Feeder control cable
may be faulty. Check or
replace.

3. The wire feeder may be faulty.
Check or replace.

RECOMMENDED
COURSE OF ACTION

1. Check the Wire Feeder switch
(S8) and associated leads. See
Wiring Diagram.

2. Check for loose or faulty con­nections on leads #224F, #2C,
#2D, #244, and #243. Also
check the sensing leads #240
and #242.

3. Check the Idler switch (S5) and
associated leads. See Wiring
Diagram.

4. The control board may be
faulty.

1. Check to make sure that lead
#2C is not grounded. See
Wiring Diagram.

2. Remove lead #224F from the
CV output contactor . If the con­tactor does not deactivate, the
contactor may be faulty. Repair
or replace.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-19 F-19

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

FUNCTION PROBLEMS

The CV output contactor does not
deactivate (drop out) when a wire
feeder without a control cable is
connected to the RANGER 10-LX.

The battery does not stay charged. 1. Check for loose or faulty con-

1. Make sure the wire feeder is
connected properly to the
RANGER 10-LX.

2. Make sure the Wire Feeder
switch (S8) is in the “NO CON­TROL CABLE” position.

3. The CV output contactor will
normally be activated (closed) if
the Idler switch (S5) is in the
“HIGH” position.

nections at the battery and
engine charging system.

RECOMMENDED
COURSE OF ACTION

1. Remove lead #224F from the
CV output contactor . If the con­tactor does not deactivate, the
contactor may be faulty. Repair
or replace.

2. The control board may be
faulty.

1. Perform the Charging Circuit

Test.

2. The battery may be faulty.
Check or replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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RANGER 10-LX

F-20 F-20

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The welding arc is “cold.” The
engine runs normally (3700 RPM
no load). The auxiliary power is
functioning normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

WELDING PROBLEMS

1. Check for loose or faulty con­nections at the weld output ter­minals and welding cable con­nections.

2. The welding cables may be too
long or coiled, causing an
excessive voltage drop.

RECOMMENDED
COURSE OF ACTION

1. Check for the correct open cir­cuit voltage (OCV) at the weld­ing output terminals. If the cor­rect voltage is present at the
output terminals, then check for
loose connections on the heavy
current carrying leads inside the
RANGER 10-LX. See Wiring
Diagram.

2. If the OCV is low at the welder
output terminals, perform the

Engine Throttle Adjustment
Test.

3. Perform the Output Rectifier
Bridge Test.

4. Check for shorted or grounded
windings in the reactor and also
in the main stator. See Wiring
Diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

RANGER 10-LX

F-21 F-21

TROUBLESHOOTING & REPAIR

ROTOR VOLTAGE TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the correct DC voltage is being applied to the rotor at maximum
engine speed (3700 RPM). This information will aid the technician in determining if the gen­erator field is operating properly.

MATERIALS NEEDED

Volt/Ohmmeter
5/16” Nut driver
3/8” Nut driver
Wiring Diagram

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RANGER 10-LX

F-22 F-22

TROUBLESHOOTING & REPAIR

ROTOR VOLTAGE TEST (continued)

FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST

TEST PROCEDURE

1. With the 5/16” and 3/8” nut driver, remove
the sheet metal screws from the right hand
case side.

2. Carefully remove the right case side.

3. Set the volt/ohmmeter to the DC volts
position.

4. Connect the positive meter probe to the
brush nearest the rotor lamination (lead
#200A). See Figure F.1 for location.

5. Connect the negative meter probe to the
other brush (lead #219).

6. Start the engine and run it at high idle (3700
RPM). Set the output control to the MAXI­MUM position (position 10).

7. Check the voltage reading on the voltmeter .
It should read between 37 and 47 VDC.

8. If the voltage reading is low or not present,
the generator field is not functioning prop­erly. Perform the Rotor Resistance Test.
The field diode bridge (D2), the field capac­itor (C2), and/or the control board may be
faulty.

