SVM168-B
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®
RANGER 10,000 /10,000 PLUS
For use with machine code numbers: Kohler 11041, 11151, 11394
Honda 11095, 11398
Robin/Subaru 11253. 11395
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.
April, 2010
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
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 Welding 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
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding 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.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.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.
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___________________________________________________
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.
RANGER® 10,000 & RANGER® 10,000 PLUS
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 ʻ95
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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c.
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.
vapors
to
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5.d. 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.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ʻ09
RANGER® 10,000 & RANGER® 10,000 PLUS
iii iii
SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
6.a.
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent 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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Remove fire hazards from the welding area.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
If
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.
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
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6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
Jan ʻ09
RANGER® 10,000 & RANGER® 10,000 PLUS
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:
Sûr
eté Pour Soudage A L’Arc
rotegez-vous contre la secousse électrique:
1. P
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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” CSA Standard
W 117.2-1974.
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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 nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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
RANGER® 10,000 & RANGER® 10,000 PLUS
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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-481 Series
vv
RANGER® 10,000 & RANGER® 10,000 PLUS
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation ..............................................................................................................Section A
Technical Specifications............................................................................................A-2
Safety Precautions ....................................................................................................A-4
Machine Grounding...................................................................................................A-4
Spark Arrestor ...........................................................................................................A-4
Towing ............. .........................................................................................................A-4
Pre-Operation Service...............................................................................................A-5
Fuel ... ..................................................................................................................A-5
Oil.........................................................................................................................A-5
Battery Connections ............................................................................................A-5
Welding Output Cables .............................................................................................A-6
Angle of Operation ....................................................................................................A-6
High Altitude Operation.............................................................................................A-6
Location/Ventilation...................................................................................................A-7
Connection of Wire Feeders .....................................................................................A-7
Additional Safety Precautions ...................................................................................A-7
Welder Operation ......................................................................................................A-7
Auxiliary Power..........................................................................................................A-8
120V Duplex Receptacles .........................................................................................A-8
Motor Starting ...........................................................................................................A-8
Electrical Devices used w/RANGER® 10,000 ..........................................................A-9
Auxiliary Power While Welding................................................................................A-10
Stand-by Power Connections .................................................................................A-10
Connection of RANGER® 10,000 to Premises Wiring (Drawing) ...........................A-11
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RANGER® 10,000 & RANGER® 10,000 PLUS
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER® 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1)
INPUT - GASOLINE ENGINE
Make/Model
Description
Horsepower
Operating
Speed (RPM)
Displacement
cu. in.
(cu.cm.)
Starting
System
Capacities
(K1419-4)
Kohler
CH20S
(K2160-3)
(K2160-4)
Honda
GX620KI
(K2468-1)
Subaru Robin
EH64
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
RATED OUTPUT @ 104°F (40°C)- WELDER
20 HP @
3600 RPM
Kohler
High Idle 3700
20 HP@
3600 RPM
Honda
20.5 HP@
3600 RPM
ROBIN/SUBARU
AC Constant Current 225A / 25V / 100%
DC Constant Current 210A / 25V / 100%
DC Constant Voltage 200A / 20V / 100%
Full Load 3500
Low Idle 2200
Welding Output
38(624)
Kohler
37.5 (614)
Honda
39.9 (653)
ROBIN/SUBARU
12VDC
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
Fuel:
9 Gal (34 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
Fuel:
9 Gal (34 L)
Lubricating Oil
1.9 Qts. (1.8L)
Fuel:
12 Gal (45.4 L)
Lubricating Oil
1.6 Qts. (1.6L)
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RATED OUTPUT @ 104°F (40°C)- GENERATOR
Auxiliary Power
9,000 Watts Continuous, 60 Hz AC
10,000 Watts Peak, 60 Hz AC
120/240 Volts
1
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-4
770 mm 485 mm 1067 mm 505 lbs. (229kg) K2160-3
528 lbs. (240kg) K2468-1
1. Output rating in watts is equivalent to volt - amperes at unity 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® 10,000 & RANGER® 10,000 PLUS
A-3 A-3
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 10,000 PLUS (K1419-5 ), (K2468-2)
INPUT - GASOLINE ENGINE
Make/Model
Description
Horsepower
Operating
Speed (RPM)
Displacement
cu. in.
(cu.cm.)
Starting
System
Capacities
(K1419-5)
Kohler
CH23S
(K2468-2)
Subaru Robin
EH65
9,000 Watts Continuous, 60 Hz AC
10,500 Watts Peak, 60 Hz AC
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
23 HP @
3600 RPM
22 HP@
3600 RPM
SUBARU ROBIN
RATED OUTPUT @ 104°F (40°C)- WELDER
AC Constant Current 225A / 25V / 100%
DC Constant Current 210A / 25V / 100%
DC Constant Voltage 200A / 20V / 100%
RATED OUTPUT @ 104°F (40°C)- GENERATOR
RANGER 10,000 PLUS
120/240 Volts
Kohler
High Idle 3700
Full Load
3500
Low Idle 2200
Welding Output
Auxiliary Power
41(674)
Kohler
39.9 (653)
SUBARU ROBIN
1
RANGER 10,000
9,000 Watts Continuous, 60 Hz AC
10,000 Watts Peak, 60 Hz AC
120/240 Volts
12VDC
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
Lubricating Oil:
2.0 Qts. (1.9 L)
Lubricating Oil
1.6 Qts. (1.6L)
Fuel:
9 Gal (34 L)
Fuel:
9 Gal (34 L)
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PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-5
770 mm 485 mm 1067 mm 528 lbs. (240kg) K2468-2
505 lbs. (229kg) K2160-4
1. Output rating in watts is equivalent to volt - amperes at unity 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® 10,000 & RANGER® 10,000 PLUS
A-4 A-4
INSTALLATION
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, itʼs
frame must be electrically bonded to the metal frame of
the vehicle. Use a #8 or larger copper wire connected
between the machine grounding stud and the frame of
the vehicle.
Where this engine driven welder is connected to
premises wiring such as that in your home or shop, itʼs
frame must be connected to the system earth ground.
See further connection instructions in the section entitled “Standby Power Connections”, as well as the article on grounding in the latest National Electrical Code
and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The National Electrical
Code lists a number of alternate means of grounding
electrical equipment. A machine grounding stud
marked with the symbol is provided on the front of
the welder.
SPARK ARRESTER
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
MACHINE GROUNDING
Because this portable engine driven welder or generator creates itʼs own power, it is not necessary to connect itʼs frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).
WARNING
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies
power must:
• be grounded to the frame of the welder using a
grounded type plug, or be double insulated.
Some federal, state, or local laws may require that
gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this welder does not
qualify as a spark arrester. When required by local regulations, the K894-1 spark arrester must be installed
and properly maintained.
CAUTION
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincolnʼs K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of
attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the
factors to be considered are as follows:
(1)
is
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Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
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RANGER® 10,000 & RANGER® 10,000 PLUS
1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
A-5 A-5
INSTALLATION
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated;
environmental conditions.
5. Conformance with federal, state and local laws
(1) Consult applicable federal, state and local laws regarding specif-
ic requirements for use on public highways.
VEHICLE MOUNTING
(1)
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacture’s instructions.
------------------------------------------------------------------------
FUEL
Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.
WARNING
• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in or weld to the RANGER® 10,000
or the RANGER® 10,000 PLUS
base.
-----------------------------------------------------------------------
OIL
LUBRICATION SYSTEM CAPACITY
(INCLUDING FILTER)
Kohler CH20S / CH23S - 2.0 Quarts (1.9 Liters)
Honda GX620KI - 1.9 Quarts (1.8 Liters)
Robin Subaru EH64 /EH65 - 1.6 Quarts (1.6 Liters)
The RANGER® 10,000 and the RANGER® 10,000
PLUS are shipped with the engine crankcase filled
with SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip
stick, add oil as required. Make certain that the oil filler
cap is tightened securely. Refer to the engine Ownerʼs
Manual for specific oil recommendations.
PRE-OPERATION SERVICE
CAUTION
READ the engine operating and maintenance
instructions supplied with this machine.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
GASOLINE
can cause fire
or explosion.
fumes to clear before starting
engine.
• Do not overfill tank, fuel expansion may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
CAUTION
BATTERY CONNECTIONS
Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
-----------------------------------------------------------------------
This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is discharged and does not have enough power to start the
engine, see the battery charging instructions in the
Battery section.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the battery with the correct polarity.
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RANGER® 10,000 & RANGER® 10,000 PLUS
A-6 A-6
INSTALLATION
WELDING OUTPUT CABLES
With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if necessary. Loose connections will result in overheating of the
output studs.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated are
the distance from the welder to work and back to the
welder again. Cable sizes are increased for greater
lengths primarily for the purpose of minimizing cable
voltage drop.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
225 Amps
100% Duty Cycle
0-100 Ft.
100-200 Ft.
200-250 Ft.
1 AWG
1 AWG
1/0 AWG
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
level condition which is where the optimum performance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintaining
the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.
When operating at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.