9. If the voltage reading is normal, the field
circuit is functioning properly. Install the
right case side with the sheet metal screws
and the 5/16” and 3/8” nut drivers.

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RANGER 10-LX

F-23 F-23

TROUBLESHOOTING & REPAIR

ROTOR RESISTANCE TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.

MATERIALS NEEDED

Volt/Ohmmeter
5/16” Nut driver
3/8” Nut driver
Wiring Diagram

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RANGER 10-LX

F-24 F-24

TROUBLESHOOTING & REPAIR

ROTOR RESISTANCE TEST (continued)

FIGURE F.2 – LEADS 200A AND 219 REMOVED

TEST PROCEDURE

1. With the 5/16” and 3/8” nut drivers, remove
the sheet metal screws from the right hand
case side.

2. Carefully remove the right case side.

3. Conduct the test with the engine OFF.

4. Isolate the rotor electrically by removing
the generator brush leads. Refer to Figure
F.2 as you perform the remaining steps.

5. Remove lead #219 from the negative brush.

6. Remove lead #200A from the positive
brush.

7. Measure the resistance across the rotor
slip rings.

a. Set the ohmmeter on the low scale

(X1).

b. Place one meter probe on one of the

rotor slip rings. Place the other probe
on the other slip ring.

c. Check the resistance across the slip

rings. It should read approximately 5
or 6 ohms.

8. 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 ground. The machine
ground stud works well.

C. Check the resistance. It should read

very high, at least 0.5 megohm
(500,000 ohms).

If the test does not meet the resistance
specifications, then the rotor may be
faulty. Replace the rotor.

If the test does meet the resistance speci­fications, then the rotor is okay.

9. Connect lead #200A to the positive brush,

which is the one nearest the rotor lamina­tion. Connect lead #219 to the negative
brush.

10. Reinstall the right case side using the
sheet metal screws and the 5/16” and
3/8” nut drivers.

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RANGER 10-LX

F-25 F-25

TROUBLESHOOTING & REPAIR

AUXILIARY AND FIELD WINDING TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the correct AC voltages are being generated from the stator
windings.

MATERIALS NEEDED

Volt/Ohmmeter
5/16” Nut driver
4/8” Nut driver
Wiring Diagram

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RANGER 10-LX

F-26 F-26

TROUBLESHOOTING & REPAIR

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.3 – LOCATION OF LEADS #3 AND #5

TEST PROCEDURE

To test the 115 VAC winding:

1. With the 5/16” and 3/8” nut drivers, remove
the sheet metal screws from the left case
side.

2. Carefully remove the left case side.

3. Set the voltmeter to the AC volts position.

4. Connect the voltmeter probes to leads #3
and #5 where they connect to the 115VAC
receptacle. See Figure F.3.

5. Start the engine and run it at high idle (3700
RPM).

6. Set the output control to the maximum
position (position 10).

7. Check the AC voltage reading. It should be
approximately 125VAC.

To test the 230 VAC winding:

1. With the 5/16” and 3/8” nut drivers, remove
the sheet metal screws from the left case
side.

2. Carefully remove the left case side.

3. Set the voltmeter to the AC volts position.

4. Connect the voltmeter probes to leads #6
and #3 where they connect to the 230 VAC
receptacle.

NOTE: It is easier to insert the probes directly
into the receptacle to perform this test.
However, the probes may not reach in far
enough to make or keep a good connection.
In this case, before you start the engine, insert
two test probes into the receptacle. Hold the
test probes firmly in place to measure voltage
(step 7).

5. Start the engine and run it at high idle (3700
RPM)

6. Set the output control to the maximum
position (position 10)

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7. Check the AC voltage reading. It should be
approximately 240 VAC.