LIFTING
WARNING
• Lift only with equipment of adequate lifting capacity.
• Be sure machine is stable when
lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer
or gas cylinder.
FALLING • Do not lift machine if lift bale is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, Welder output de-rating may be necessary.
Kohler and Subaru Robin Models:
For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above 3000ft. (914m).
Honda Model:
For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above sea level.
If operation will consistently be at altitudes above 5,000 ft.
(1525m), a carburetor jet designed for high altitudes should
be installed. This will result in better fuel economy, cleaner
exhaust and longer spark plug life. It will not give increased
power. Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine manufacturer.
CAUTION
Do not operate with a high altitude jet installed at altitudes below 5000 ft. This will result in the engine running
too lean and result in higher engine operating temperatures which can shorten engine life.
--------------------------------------------------------------------------------
Muffler Relocation
WARNING
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The RANGER® 10,000 and the RANGRER 10,000
PLUS weigh approximately 575 lbs. with a full tank of
gasoline. A lift bail is mounted to the machine and
should always be used when lifting the machine.
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RANGER® 10,000 & RANGER® 10,000 PLUS
Shut off welder and allow muffler to cool before touch-
•
ing muffler.
--------------------------------------------------------------------------------
The RANGER® 10,000 PLUS AND RANGER® 10,000 are
shipped with the exhaust coming out on the left side. The
exhaust can be changed to the opposite side by removing
the two screws that hold the exhaust port cover in place and
installing the cover on the opposite side. (Operating the
RANGER® 10,000 PLUS AND RANGER® 10,000 without
the cover in place will result in a higher noise level and no
increase in machine output.)
A-7 A-7
INSTALLATION
LOCATION / VENTILATION
The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
STACKING
RANGER® 10,000 machines cannot be stacked.
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
WARNING
Shut off welder before making any electrical
connections.
-----------------------------------------------------------------------WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER
The LN-15 has an internal contactor and the electrode
is not energized until the gun trigger is closed. When
the gun trigger is closed the wire will begin to feed and
the welding process is started.
a. Shut the welder off.
Connect the electrode cable from the LN-15 to
b.
the
“ELECTRODE” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.
c. Set the Polarity switch to the desired polarity, either
DC (-) or DC (+).
d. Attach the single lead from the front of the LN-15
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
e. Set the “RANGE” switch to the “WIRE FEED-CV”
position
f. Place the Engine switch in the “High Idle” position.
g. Adjust the wire feed speed at the LN-15 and adjust
the welding voltage with the output “CONTROL” at
the welder.
Note: LN-15 Control Cable model will not work with
the RANGER® 10,000.
CONNECTION OF THE LN-25
a. Shut the welder off.
Connect the electrode cable from the LN-25 to
b.
the
“ELECTRODE” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.
c. Position the welder “Polarity” switch to the desired
polarity, either DC (-) or DC (+).
Output “CONTROL” must be set above 3.
d. Position the “RANGE” switch to the “WIRE FEED”
position.
e. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.
f. Place the engine switch in the “AUTO” position.
g. Adjust wire feed speed at the LN-25 and adjust the
welding voltage with the output “CONTROL” at the
welder.
NOTE: The welding electrode is energized at all times,
unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the
LN-25 contactor may not pull in.
CONNECTION OF K930-2 TIG MODULE TO THE
RANGER® 10,000 OR RANGER® 10,000 PLUS.
The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.
NOTE: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if
any other high frequency equipment is used, a
Bypass Capacitor Kit (T12246) must be
installed in the RANGER® 10,000.
.
INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the roof and case sides
in place as this provides maximum protection from
moving parts and assures proper cooling air flow.
Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Ownerʼs Manual.
WELDER OPERATION
WELDER OUTPUT
• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.
• Duty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty Cycle
for the RANGER® 10,000 is 100%.
RANGER® 10,000 and RANGER® 10,000 PLUS
Constant Current 225 Amps AC @ 25 Volts
210 Amps DC @ 25 Volts
Constant Voltage 200 Amps DC @ 20 Volts
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RANGER® 10,000 & RANGER® 10,000 PLUS
A-8 A-8
GND
120 V
120 V*
240 V
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
INSTALLATION
AUXILIARY POWER
The RANGER® 10,000 can provide up to 9,000 watts
of 120/240 volts AC, single phase 60Hz power for continuous use, and up to 10,000 watts of 120/240 volts
AC, single phase 60Hz power peak use.
The RANGER® 10,000 PLUS can provide up to 9,000
watts of 120/240 volts AC, single phase 60Hz power
for continuous use, and up to 10,500 watts of 120/240
volts AC, single phase 60Hz power peak use.
The front of the machine includes three receptacles for
connecting the AC power plugs; one 50 amp 120/240
volt NEMA 14-50R receptacle and two 20 amp 120 volt
NEMA 5-20R receptacles. Output voltage is within +/10% at all loads up to rated capacity.
120 V DUPLEX RECEPTACLES
CAUTION
Do not connect any plugs that connect to the
power receptacles in parallel.
------------------------------------------------------------------------
Start the engine and set the “IDLER” control switch to
the desired operating mode. Set the “CONTROL” to
10. Voltage is now correct at the receptacles for auxiliary power.
120/240 VOLT DUAL VOLTAGE RECEPTACLE
The 120/240 volt receptacle can supply up to 38 amps
of 240 volt power to a two wire circuit, up to 38 amps
of 120 volts power from each side of a three wire circuit (up to 76 amps total). Do not connect the 120 volt
circuits in parallel. Current sensing for the automatic
idle feature is only in one leg of the three wire circuit as
shown in the following column.
RANGER® 10,000 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
The 120V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.
The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle.
MOTOR STARTING
Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a
1.5 hp motor is approximately 20 amperes (10
amperes for 240 volt motors). The motor may be run at
full load when plugged into only one side of the duplex
receptacle. Larger motors through 2 hp can be run provided the receptacle rating as previously stated is not
exceeded. This may necessitate 240V operation only.
15
20
15
20
38
Voltage
Volts
120
120
240
240
240
Current
(Amps)
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Load
(Watts)
1800
2400
3600
4800
9000
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
30
60
(9)
(18)
Conductor size is based on maximum 2.0% voltage drop.
RANGER® 10,000 & RANGER® 10,000 PLUS
Maximum Allowable Cord Length in ft. (m) for Conductor Size
40
30
75
60
(12)
(9)
(23)
(18)
75
50
150
100
50
(23)
(15)
(46)
(30)
(15)
125
88
225
175
90
(38)
(27)
(69)
(53)
(27)
175
138
350
275
150
(53)
(42)
(107)
(84)
(46)
300
225
600
450
225
(91)
(69)
(183)
(137)
(69)
A-9 A-9
ELECTRICAL DEVICE USE WITH THE RANGER® 10,000 or RANGER® 10,000 PLUS.
Type Common Electrical Devices Possible Concerns
Resistive Heaters, toasters, incandescent NONE
light bulbs, electric range, hot
pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage
appliances with electrical control. regulation can cause the capac-
INSTALLATION
TABLE lll
itative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE
TYPE LOADS.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required,
and liabilities still exist. DO
NOT USE THESE DEVICES
WITH A RANGER® 10,000
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER® 10,000 or RANGER® 10,000 PLUS.
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RANGER® 10,000 & RANGER® 10,000 PLUS
A-10 A-10
INSTALLATION
AUXILIARY POWER WHILE WELDING
Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time). Also,
the “Output Control” is set at “10” for maximum auxiliary power.
TABLE I
SIMULTANEOUS WELDING AND POWER
Output Selector Permissible Power Permissible Auxiliary
Setting Watts (Unity Power Current in Amperes
Factor) @ 120V
Max. Stick or Wire
Feed Setting None 00
145 Stick Setting 3450 32 16
90 Stick Setting 6000 50
NO WELDING 9000 76
*-or- @ 240V
** 25
** 38
1. Install a double pole, double throw switch between
the power company meter and the premises
disconnect.
Switch rating must be the same or greater than
the customerʼs premises disconnect and service
overcurrent protection.
2. Take necessary steps to assure load is limited to
the capacity of the RANGER® 10,000 by installing
a 40 Amp 240V double pole circuit breaker.
Maximum rated load for the 240V auxiliary is 38
amperes. Loading above 38 amperes will reduce
output voltage below the allowable -10% of rated
voltage which may damage appliances or other
motor-driven equipment.
3. Install a 50 amp 120/240V plug (NEMA type 14-50)
to the Double Pole Circuit Breaker using a 4 con
ductor cable that is properly sized for the ampacity
and length to be used.
(The 50amp 120/240V plug is available in the
optional plug kit.)
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 40A per 120VAC branch circuit
when splitting the 240 VAC output.
STANDBY POWER CONNECTIONS
The RANGER® 10,000 or RANGER® 10,000 PLUS is
suitable for temporary, standby, or emergency power
using the engine manufacturerʼs recommended maintenance schedule.
The RANGER® 10,000 or RANGER® 10,000 PLUS
can be permanently installed as a standby power unit
for 240V-3 wire, single phase 38 ampere service.
WARNING
Connections must be made by a licensed electrician who can determine how the 120/240V power
can be adapted to the particular installation and
comply with all applicable electrical codes. The following information can be used as a guide by the
electrician for most applications. (Refer to the connection diagram shown in Figure A.1.)
-------------------------------------------------------------------------
4. Plug this cable into the 50 amp 120/240V
receptacle on the RANGER® 10,000 case front.
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RANGER® 10,000 & RANGER® 10,000 PLUS
A-11 A-11
240 Volt
60 Hz.
3-Wire
Service
P
OWER
COMPANY
M
ETER
2
40 VOLT
1
20 VOLT
1
20 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
4 CONDUCTOR COPPER CABLE
SEE NATIONAL ELECTRICAL CODE
FOR WIRE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
40 AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
S
WITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
P
ROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
INSTALLATION
Figure A.1
CONNECTION OF RANGER® 10,000 OR RANGER® 10,000 PLUS TO PREMISES WIRING
WARNING
Connection of RANGER® 10,000 to premises
wiring must be done by a licensed electrician and
must comply with the National Electrical Code and
all other applicable electrical codes.
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RANGER® 10,000 & RANGER® 10,000 PLUS
A-12 A-12
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation ................................................................................................................Section B
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Controls Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Welding Process (Stick/Tig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Summary of Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
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RANGER® 10,000 & RANGER® 10,000 PLUS
B-2 B-2
OPERATION
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
• Always operate the welder with the hinged door
closed and the side panels in place.
• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.
------------------------------------------------------------------------
GENERAL DESCRIPTION
The RANGER®™10,000 and RANGER® 10,000 PLUS
are twin-cylinder, gasoline driven, multi-process arc
welders and AC power generators. They are built with
a heavy gauge steel case for durability on the job site.
WELDER CONTROLS - FUNCTION AND
OPERATION
ENGINE SWITCH
The engine switch is used to Start the Engine, Select
High Idle or Auto Idle while the engine is running, and
stop the Engine.
When placed in the “OFF” position, the ignition
circuit is de-energized to shut down the engine.
When held in the “START” position, the engine
starter motor is energized.
When in “HIGH IDLE” ( ) position, the engine will
run continuously at high speed.
When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:
• Welding
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.
After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.
• Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles,
the engine will accelerate to high speed. If no
power is being drawn from the receptacles (and
not welding) for 10-14 seconds, the idler reduces
the engine speed to low idle.
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RANGER® 10,000 & RANGER® 10,000 PLUS
B-3 B-3
OPERATION
“ RANGE” SWITCH
The “Range” switch is used to select one of three
amperage ranges with generous overlap for Stick/TIG
welding, or one Wire Feed welding range.
Process Range Setting Current Range
STICK/TIG
(constant current)
(3 range settings)
WIRE FEED
(constant voltage)
(one range setting)
90 Max.
145 Max.
210DC/225AC Max.
15 to 25V
40 to 90 Amps
70 to 145 Amps
120 to 210 (DC) 225(AC)
Up to 200 Amps
CAUTION
Never change the “RANGE” Switch setting while
welding. This will damage the switch.
------------------------------------------------------------------------
“ CONTROL” DIAL
Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and welding
voltage control with the Range switch set in the wire
feed mode.
POLARITY SWITCH
Provides three selectable welding polarities: AC, DC+ & DC- .
CAUTION
Never change the Polarity switch setting while welding.
This will damage the switch.
-------------------------------------------------------------------------------------------------------------------
RANGER® 10,000 AND RANGER® 10,000 PLUS APPROXIMATE FUEL CONSUMPTION
Low Idle - No Load
2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
225 Amps @ 25 Volts
DC CC Weld Output
210 Amps @ 25 Volts
DC CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power
9000 Watts
KOHLER
20 H.P. COMMAND
23 HP CH23S
.4 Gallons/Hour
(1.5 Liters/Hour)
.7 Gallons/Hour
(2.8 Liters/Hour)
1.2 Gallons/Hour
(4.6 Liters/Hour)
1.3 Gallons/Hour
(4.9 Liters/Hour)
1.2 Gallons/Hour
(4.5 Liters/Hour)
1.4 Gallons/Hour)
(5.3 Liters/Hour)
HONDA
20 H.P. GX620KI
.3 Gallons/Hour
(1.3 Liters/Hour)
.7 Gallons/Hour
(2.8 Liters/Hour)
1.3 Gallons/Hour
(5 Liters/Hour)
1.5 Gallons/Hour
(5.9 Liters/Hour)
1.2 Gallons/Hour
(4.5 Liters/Hour)
1.7 Gallons/Hour)
(6.5 Liters/Hour)
ROBIN / SUBARU
20.5 H.P. P220
22.5 HP EH665
.6 Gallons/Hour
(2.3 Liters/Hour)
.8 Gallons/Hour
(3.0 Liters/Hour)
1.5 Gallons/Hour
(5.8 Liters/Hour)
1.6 Gallons/Hour
(6.1 Liters/Hour)
1.2 Gallons/Hour
(4.5 Liters/Hour)
1.6 Gallons/Hour)
(6.1 Liters/Hour)
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RANGER® 10,000 & RANGER® 10,000 PLUS
B-4 B-4
OPERATION
STARTING/SHUTDOWN INSTRUCTIONS
STARTING THE ENGINE
WARNING
• Do not touch electrically live parts
of electrode with skin or wet
clothing.
• Keep flammable material away.
• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.
• Keep your head out of the fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
Be sure all Pre-Operation Maintenance has been performed. Also, read the Engine Ownerʼs Manual before
starting for the first time.
Remove all loads connected to the AC power receptacles. Use the choke control as follows:
STOPPING THE ENGINE
Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.
Stop the engine by placing the Engine switch in the
“OFF” position.
A fuel shut off valve is not required on the RANGER®
10,000 because the fuel tank is mounted below the
engine.
BREAK-IN PERIOD
It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approximately 50 running hours).
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.
HONDA ENGINE - If the engine is cold, pull the choke
control out. Do Not use the choke if the engine is warm
or hot.
Turn the engine switch to the “start” position and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
the switch to the Auto Idle position.
Do not turn the switch to the “start” position while the
engine is running because this will cause damage to
the ring gear and/or starter motor.
After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.
and turn
/
The engine manufacturerʼs recommendation for the
running time until the first oil change is as follows:
KOHLER HONDA ROBIN/SUBARU
5 HRS. First Month 25 HRS.
or 20 HRS.
The oil filter is to be changed at every second oil
change. Refer to the Engine Ownerʼs Manual for more
information.
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RANGER® 10,000 & RANGER® 10,000 PLUS
B-5 B-5
OPERATION
WELDING PROCESS
For any electrodes the procedures should be kept within the rating of the machine. For electrode information
see the appropriate Lincoln publication.
STICK (CONSTANT CURRENT) WELDING
Connect welding cables to the "TO WORK” and
"ELECTRODE” studs. Start the engine. Set the
"Polarity” switch to the desired polarity. The “RANGE”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The “OUTPUT” Control provides fine adjustment of the welding current within the select range. For
maximum output within a selected range set the “OUTPUT” Control at 10. For minimum output within a
selected range set the “OUTPUT” Control at 5. (“OUTPUT” Control settings below 5 may reduce arc stability) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUTPUT” Control near the maximum to achieve the
desired welding current.
RANGE SETTING
90 MAX.
145 MAX.
TYPICAL
ELECTRODE SIZE
3/32
1/8
CURRENT RANGE
40 TO 90 AMPS
70 TO 145 AMPS
SETTINGS FOR 1% THORIATED TUNGSTEN
TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE
1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps
The K930-[ ] TIG Module should be used with the
RANGER® 10,000 on high idle to maintain satisfactory
operation. It can be used in the AUTO position but the
delay going to low idle after welding is ceased will be
increased if the AFTER FLOW CONTROL is set above 10
seconds.
NOTE: For AC TIG Welding, the maximum TIG welding
output currents on each range setting will be approximately 50% higher than those marked on the nameplate.
This is due to the special nature of the AC TIG welding
arc. Do not AC TIG weld on the 225AC range setting. The
output current may exceed the rating of the RANGER®
10,000.
WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)
The Innershield® electrode recommended for use with
the RANGER® 10,000 is NR
-211-MP. The electrode
®
sizes and welding ranges that can be used with the
RANGER® 10,000 are shown in the following table:
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210(DC)/225(AC)
MAX.
5/32
120 TO 210(DC),
225(AC) AMPS
The RANGER® 10,000 can be used with a broad
range of AC and DC stick electrodes. See “Welding
Tips 1” included with the RANGER® 10,000 for electrodes within the rating of this unit and recommended
welding currents of each.
TIG (CONSTANT CURRENT) WELDING
The K930-[ ] TIG Module installed on a RANGER®
10,000 provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding processes.
Output control is from the RANGER® 10,000. The output control on the TIG Module is not functional. After
flow time is adjustable from 0 to 55 seconds.