RANGER 10-LX

F-27 F-27

TROUBLESHOOTING & REPAIR

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.4 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER

Field Bridge Rectifier
(see inset)

To test the field winding:

1. With the 5/16” and 3/8” nut drivers, remove
the sheet metal screws from the right case
side.

2. Carefully remove the right case side.

3. Set the voltmeter to the AC volts position.

4. Connect the voltmeter probes to leads #7
and #9 where they connect to the field
bridge rectifier. See Figure F.4.

5. Start the engine and run it at high idle (3700
RPM).

6. Set the output control to the maximum
position (position 10).

7. Check the AC voltage reading. It should be
between 40 and 47 VAC.

Capacitor

If any one or more of the readings are missing
or not within specifications, then check for
loose or broken wires between the test points
and the stator windings. See the Wiring
Diagram. Make sure the windings are NOT
grounded internally to the stator iron. If the
leads are intact, then the stator may be faulty.
Replace the stator. If the voltage readings are
within specifications, then the windings are
good and functioning properly.

7. Reinstall the right case side using the 5/16”
and 1/8” nut drivers and sheet metal
screws.

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RANGER 10-LX

F-28 F-28

TROUBLESHOOTING & REPAIR

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.4A – 14 PIN AMPHENOL PIN ASSIGNMENTS

C

Y

D

E

M

B

L

Z

K

A

J

N

F

G

X

H

To test the feeder winding:

1. Using the 5/16” and 1/8” nut drivers,
remove the sheet metal screws from the
right case side.

2. Carefully remove the right case side.

3. Set the voltmeter to the AC volts position.

4. Connect the voltmeter probes to leads #31
and #32 where they connect to the circuit
breaker CB2 and the 14 pin amphenol. See
the Wiring Diagram.

NOTE: It is possible to check this voltage
reading at the amphenol by inserting the test
probes at pin A (for lead #32) and pin J (for lead
#31A). See Figure F.4A. However, if you use
this method and get no voltage reading, it
could mean there is a break or loose connec­tion in the leads between the circuit breaker
and the amphenol. Check the reading again
and with one probe at the circuit breaker con­nection for lead #31 and the other probe at
amphenol pin A.

5. Start the engine and run it at high idle (3700
RPM).

6. Set the output control to the maximum
position (position 10).

8. Check the AC voltage reading. It should be
between 115 and 126 VAC.

W

I

9. Connect the voltmeter probes to leads #31
and #42 where they connect to the circuit
breaker CB2 and the 14 pin amphenol. See
the Wiring Diagram.

NOTE: It is possible to check this voltage
reading at the amphenol by inserting the test
probes at pin K (for lead #42) and I (for lead
#31B). See Figure 4A. However, if you use this
method and get no voltage reading, it could
mean there is a break or loose connection in
the leads between the circuit breaker and the
amphenol. Check the reading again with one
probe at the circuit breaker connection for lead
#31 and the other probe at amphenol pin K.

10. Set the output control to the maximum

position. (position 10).

11. Check the AC voltage reading. It should

be between 43 and 50 VAC.

If the voltage readings are within specifica­tions, then the windings are good and func­tioning correctly.

If any one or more of the readings are missing
or not within specifications, then check for
loose or broken wires between the test points
and the stator windings. See the wiring dia­gram. Make sure that the windings are NOT
grounded internally to the stator iron. If the
leads are intact, then the stator may be faulty.
Replace the stator.

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RANGER 10-LX

12. Reinstall the right case side using the

5/16” and 3/8” nut drivers and sheet metal
screws.

F-29 F-29

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if there are faulty diodes in the output rectifier bridge.

MATERIALS NEEDED

Volt/Ohmmeter (Diode Tester)
5/16” Nut driver
3/8” Nut driver
1/2” Wrench
Wiring Diagram

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RANGER 10-LX

F-30 F-30

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE TEST (continued)

FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS

Left side (–)

TEST PROCEDURE

1. Using the 5/16” and 3/8” nut drivers,
remove the sheet metal screws from the
right and left case sides.

2. Carefully remove the right and left case
sides.

3. Conduct this test with the engine OFF.

4. Locate the two halves of the output r ectifier.
The negative plate is located on the lower
left side of the machine behind the case
front. The positive plate is located on the
lower right side of the machine behind the
case front. See Figure F.5.