When using the RANGER® 10,000 for AC TIG welding
of aluminum, the following settings and electrodes are
recommended:
SETTINGS FOR PURE TUNGSTEN
TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS \CURRENT RANGE
1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/16 90 40 - 80 Amps
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RANGER® 10,000 & RANGER® 10,000 PLUS
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A
The RANGER® 10,000 is recommended for limited “MIG”
welding (GMAW - gas metal arc welding). The recommended electrodes are .030” and .035” L-50 and L-56.
They must be used with a blended shielding gas such as
C25 (75% Argon - 25% CO
). The welding ranges that
2
can be used with the RANGER® 10,000 are shown in the
following table:
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.030 75 - 300 50A to 130A
.035 100 - 250 90A to 175A
ARC GOUGING
The RANGER® 10,000 can be used for limited arc gouging. Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:
ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)
1/8 30 - 60 Amps
5/32 90 - 150 Amps
3/16 150 - 250 Amps
B-6 B-6
CONTROL ELECTRODE
PROCESS CABLE IDLE WHEN NOT TO START
USED MODE WELDING WELDING
STICK No AUTO Hot Touch electrode to work.
WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding
TIG, TIG MODULE WITH Yes High Cold Press Arc Start Switch
WITH CONTACTOR KIT contactor closes,
CONTROL CABLE, & ARC welding starts immediately.
START SWITCH
OPERATION
Summary of Welding Processes
Welding starts immediately
and engine goes to high
idle.
starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”
WIRE FEED, LN-15 No High Cold Press gun trigger.
ACROSS the ARC LN-15 contactor closes,
(has internal contactor) Welding starts immediately
Note: Output Control must
be set above “3”.
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RANGER® 10,000 & RANGER® 10,000 PLUS
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories............................................................................................................Section C
Optional Equipment ..................................................................................................C-2
Recommended Equipment .......................................................................................C-3
Stick...................................................................................................................C-3
Wirefeed.............................................................................................................C-3
TIG .....................................................................................................................C-3
Plasma Cutting ..................................................................................................C-3
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RANGER® 10,000 & RANGER® 10,000 PLUS
C-2 C-2
ACCESSORIES
OPTIONAL EQUIPMENT (Field Installed)
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS - For road, off-road and in-plant
and yard towing. (For highway use, consult applicable
federal, state and local laws regarding requirements for
brakes, lights, fenders, etc.)
Order K957-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack
K889-2 & -3 Two-Wheel Undercarriage - For moving
by hand. Overall Width 29 in (.74m) Both have pneumatic tires. Puncture proof tires included with K889-3.
K1631-1 Puncture Proof Wheel Kit - For converting
K889-2 or K933-1 to puncture proof pneumatic tires.
K893-1 Caster for Undercarriage - Mounts to the
front of the K889-2 or 3 to allow easy movement on
smooth surfaces. Includes 6” diameter hard rubber
wheel and convenient toe-on, toe-off locking brake.
K802-R Power Plug Kit- provides four 120V plugs
rated at 15 amps each and one dual voltage, Full KVA
plug rated at 120/240V, 50 amps.
K802-N Power Plug Kit - Provides four 120V plugs
rated at 20 amps each and one dual voltage, full KVA
plug rated at 120/240V, 50 amps.
K894-1 Spark Arrester Kit - Includes a heavy gauge
steel, approved spark arrester and clamp for easy
mounting to muffler exhaust pipe.
K1690-1 GFCI RECEPTACLE KIT -
approved120V ground fault circuit interrupter duplex type
receptacle with cover and installation instructions.
Replaces the factory installed 120V duplex receptacle.
Each receptacle of the GFCI Duplex is rated at 20 Amps,
the maximum total current from the GFCI Duplex is limited to the 20 Amps. Two kits are required.
K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
(which accepts 4-prong plugs) and converts it to a
NEMA 6-50R receptacle, (which accepts 3-prong
plugs.)
Includes one UL
K933-1 Four Wheel Undercarriage - For Hand
Moving. Rear pneumatic tires, front molded wheels.
K934-1 Cylinder Brackets - For use with K933-1. For
transporting one welding gas cylinder.
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCARRIAGE - For moving by hand at construction sites.
Heavy duty puncture resistant pneumatic tires.
K1770-1 UNDERCARRIAGE (FACTORY) - For moving by hand on a smooth surface. One or two gas cylinders can be mounted on the rear of the undercarriage
with the installation of K1745-1 Cylinder Holder(s).
Heavy duty puncture resistant pneumatic tires and
front caster.
K1745-1 GAS CYLINDER HOLDER
Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.
K1788-1 ROLL CAGE - Gives added damage protection. Attaches to K1737-1, K1770-1, and K957-1.
T12153-9 Full-KVA Power Plug - One dual voltage plug
rated at 120/240V, 50 amps.
K930-2 TIG Module - Provides high frequency and
shielding gas control.for AC and DC GTAW (TIG) welding applications. Its compact case is designed foe easy
carrying, complete with a handle. High frequency
bypass is built in
Requires K938-1 Contactor Kit, K936-4 Control Cable,
and K814 Arc Start Switch.
K938-1 Contactor Kit - For use with TIG Module,
Provides a “cold” electrode until the triggering device
(Arc Start Switch) is pressed.
K936-4 Control Cable - Connects TIG Module to
RANGER® 10,000.
K814 Arc Start Switch - Attaches to the TIG torch for
convenient finger control.
K937-45 Control Cable Extension - Allows TIG Module
to be operated at distances up to 200ft. from the power
source. Available in 45ft. (13.7m).
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K886-1 Canvas Cover -To protect the RANGER®
10,000 when not in use. Made from attractive red canvas material which is flame retardant, mildew resistant,
and water repellent.
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RANGER® 10,000 & RANGER® 10,000 PLUS
K844-1 Water Valve Kit - For use with water cooled
TIG torch, Installs inside of TIG Module.
K939-1 Docking Kit - For Mounting the K930-2 TIG
Module on top of the RANGER® 10,000.
C-3 C-3
ACCESSORIES
RECOMMENDED EQUIPMENT
STICK
K704 Accessory Kit - For Stick Welding. Includes 35 ft (10.7m).
• 2/0 AWG electrode cable, 30 ft. (9.1m)
• 2/0 AWG work cable with lugs, headshield, filter plate, work
clamp, and electrode holder. 400 amp capacity.
K875 Accessory Kit - For stick welding. Includes 20 Ft. (6.1m).
#6 electrode cable with lug, 15 Ft. (4.6m) #6 work cable with
lugs, headshield, filter plate, work clamp, and electrode holder
and sample pack of mild steel electrode. 150 amp capacity.
WIRE FEED
K449 LN-25 - Includes internal contactor for across the
arc operation (no control cable). Provides “cold” electrode until gun trigger is pressed. Includes gas solenoid.
K1870-1 LN-15 Across the Arc
PLASMA CUTTING:
K1580-1- Pro-Cut 55 (Requires full KVA Adapter
K1816-1).
Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.
K126-2 Magnum 350 Innershield Gun (for LN-25, LN-
15).
K1802-1 Magnum 300 MIG Gun (for LN-25, includes
Connector Kit).
K470-2 Magnum 300 MIG Gun (for LN-15, requires
K466-10 Magnum Gun Connector Kit).
K1500-1 Gun Receiver Bushing (for LN-15, K126-2)
Note: See Wire Feeder IM Manual for appropriate
Drive Roll & Guide Tube Kits.
TIG WELDING
K1783-9- PTA-26V TIG Torch.
KP509- Magnum Parts Kit and Argon gas.
K930-2- TIG Module.
Required TIG Equipment:
K938-1 Connector Kit
K936-4 Control Cable
K814 Arc Start Switch
Optional TIG Equipment:
K939-1 Docking Kit
K937-45 Control Cable Extension
K844-1 Water Valve Kit
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RANGER® 10,000 & RANGER® 10,000 PLUS
C-4 C-4
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
Section D-1 Section D-1
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Maintenance ...........................................................................................................Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Engine Oil Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Change the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Hardware & Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Engine Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
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RANGER® 10,000 & RANGER® 10,000 PLUS
D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
mainte nance. Remove guards only wh en
necessary and replace them when the maintenance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust outside.
CAUTION
Make certain that the oil filler cap is securely tightened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.
• OIL - Maintenance schedule for changing the oil and
oil filter after break-in :
KOHLER HONDA
6 Months
Oil 100 HRS. 100 HRS. 100 HRS.
1 Year or
Oil Filter 200 HRS. 200 HRS. 200 HRS.
The above schedule is for normal operating conditions.
More frequent oil changes are required with dusty, high
temperature and other severe operating conditions.
Refer to the maintenance section of the Engine
Owner's Manual for more information.
NOTE: Engine life will be reduced if the oil and oil fil-
ter are not changed according to the manufacturerʼs recommendation.
ROBIN / SUBARU
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information
throughout this operator’s manual and
the Engine manual as well.
------------------------------------------------------------
Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, clothing, and tools away from gears, fans, and all other moving parts when starting, operating, or repairing the
equipment.
ROUTINE MAINTENANCE
• At the end of each dayʼs use, refill the fuel tank to
minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and
add oil if indicated.
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
and complete draining.
• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in
and twist the drain valve counterclockwise. Pull the
valve out and drain the oil into a suitable container.
• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.
• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler
•1.6 US qt. (1.3 IMP qt., 1.5 liter)-Honda GX620KI
•1.5 US qt. (1.2 IMP qt., 1.4 liter)-Robin / Subaru
With oil filter replacement:
• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler
•1.9 US qt. (1.6 Imp qt. , 1.8 liter)-Honda GX620KI
•1.6 US qt. (1.4 IMP qt., 1.6 liter)-Robin / Subaru
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RANGER® 10,000 & RANGER® 10,000 PLUS
D-3 D-3
MAINTENANCE
Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil container to be sure it includes the letters SG or SH.
SAE 10W-30 is recommended for general, all-temperature use, -5 F to 104 F (-20 C to 40 C).
See Engine Ownerʼs Manual for more specific information on oil viscosity recommendations.
Wash your hands with soap and water after handling
used oil.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.
Do not throw it in the trash, pour it on the ground or
down a drain.
OIL FILTER CHANGE
1. Drain the engine oil.
AIR CLEANER AND OTHER MAINTENANCE
• Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling
the foam pre-filter is every 25 hours and replacement of the air cleaner filter every 100 hours. More
frequent servicing is required with dusty operating
conditions. Refer to the maintenance section of the
Engine Ownerʼs Manual for more information.
• Refer to the maintenance section of the Engine
Ownerʼs Manual for the maintenance schedule,
spark plug servicing, cooling system servicing, and
fuel filter replacement.
• Blow out the machine with low pressure air periodically. In particularly dirty locations, this may be
required once a week.
• Output RANGER® Selector and Polarity Switches:
Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the handle
from maximum to minimum setting twice each
morning before starting to weld.
2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.
3. Clean the filter mounting base, and coat the gasket of
the new oil filter with clean engine oil.
4. Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil filter socket tool to tighten the filter an additional 1/2 to
7/8 turn.
5. Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.
6. Start the engine and check for oil filter leaks.
7. Stop the engine, and check the oil level. If necessary,
add oil to the upper limit mark on the dipstick.
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RANGER® 10,000 & RANGER® 10,000 PLUS
D-4 D-4
MAINTENANCE
ENGINE ADJUSTMENTS
OVERSPEED IS HAZARDOUS
WARNING
The maximum allowable high idle speed for this
machine is 3750 RPM, no load. Do NOT tamper
with governor components or setting or make any
other adjustments to increase the maximum
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
SLIP RINGS
A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary.If brushes are to
be replaced, clean slip rings with a fine emery paper.
CAUTION
Do not attempt to polish slip rings while engine is
running.
------------------------------------------------------------------------
HARDWARE
Both English and Metric fasteners are used in this
welder.
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
last.
• CONNECTING A BATTERY CHARGER - Remove battery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.
• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.
BATTERY ACID CAN BURN EYES AND SKIN.
• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.
BATTERY
1. When replacing, jumping, or otherwise connecting
the battery to the battery cables, the proper
polarity must be observed. Failure to observe
the proper polarity could result in damage to the
charging circuit. The positive (+) battery cable
has a red terminal cover.
2. If the battery requires charging from an external
charger, disconnect the negative battery cable
first and then the positive battery cable before
attaching the charger leads. Failure to do so
can result in damage to the internal charger
components. When reconnecting the cables,
connect the positive cable first and the negative
cable last.
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RANGER® 10,000 & RANGER® 10,000 PLUS
D-5 D-5
KOHLER C20S HONDA GX620KI ROBIN / SUBARU EH64
KOHLER 1205001 HONDA ROBIN / SUBARU
Oil Filter FRAM PH3614* 15410-ZJ4-999A 248-65801-00, FRAM PH4967
Air Filter KOHLER 4708303 HONDA ROBIN / SUBARU
Element FRAM CA79 17210-ZJ1-841 263-32610-A1
Air Filter KOHLER 2408302 HONDA N/A
Pre-Cleaner 17218-ZJ1-840
Fuel Filter KOHLER 2505002 HONDA ROBIN / SUBARU
FRAM G1 16910-ZE8-015 011-00600-20
Spark Plugs CHAMPION RC12YC CHAMPION -J16CR-U ROBIN / SUBARU
(Resistor (.030” GAP) NGK-ZGR5A X65-01407-30
Type) 030in, (76 mm) Gap NGK-BPR4EY
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.
MAINTENANCE
ENGINE MAINTENANCE PARTS
ENGINE MAINTENANCE PARTS
KOHLER C23S SUBARU ROBIN EH65
KOHLER 1205001 SUBARU ROBIN
Oil Filter FRAM PH8172* 248-65801-00, FRAM PH4967
Air Filter KOHLER 4708303 SUBARU ROBIN
Element FRAM CA79 263-32610-A1
Air Filter KOHLER 2408302 N/A
Pre-Cleaner
Fuel Filter KOHLER 2405010 SUBARU ROBIN
011-00600-20
Spark Plugs CHAMPION RC12YC SUBARU ROBIN
(Resistor (.030” GAP) X65-01407-30
Type) NGK-BPR4EY
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.
HONDA GX620KI
HONDA
15410-ZJ4-999A
HONDA
17210-ZJ1-841
HONDA
17218-ZJ1-840
HONDA
16910-ZE8-015
CHAMPION -J16CR-U
NGK-ZGR5A
030in, (76 mm) Gap
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RANGER® 10,000 & RANGER® 10,000 PLUS
D-6 D-6
44
11
33
55
22
FIGURE D.1 - MAJOR COMPONENT LOCATION
MAINTENANCE
1. CASEFRONT
2. OUTPUT RECTIFIER ASSEMBLY
3. BASE/UNDERCARRIAGE ASSEMBLY
4. ENGINE/ROTOR/STATOR ASSEMBLY
5. CASE TOP & SIDES
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RANGER® 10,000 & RANGER® 10,000 PLUS
STARTER ENGINE
BATTERY
IDLER
SOLENOID
OUTPUT
CONTROL
MECHANICAL
ROTATION
FIELD
CAPACITOR
ROTOR
SLIP
RINGS
115 & 230VAC
RECEPTACLES
ROTOR
STATOR
STATOR
REACTOR
RANGE
SWITCH
OUTPUT
BRIDGE
CHOKE
AC
AC
POLARITY
SWITCH
ELECTRODE
TERMINAL
WORK
TERMINAL
FLYWHEEL
ALTERNATOR
CV
TAP
PRINTED CIRCUIT
BOARD
Section E-1 Section E-1
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Theory of Operation...............................................................................................Section E
Battery, Starter, Engine, Excitation, Rotor,
Stator, and Idler Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Rotor Field Feedback and Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Weld Winding, Reactor, and Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Output Bridge, Choke, Polarity Switch, and Output Terminals . . . . . . . . . . . . . . . . .E-5
FIGURE E.1 – RANGER® 10,000 BLOCK LOGIC DIAGRAM
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RANGER® 10,000 & RANGER® 10,000 PLUS
E-2 E-2
STARTER ENGINE
B
ATTERY
IDLER
SOLENOID
OUTPUT
CONTROL
MECHANICAL
ROTAT ION
FIELD
CAPACITOR
ROTOR
S
LIP
RINGS
115 & 230VAC
RECEPTACLES
ROTOR
STAT OR
STAT OR
REACTOR
RANGE
SWITCH
O
UTPUT
BRIDGE
CHOKE
A
C
AC
POLARITY
SWITCH
E
LECTRODE
TERMINAL
WORK
TERMINAL
FLYWHEEL
ALTERNATOR
C
V
TAP
PRINTED CIRCUIT
BOARD
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID
BATTERY, STARTER, ENGINE,
ROTOR, STATOR, AND IDLER
SOLENOID
The 12VDC battery powers the starter motor. When
the engine is started and running, the battery circuit
voltage is fed, through the printed 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). Three separate and isolated windings are
incorporated in the stator lamination assembly. Each
winding set has a different number of turns producing
different magnitudes of AC output voltages. The three
windings are the weld winding, the auxiliary power
winding and the field feedback winding. The field
feedback winding provides rotor current during
machine operation. The output of the RANGER®
10,000 is dependent on two criteria: the engine RPM
and the amount of current in the rotor winding.
The flywheel alternator, located on the engine, supplies
“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 throttle linkage.
If no current is being drawn from the RANGER®
10,000, 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.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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RANGER® 10,000 & RANGER® 10,000 PLUS
E-3 E-3
STARTER ENGINE
BATTERY
I
DLER
S
OLENOID
OUTPUT
CONTROL
MECHANICAL
ROTAT ION
FIELD
CAPACITOR
ROTOR
SLIP
R
INGS
115 & 230VAC
RECEPTACLES
ROTOR
STAT OR
S
TAT O R
R
EACTOR
RANGE
SWITCH
OUTPUT
BRIDGE
CHOKE
AC
AC
POLARITY
SWITCH
ELECTRODE
TERMINAL
WORK
TERMINAL
FLYWHEEL
ALTERNATOR
CV
TAP
PRINTED CIRCUIT
BOARD
THEORY OF OPERATION
FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER
ROTOR FIELD FEEDBACK AND
AUXILIARY POWER
The AC voltage developed in the field winding is fed to
the full wave field bridge. The DC output of the bridge
is filtered by the field capacitor and controlled by the
printed circuit board according to the output 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.