5. With the 1/2” wrench, remove the nuts and
washers holding the diode pigtails and the
heavy current-carrying leads to the studs
located at the tops and bottoms of the rec­tifier plates. Note their locations and the
order of fasteners for reassembly.

Right side (+)

7. With an ohmmeter or diode tester, check
each of the four diodes from their pigtails
to their respective heat sinks.

8. Reverse the tester leads and check the
diodes again. Diodes should have a low
resistance in one polarity and a very high
resistance in the opposite polarity.

9. Replace any “shorted” or “open” diode as
the tests indicate.

10. Reconnect the diode pigtails and heavy
leads to their respective studs.

11. Reinstall the left and right case sides using
the 5/16” and 3/8” nut drivers and sheet
metal screws.

6. Electrically isolate the diode pigtails by
carefully bending them out into “free air.”

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RANGER 10-LX

F-31 F-31

TROUBLESHOOTING & REPAIR

CHARGING CIRCUIT TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the engine alternator, regulator, and associated circuitry are func­tioning properly.

MATERIALS NEEDED

Volt/Ohmmeter
5/16” Nut driver
3/8” Nut driver
Wiring Diagram

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RANGER 10-LX

F-32 F-32

TROUBLESHOOTING & REPAIR

CHARGING CIRCUIT TEST (continued)

FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR

5J

233

236

224A 222D

234

TEST PROCEDURE

1. With the 5/16” and 3/8” nut drivers,

remove the sheet metal screws from the
left case side.

2. Carefully remove the left case side.

3. Locate the engine alternator and regulator.

See Figure F.6.

4. Start the engine and run it at high idle

(3700 RPM).

5. Set the voltmeter for AC volts and measure

the AC volts at leads #233 and #234.
Normal is between 22 and 26 VAC.

6. Set the voltmeter for DC volts and measure

the DC volts at leads #222D to lead #5J
(case ground). Normal is 13.5 to 15 VDC.

7. If the correct AC volts are present at leads

#233 to #234, the engine alternator is
operating correctly. If the voltage is low or
missing, the engine alternator may be
faulty. Replace.

8. If the correct AC volts are present at leads
#233 to #234 but the DC volts are incorrect
at leads #222D to lead #5J (case ground),
the regulator may be faulty. Before replac­ing the regulator, check the wiring from the
regulator to the alternator and the charging
circuit. See the Wiring Diagram.

NOTE: If you test with probes at the plug by
the regulator and you get no reading, check
the wires back to the alternator. The problem
may be in the wiring, not the alternator.

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RANGER 10-LX

F-33 F-33

TROUBLESHOOTING & REPAIR

PROTECTION RELAY (CR1) TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the correct DC voltage is being applied to the coil of the relay and
also if the relay contacts are functioning properly.

MATERIALS NEEDED

Volt/Ohmmeter
5/16” Nut driver
3/8” Nut driver
12VDC power supply (battery)

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RANGER 10-LX

F-34 F-34

TROUBLESHOOTING & REPAIR

PROTECTION RELAY (CR1) TEST (continued)

FIGURE F.7 – CR1 LEAD CONNECTIONS

TEST PROCEDURE

1. Using the 5/16” and 3/8” nut drivers,
remove the sheet metal screws from the
left case side.

2. Carefully remove the left case side.

3. Conduct this test with the engine OFF.

4. Remove leads #252, #253, #224 and #235
from relay CR1. See Figure F.7.

5. Using the 12VDC power supply, apply
12VDC to the coil terminals “A” and “B” of
the relay.

6. Check visually to see if the relay is operat­ing when voltage is applied to the coil ter­minals. If the relay IS operating, proceed
to step #7. If the relay is NOT operating
when coil voltage is applied, then check
the resistance of the coil. Normal coil
resistance is 100 to 150 ohms. If the relay
coil is “shorted” or “open,” the relay will
NOT operate. Replace the relay.