When full field voltage is applied to the rotor and the
engine is running at high speed (3700 RPM), a 230 AC
voltage is developed in the stator auxiliary winding.
This winding is tapped to provide 115 VAC. The two
voltages, (115 VAC and 230 VAC), are connected to
the appropriate receptacles and offer 9000 watts (total)
of continuous AC power.
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RANGER® 10,000 & RANGER® 10,000 PLUS
E-4 E-4
STARTER ENGINE
BATTERY
IDLER
SOLENOID
OUTPUT
CONTROL
M
ECHANICAL
R
OTAT ION
FIELD
CAPACITOR
ROTOR
SLIP
RINGS
115 & 230VAC
RECEPTACLES
ROTOR
STAT OR
STAT OR
REACTOR
RANGE
SWITCH
O
UTPUT
B
RIDGE
C
HOKE
AC
A
C
P
OLARITY
S
WITCH
E
LECTRODE
T
ERMINAL
WORK
TERMINAL
FLYWHEEL
ALTERNATOR
CV
TAP
PRINTED CIRCUIT
BOARD
THEORY OF OPERATION
FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH
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 are brought into
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
the current path. As more turns of reactor are brought
into the circuit, the more impedance there is to current
flow. Simply stated, the more reactor 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 a tap on the stator weld winding to provide
a lower but “stiffer” output voltage.
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RANGER® 10,000 & RANGER® 10,000 PLUS
E-5 E-5
STARTER ENGINE
BATTERY
IDLER
SOLENOID
OUTPUT
CONTROL
MECHANICAL
ROTAT ION
FIELD
CAPACITOR
R
OTOR
SLIP
RINGS
115 & 230VAC
RECEPTACLES
ROTOR
STAT OR
STAT OR
REACTOR
RANGE
SWITCH
OUTPUT
BRIDGE
C
HOKE
AC
A
C
POLARITY
SWITCH
ELECTRODE
TERMINAL
WORK
T
ERMINAL
FLYWHEEL
A
LTERNATOR
CV
TAP
PRINTED CIRCUIT
BOARD
THEORY OF OPERATION
FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS
OUTPUT BRIDGE, CHOKE,
POLARITY SWITCH, 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 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 and on to the Output
Terminals.
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RANGER® 10,000 & RANGER® 10,000 PLUS
E-6 E-6
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
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-13
Test Procedures
Rotor Voltage Test ................................................................................................F-15
Rotor Resistance Test ..........................................................................................F-17
Auxiliary and Field Winding Test...........................................................................F-21
Output Rectifier Bridge Test .................................................................................F-25
Charging Circuit Test ............................................................................................F-27
Engine Throttle Adjustment Test ..........................................................................F-29
Oscilloscope Waveforms ............................................................................................F-33
Normal Open Circuit Voltage Waveform (115 VAC Supply) .................................F-33
Typical DC Weld Output Waveform (CV Mode) – Machine Loaded .....................F-34
Typical DC Weld Output Waveform (CC Mode) – Machine Loaded ....................F-35
Typical AC Weld Output Waveform – Machine Loaded .......................................F-36
Abnormal Open Circuit Weld Voltage Waveform (CV Mode, one diode open)....F-37
Abnormal Open Circuit DC Weld Voltage Waveform ...........................................F-38
Normal Open Circuit Weld Voltage Waveform (CV Mode) ...................................F-39
Normal Open Circuit DC Weld Voltage Waveform ...............................................F-40
Normal Open Circuit AC Weld Voltage Waveform ...............................................F-41
Replacement Procedures............................................................................................F-43
Brush Removal and Replacement........................................................................F-43
Printed Circuit Board Removal and Replacement ...............................................F-47
Output Rectifier Bridge Removal and Replacement ............................................F-51
Engine Rotor Removal and Replacement (Kit S20788) .......................................F-55
Retest After Repair......................................................................................................F-60
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RANGER® 10,000 & RANGER® 10,000 PLUS
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. LOCATE 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 procedures referred 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.
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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 1-888-935-3877.
RANGER® 10,000 & RANGER® 10,000 PLUS
F-3 F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
CAUTION
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.
- R emove your bod y ʼ s st a t ic
charge before opening the staticshielding bag. Wear an anti-static
wri s t strap. For safety, u s e a 1
Meg ohm resistive cord connected
to a gr o un ded pa r t of t he
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
equipment frame.
- If you donʼt have a wrist strap,
touch an un-painted, gro unded,
part of the equipment frame. Keep
touc h i ng t h e fr a me t o pre v ent
stat i c b uild- u p . B e s u re 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. Donʼt set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
donʼt 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 i f t he failure
symp t o m ha s b e en co rrect e d b y t h e
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their ope rating
temperature.
5. Re m ove the r e pl aceme n t PC boar d a nd
subs t i tute it with the or i g inal PC boar d 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
fo r b ad c onnecti ons in the control wi ring
harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the PC
boar d was t h e pr o bl em. R ei nstal l the
replacement PC board and test the machine.
6. Al w ays in d icate that this proce d ure wa s
foll o w ed when w a rrant y r eports a r e t o 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.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-4 F-4
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
Major Physical or Electrical Damage is Evident.
No weld output and no auxiliary power. Engine runs normally.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. Check the brushes for wear and
proper contact to the rotor slip
rings.
RECOMMENDED
COURSE OF ACTION
1. Contact The Lincoln Electric
Service Dept. 1-888-935-3877.
1. Perform the Rotor Voltage
Test.
2. Check for the presence of
12VDC (at the pc board) from
lead #216 to frame ground.
This is the “flashing” voltage
and is present only when the
Start, Run, Stop switch S3 is in
the “Start” position. If the 12
VDC is missing check the leads,
switches and connections
associated with the lead #216.
See Wiring Diagram.
Check for the presence of 12
VDC (at the pc board) from lead
#224 to frame ground. This is
the supply voltage to the board
and is present when the engine
is running and the S3 switch is
in the “Run” position. If the
12VDC is missing check the
leads, switches and connections associated with the lead
#224. See Wiring Diagram.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
3. If Rotor Voltage Test is normal,
then preform the Rotor
Resistance Test.
4. If the Rotor Voltage Test is NOT
normal, perform the Auxiliary
and Field Winding Voltage
Test. Then check the Field
Diode Bridge (D2) and the Field
Capacitor (C1). Replace if necessary. If the Field Bridge and
Field Capacitor are good, then
the Printed Circuit 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
1-888-935-3877.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
RANGER® 10,000 & RANGER® 10,000 PLUS
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 runs normally.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Check the open circuit voltage
(OCV) at the welder output terminals, engine at high idle (3650
RPM). Normal maximum is 73
to 80VAC. Normal DC maximum is 67 to 72VDC. If the
OCV is OK then proceed to
Step #2. If the OCV is not present at the welder output terminals, contact your local Lincoln
Authorized Field Service
Facility.
2. Check the welding cables,
clamps and electrode holder for
loose or broken connections.
RECOMMENDED
COURSE OF ACTION
1. Disconnect lead W1 from the
Output Bridge (D1) and check
for the presence of 80VAC from
lead W1 to lead W2 on the main
stator winding. See wiring dia-
gram. If the AC voltage is NOT
present, the winding in the stator 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 AC voltage is present, proceed to step
#2.
2. Check the Reactor, Range
Switch (S1) 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.
3. Check the Choke (L1), Polarity
Switch (S2) 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.
4. Check the weld output terminals and associated wires for
loose or faulty connections.
5. Perform the Output 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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-6 F-6
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
No auxiliary power, welding output is normal. Engine runs normally.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. If machine is equipped with circuit breakers, check circuit
breakers CB1 thru CB5. 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 receptacle(s).
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.
3. If machine is equipped with cir-
cuit breakers, check for faulty
breakers and loose or faulty
connections on associated
wiring.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
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. The brushes may be worn.
Contact your local Lincoln
Authorized Service Facility.
2. The engine RPM may be low.
RECOMMENDED
COURSE OF ACTION
1. If the engine HIGH IDLE RPM is
low, then 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. 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 Printed Circuit 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.
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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-8 F-8
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
No DC welding output. AC welding
output and auxiliary power is normal.
No AC welding output. DC welding
output and auxiliary power is normal.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Make sure the Polarity Switch 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 Switch 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 Bridge Test.
2. Check the Choke (L1), the
Polarity Switch (S2) and associated wires for loose or faulty
connections. Check the choke
winding for continuity and test
to be sure it is NOT grounded
the choke iron.
1. Check the operation of the
Polarity Switch (S2). 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
.
gram
Wiring Dia-
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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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
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
(S1) is in the proper position
(CV) and “seated” correctly.
2. Make sure the wire feeder is
connected correctly.
RECOMMENDED
COURSE OF ACTION
1. Check the operation of the
Range Switch (S1) and check
the associated wires for loose
or faulty connections. See
Wiring Diagram.
2. Check for continuity from lead
C1 to lead W1 located in the
main stator. See Wiring Dia-
gram.
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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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-10 F-10
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
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 (S4)
is in the “Auto” position.
2. Make sure there is NOT an
external load on the weld terminals nor the auxiliary power
receptacles.
RECOMMENDED
COURSE OF ACTION
1. With the Idler Switch (S4) in the
“Auto” position, check for the
presence of 12VDC at leads
#213 to #215 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
#213 to #215, then test for
12VDC from lead #213 to
ground (lead #5). See Wiring
Diagram. If 12VDC is present,
then check lead #215 for continuity (zero ohms) from the Idler
Solenoid to the Printed Circuit
Board plug 3J1. If lead #215 is
OK, then the Printed Circuit
Board may be faulty. Replace.
3. If there is NOT 12VDC from lead
#213 to ground (lead #5), then
check the Idler Switch (S4) for
proper operation and associated wires for loose or
faulty connections.
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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
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.
Engine will not go to high idle when attempting to weld or when the auxiliary power is loaded. Welding output and auxiliary power output is normal when Idler Switch is in the “HIGH” position.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
ENGINE PROBLEMS
1. Make sure the welding cables
and connections are tight.
1. Make sure the welding cables
and connections are tight.
2. Automatic idler may not func-
tion if the auxiliary power is
loaded to less than 150 Watts.
RECOMMENDED
COURSE OF ACTION
1. Check for broken or faulty connections in the sensing leads
(#254 and #254A). Make sure
their connections are tight at
the Electrode Output Terminal
and also at the Polarity Switch.
See Wiring Diagram.
2. Make sure the leads are looped
three times through the current
sensor on the Printed Circuit
Board.
1. Check for broken or faulty connections in the sensing leads.
(#254 and #254A). Make sure
their connections are tight at
the Electrode Terminal and also
at the Polarity Switch. See
Wiring Diagram.
2. Check lead #3, making sure it is
looped through the current sensor on the Printed Circuit Board.
3. The Printed Circuit 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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-12 F-12
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
ENGINE PROBLEMS
Engine will not crank or cranks very slow.
The Engine shuts off. 1. The Engine may be low on or
Engine does not develop full power.
1. Check for loose or faulty battery
cable connections.
2. The battery may be faulty.
3. Check the ammeter to see if the
battery is charging. If not, the
charging circuit may be defective.
out of fuel.
2. The Oil level may be low.
Check and fill to proper level.
3. The fuel filter may be clogged.
1. The fuel filter may be clogged.
Replace if necessary.
RECOMMENDED
COURSE OF ACTION
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.
1. The oil pressure switch may be
faulty. Replace if necessary.
2. The fuel shut off solenoid may
be faulty (Kohler Engines only).
1. Due to wear, the engine may be
in need of repair.
2. The air filter may be clogged.
Replace if necessary.
3. The spark plug(s) may be faulty.
Replace if necessary.
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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-13 F-13
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The welding arc is “cold.” Engine
runs normally (3700 RPM no load).
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 cable 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 welder
output terminals (80VAC Max.
72VDC Max.). If the correct
voltage is present at the output
terminals, then check for loose
connections on the heavy current carrying leads inside the
RANGER® 8. See Wiring
Diagram.
2. If the OCV is low at the welder
output terminals, then 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.
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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
1-888-935-3877.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-14 F-14
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-15 F-15
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 1-888-935-3877.
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
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-16 F-16
Slip Rings
Brushes
Lead 219
+
-
Lead 200A
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST
FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST
(continued)
TEST PROCEDURE
1. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
2. Remove the rubber gasket (cover seal)
from the lift bail.
3. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
4. Remove the case top, then reinstall the
fuel cap.
5. With the 5/16” nut driver, remove the 5
screws holding the right case side.
6. Remove the right case side by lifting up
and out.
7. Set the volt/ohmmeter to the DC volts
position.
8. Connect the positive meter probe to the
brush nearest the rotor lamination (lead
200A). See Figure F.1 for location.
9. Connect the negative meter probe to the
other brush (lead 219).
10. Start the engine and run it at high idle
(3650 RPM). Set the output control to the
MAXIMUM position (position 10).]
11. Check the voltage reading on the voltmeter. It should read between 37 and 46
VDC.
12. 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 (C1), and/or the Printed
Circuit Board may be faulty.
13. If the voltage reading is normal, the field
circuit is functioning properly. Install the
right case side with the 5 sheet metal
screws with the 5/16” nut driver. Remove
the fuel cap; install the case top and tighten the 6 sheet metal screws with the
5/16” nut driver. Install the rubber gasket
over the lift bail and install the fuel cap.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-17 F-17
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 1-888-935-3877.
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
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-18 F-18
Lead 219
Lead 200A
+
-
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE TEST
FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS
(continued)
TEST PROCEDURE
1. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
2. Remove the rubber gasket (cover seal)
from the lift bail.
3. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
4. Remove the case top, then replace the
fuel cap.
5. With the 5/16” nut driver, remove the 5
screws holding the right case side.
6. Remove the right case side by lifting up
and out.
7. Conduct the test with the gasoline engine
OFF.
8. Remove the spark plug wires to prevent
accidental engine kickback or starting.
9. Isolate the rotor electrically by removing
the generator brush leads. Refer to
Figure F.2 as you perform the remaining
steps.
10. Remove lead 219 from the negative
brush.
11. Remove lead 200A from the positive
brush.
12. 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 between 4 and 5
ohms.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-19 F-19
13. 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.
14. Connect lead 200A to the positive
brush, which is the one nearest the rotor
lamination. Connect lead 219 to the
negative brush.
TROUBLESHOOTING & REPAIR
15. Reinstall the case side, case top, fuel
cap, lift bail gasket and spark plug wires.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-20 F-20
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-21 F-21
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 1-888-935-3877.
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
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-22 F-22
Lead #3
Lead #5
115V
Receptacle
Machine
C
ase
F
ront
TROUBLESHOOTING & REPAIR
AUXILIARY AND FIELD WINDING TEST
FIGURE F.3 – LOCATION OF LEADS #3 AND #5
(continued)
TEST PROCEDURE
To test the 115 VAC winding:
1. Remove the fuel cap and lift bail rubber
gasket. With the 5/16” nut driver, remove
the case top and left side; then reinstall the
fuel cap.
2. Connect the volt/ohmmeter probes to
leads #3 and #5 where they connect to the
115 VAC receptacle. See Figure F.3.
3. Start the engine and run it at high idle (3650
RPM).
4. Set the output control to the maximum
position (position 10).
5. Check the AC voltage reading. It should be
approximately 125 VAC.
To test the 230 VAC winding:
1. Remove the fuel cap and lift bail rubber
gasket. With the 5/16” nut driver, remove
the case top and left side; then reinstall
the fuel cap.
2. Connect the volt/ohmmeter 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 gasoline
engine, insert two test probes into the receptacle. Hold the test probes firmly in place to
measure voltage (Step 5).
3. Start the engine and run it at high idle (3650
4. Set the output control to the maximum
RPM)
position (position 10).
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5. Check the AC voltage reading. It should be
approximately 240 VAC.
RANGER® 10,000 & RANGER® 10,000 PLUS
F-23 F-23
TROUBLESHOOTING & REPAIR
AUXILIARY AND FIELD WINDING TEST
To test the field winding:
1. Remove the fuel cap and lift bail rubber
gasket. With the 5/16” nut driver, remove
the case top and left side; then reinstall
the fuel cap.
2. Connect the volt/ohmmeter probes to leads
#7 and #9 where they connect to the Field
Idle Control P.C. Board.
3. Start the engine and run it at high idle (3650
RPM).
4. Set the output control to the maximum
position (position 10).
5. Check the AC voltage reading. It should be
between 36 and 43 VAC.
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.
(continued)
If the voltage readings are within specifications, then the windings are good and functioning properly.
6. Reinstall the case side, case top, fuel cap,
and lift bail gasket.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-24 F-24
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-25 F-25
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 1-888-935-3877.
TEST DESCRIPTION
This test will determine if there are faulty diodes in the Output Rectifier Bridge.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
7/16” wrench or 7/16” socket wrench and 6” socket extension
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-26 F-26
(-)
(+)
(+)
(+)
(
-)
(-)
OUTPUT RECTIFIER
ENGINE
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE TEST
FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS
(continued)
TEST PROCEDURE
1. Remove the spark plug wires to prevent
accidental engine kickback or starting.
2. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
5. Remove the case top, then replace the fuel
cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
7. Remove the right case side by lifting up and
out.
8. Conduct the test with the gasoline engine
OFF.
9. Locate the Output Rectifier Bridge behind
the machine case front.