7. With 12VDC applied to the relay coil, use
the ohmmeter to check for continuity (zero
ohms) from terminals #4 to #7. If zero or a
very low resistance is measured, the con­tacts are okay. If a high or infinite resis­tance is measured, the contacts are faulty.
If NO voltage is applied to the coil termi­nals, the resistance from #4 to #7 should
be infinite.

8. Install the left case side using the 5/16”
and 3/8” nut drivers and sheet metal
screws.

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RANGER 10-LX

F-35 F-35

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

If the machine output is low, this test will determine whether the engine is operating at the
correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjusting the
throttle to the correct RPM are given.

MATERIALS NEEDED

5/16” Nut driver
3/8” Nut driver
1/2” wrench
10mm wrench
7/16” wrench
Strobe-tach, frequency counter, or oscilloscope
Chalk

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RANGER 10-LX

F-36 F-36

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.8 – MARK LOCATION, STROBE/TACH METHOD

Flywheel

Chalk mark

TEST PROCEDURE

This test can be conducted by any one of three
methods.

Strobe-tach Method:

1. With the 5/16” nut drivers, remove the sheet
metal screws from the right case side.

2. Carefully remove the right case side.

3. Carefully lift the double door assembly to
gain access to the engine compartment.

4. With the chalk, mark one of the flywheel
bolts. See Figure F.8 for location. Conduct
this procedure with the engine OFF.

5. Connect the strobe-tach according to the
manufacturer’s instructions.

6. Start the engine and direct the strobe-tach
light on the flywheel and synchronize it to
the rotating mark.

7. With the machine at HIGH IDLE, the tach
should read between 3650 and 3700 RPM.
WIth the machine at LOW IDLE, the tach
should read between 2150 and 2220 RPM.

8. If any of the readings is incorrect, adjust the
throttle as follows.

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RANGER 10-LX

F-37 F-37

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.9 – HIGH IDLE ADJUSTMENT NUT

Lock Nut

Adjustment Screw

Adjust HIGH IDLE: First make sure there is
NOT a load on the machine. Use the 10mm
wrench to loosen the lock nut. See Figure F.9
for location of adjustment screw and lock nut.
With the 10mm wrench turn the adjustment
screw counterclockwise to increase the high
idle RPM. Note: It is usually NOT necessary to
cut or remove the wire and seal. Adjust the
speed until the tach reads between 3650 and
3700 RPM.

Adjust LOW IDLE: First make sure there is
NOT a load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16”
wrench to loosen the lock nut. See Figure F.10
for location. Use the 1/2” wrench to adjust the
solenoid, which changes the amount of throw
in the throttle lever arm. Adjust the nut until the
tach reads between 2150 and 2220 RPM.

Frequency Counter Method

1. Plug the frequency counter into one of the
115 VAC receptacles.

Lock Nut

Adjustment Screw

2. Start the engine and check the frequency
counter. At HIGH IDLE (3700 RPM), the
counter should read 63 Hz. At LOW IDLE
(2200 RPM), the counter should read 37 Hz.
Note that these are median measurements:
Hertz readings may vary slightly above or
below.

3. If either of the readings is incorrect, adjust
the throttle as follows:

Adjust HIGH IDLE: First make sure there is
NOT a load on the machine. Use the 10mm
wrench to loosen the lock nut. See Figure F.9.
for location of adjustment screw and lock nut.
With the10mm wrench, turn the adjustment
screw counterclockwise to increase the high
idle RPM. Note: It is usually NOT necessary to
cut or remove the wire and seal. Adjust the
speed until the frequency is 63 Hz.

Adjust LOW IDLE: First make sure there is NOT
a load on the machine. Set the IDLE switch to
AUTO and wait for the engine to change to low
idle speed. Use the 7/16” wrench to loosen the
lock nut. See Figure F.10. for location. Use
the 1/2” wrench to adjust the solenoid, which
changes the amount of throw in the throttle
lever arm. Adjust the nut until the frequency is
37 Hz.

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RANGER 10-LX

F-38 F-38

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.10 – LOW IDLE ADJUSTMENT NUT

7/16” Lock Nut

1/2” Adjustment Nut

Oscilloscope Method:

1. Connect the oscilloscope to the 115 VAC
receptacle, according to the manufactur­er’s instructions. At 3700 RPM, the wave­form should exhibit a period of 15.8 mil­liseconds. At 2200 RPM, the waveform
should exhibit a period of 27.02 millisec­onds. Refer to NORMAL OPEN CIRCUIT
VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE – NO LOAD in this section of
the manual.

2. If either waveform periods is incorrect,
adjust the throttle as follows:

Adjust HIGH IDLE: First make sure there is
NOT a load on the machine. Use the
10mm wrench to loosen the lock nut. See
Figure F.9 for location of the adjustment
screw and lock nut. With the 10mm
wrench, turn the adjustment screw coun­terclockwise to increase the high idle RPM.
Note: It is usually NOT necessary to cut or
remove the wire and seal. Adjust the
speed until the period is 15.8 milliseconds.

Adjust LOW IDLE: First make sure there is
NOT a load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 7/16”
wrench to loosen the lock nut. See Figure
F.10 for location. Use the 1/2” wrench to
adjust the solenoid, which changes the
amount of throw in the throttle lever arm.
Adjust the nut until the period is 27.02 mil­liseconds.

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RANGER 10-LX

F-39 F-39

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

15.8 ms
CH1

0 volts

50 volts

This is the typical auxiliary 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.

Note: Scope probes connected at
machine 115VAC receptacle.

5 ms

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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RANGER 10-LX

F-40 F-40

TROUBLESHOOTING & REPAIR

TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP)

MACHINE LOADED

CH1

0 volts

20 volts

5 ms

MACHINE LOADED TO 250 AMPS AT 30VDC

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. The machine
was loaded with a resistance grid
bank.

Note: Scope probes connected at
machine output terminals.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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RANGER 10-LX

F-41 F-41

TROUBLESHOOTING & REPAIR

TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM

MACHINE LOADED

CH1

0 volts

20 volts

MACHINE LOADED TO 250 AMPS AT 25 VDC

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. The machine
was loaded with a resistance grid
bank.

Note: Scope probes connected at
machine output terminals.

5 ms

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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RANGER 10-LX

F-42 F-42

TROUBLESHOOTING & REPAIR

TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM

MACHINE LOADED

CH1

0 volts

20 volts

5 ms

MACHINE LOADED TO 250 AMPS AT 25VDC

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. The machine
was loaded with a resistance grid
bank.

Note: Scope probes connected at
machine output terminals.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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RANGER 10-LX

F-43 F-43

TROUBLESHOOTING & REPAIR

ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM

HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM

ONE OUTPUT DIODE NOT FUNCTIONING

CH1

0 volts

50 volts

This is NOT the typical DC (+) output
voltage waveform. One output diode
is not functioning. Note the “gap” in
the waveform. One output diode was
disconnected to simulate an open or
non-functioning output diode. Each
vertical division represents 50 volts
and each horizontal division repre­sents 5 milliseconds in time.

Note: Scope probes connected at
machine output terminals.

5 ms

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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RANGER 10-LX

F-44 F-44

TROUBLESHOOTING & REPAIR

ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

(HIGH CV MODE)

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

OUTPUT CAPACITOR BANK NOT FUNCTIONING

CH1

0 volts

50 volts

This is NOT the typical CV output
voltage waveform. The capacitor
bank is not functioning. Note the
“ripple” in the waveform. The capac­itor bank was disconnected to simu­late an open or non-functioning
capacitor bank. Each vertical divi­sion represents 50 volts and each
horizontal division represents 5 mil­liseconds in time.

Note: Scope probes connected at
machine output terminals.

5 ms

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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RANGER 10-LX

F-45 F-45

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

CH1

0 volts

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.

Note: Scope probes connected at
machine output terminals.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

5 ms

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RANGER 10-LX

F-46 F-46

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

CH1

0 volts

50V

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.

Note: Scope probes connected at
machine output terminals.

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

5 ms

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RANGER 10-LX