10. With the 7/16” wrench or socket wrench
and 6” extension, remove the nuts and
washers holding the diode bridge pigtails
and the heavy current-carrying leads to
the studs located in the middle of the rectifier assembly. Note their locations and
the order of fasteners for reassembly.
11. Electrically isolate the (-) diode connectors
by slightly bending them back into “free
air.”
12. With an ohmmeter or diode tester, check
each of the four diodes from their connector to their respective heat sinks. See
Figure F.4.
13. 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.
14. Replace any “shorted” or “open” diode
bridge assembly the tests indicate.
15. Reconnect the diode connectors and
heavy leads to their respective studs.
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16. Reinstall the case side, case top, fuel cap,
lift bail gasket and spark plug wires.
RANGER® 10,000 & RANGER® 10,000 PLUS
F-27 F-27
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 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the Flywheel Alternator, Regulator, and associated circuitry are
functioning properly.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-28 F-28
Voltage
Regulator
Ground
Lead
(Green)
Engine
AC Lead
DC Lead
AC Lead
TROUBLESHOOTING & REPAIR
CHARGING CIRCUIT TEST
FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR
(continued)
TEST PROCEDURE
1. Start the engine and run it at high idle
(3650 RPM).
2. Set the voltmeter for AC volts and place
one meter probe on each of the two outside leads that attach to the engine voltage
regulator. See Figure F.5 for location.
Check for 42-52 VAC at the voltage regulator.
3. If the AC voltage is low or not present, the
engine flywheel alternator may be faulty.
This is an engine problem; consult your
local engine repair facility.
4. If the voltage reading is correct, then check
the output of the voltage regulator to determine the charging voltage for the battery.
Run the engine at high idle (3650 RPM).
Set the voltmeter for DC volts and place
one meter probe on the middle lead and
one probe on the green ground wire connected to the voltage regulator. See Figure
F.5 for location. Check for 13-15 VDC.
5. If the DC voltage reading is incorrect or not
present, the voltage regulator may be
faulty. Replace the entire voltage regulator
module.
6. If the DC voltage reading is correct, check
the associated wiring and circuitry. See
the Wiring Diagram.
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F-29 F-29
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 1-888-935-3877.
TEST DESCRIPTION
If the machine output is low, this test will determine whether the gasoline 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” open end or box wrench
Strobe-tach, frequency counter, oscilloscope, or vibratach
Black or red marking pencil
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F-30 F-30
Blower Paddle
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD
(continued)
TEST PROCEDURE
This test can be conducted by any one of four
methods.
Strobe-tach Method:
1. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
2. Remove the rubber gasket (cover seal) from
the lift bail.
3. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
4. Remove the case top, then replace the fuel
cap.
5. Conduct this procedure with the gasoline
engine OFF.
6. Remove the spark plug wires to prevent
accidental engine kickback or starting.
7. With the black or red marking pencil, place
a mark on one of the blower paddles. See
Figure F.6 for location.
8. Connect the strobe-tach according the
manufacturer’s instructions.
9. Reconnect the spark plug wires and start
the engine. Direct the strobe-tach light on
the blower paddle and synchronize it to
the rotating mark.
10. With the machine at HIGH IDLE the tach
should read between 3650 and 3750 RPM.
With the machine at LOW IDLE the tach
should read between 2150 and 2250 RPM.
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F-31 F-31
Throttle
linkage
Choke
Cable
3/8" High Idle
Adjustment Nut
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
FIGURE F.7
HIGH IDLE ADJUSTMENT NUT
Housing
(continued)
FIGURE F.8
LOW IDLE ADJUSTMENT NUT
Solenoid
3/8" Low Idle
Adjustment
Nut
Muffler
Rod
11. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjustment nut. Turn the nut clockwise to
increase HIGH IDLE speed. Adjust the
speed until the tach reads between 3650
and 3750 RPM.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLE
switch to AUTO and wait for the engine to
change to low idle speed. Use the 3/8”
wrench to adjust the solenoid nut, which
changes the amount of throw in the throttle
lever arm. See Figure F.8 for location of the
adjustment nut. Adjust the nut until the
tach reads between 2150 and 2250 RPM.
Frequency Counter Method
1. Plug the frequency counter into one of the
115 VAC auxiliary receptacles.
2. Start the engine and check the frequency
counter. At HIGH IDLE (3700 RPM), the
counter should read 60.8 to 62.5 Hz. At
LOW IDLE (2200 RPM), the counter
should read 35.8 to 37.5 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: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.7 for location of the adjustment nut. Turn the nut clockwise to in crease HIGH IDLE speed. Adjust the
speed until the frequency reads between
60.8 and 62.5 Hz.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLER
switch to AUTO and wait for the engine to
change to low idle speed. Use the 3/8”
wrench to adjust the solenoid nut, which
changes the amount of throw in the throttle
lever arm. See Figure F.8 for location of the
adjustment nut. Adjust the nut until the frequency reads between 35.8 and 375.Hz.
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F-32 F-32
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
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 16.2 milliseconds. At 2200 RPM, the waveform
should exhibit a period of 27.3 milliseconds. Refer to NORMAL OPEN CIRCUIT
VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD in this sec-
tion of the manual.
2. If either waveform periods is incorrect,
adjust the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjust-
ment nut. Adjust the speed until the period
is 16.2 milliseconds.
Adjust LOW IDLE: First make sure there is
no load on the machine. Set the IDLER
switch to AUTO and wait for the engine to
change to low idle speed. Use the 3/8”
wrench to adjust the solenoid nut, which
changes the amount of throw in the throttle
lever arm. See Figure F.9 for location of
the adjustment nut. Adjust the speed until
the period is 27.3 milliseconds.
(continued)
Vibratach Method:
1. Place the vibratach as close to the engine
as possible. With the machine case top
removed, the top of the air cleaner is the
best location.
2. Start the engine and observe the whip
handle of the vibratach. At HIGH IDLE
(3700 RPM), the whip handle should
exhibit maximum oscillation. At LOW IDLE
(2200 RPM), the whip handle should
exhibit minimum oscillation. Note that
these are median measurements; vibratach readings may vary slightly above or
below:
3. If either of the vibratach indications is
incorrect, adjust the throttle as follows:
Adjust HIGH IDLE: Use the 3/8” wrench to
turn the spring-loaded adjustment nut.
See Figure F.8 for location of the adjust-
ment nut. Turn the nut clockwise to
increase HIGH IDLE speed. Adjust the
speed until the vibratach whip handle
exhibits maximum oscillation at 3650 to
3750 RPM.
Adjust LOW IDLE: First make sure that
there is no load on the machine. Set the
IDLER switch to AUTO and wait for the
engine to change to low idle speed. Use
the 3/8” wrench to adjust the solenoid nut,
which changes the amount of throw in the
throttle lever arm. See Figure F.9 for loca-
tion of the adjustment nut. Adjust the
speed until the vibratach whip handle
exhibits minimum oscillation at 2150 to
2250 RPM.
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F-33 F-33
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM
16.2 ms
CH1
0 volts
50 volts
This is the typical AC 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 115 VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
5 ms
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F-34 F-34
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE)
MACHINE LOADED
CH1
0 volts
20 volts
MACHINE LOADED TO 200 AMPS AT 20 VDC
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.
5 ms
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-35 F-35
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
MACHINE LOADED
CH1
0 volts
20 volts
5 ms
MACHINE LOADED TO 200 AMPS AT 26 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.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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F-36 F-36
TROUBLESHOOTING & REPAIR
TYPICAL AC WELD OUTPUT WAVEFORM
MACHINE LOADED
CH1
0 volts
20 volts
5 ms
MACHINE LOADED TO 225 AMPS AT 25 VDC
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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F-37 F-37
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
ONE OUTPUT DIODE NOT FUNCTIONING
CH1
0 volts
20 volts
This is NOT the typical CV 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
nonfunctioning output diode. Each
vertical division represents 20 volts
and each horizontal division represents 5 milliseconds in time.
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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F-38 F-38
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
nonfunctioning 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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F-39 F-39
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (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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F-40 F-40
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
CH1
0 volts
50 volts
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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F-41 F-41
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
CH1
0 volts
50 volts
This is the typical AC 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® 10,000 & RANGER® 10,000 PLUS
F-42 F-42
NOTES
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F-43 F-43
TROUBLESHOOTING & REPAIR
BRUSH REMOVAL AND REPLACEMENT
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 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in accessing the generator brushes for
maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
5/16” open end wrench
7/16” wrench
Slot head screw driver
Needle nose pliers
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F-44 F-44
TROUBLESHOOTING & REPAIR
BRUSH REMOVAL AND REPLACEMENT
PROCEDURE
1. Remove the spark plug wires.
2. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal)
from the lift bail.
4. Remove the fuel cap. The rubber gasket
for the fill tube with come off with the case
top.
5. Remove the case top, then reinstall the
fuel cap.
6. WIth the 5/16” nut driver, remove the 5
screws holding the right case side.
7. Remove the right case side by lifting up
and out.
8. With the needle nose pliers, gently remove
the blue and the red wires from the
brushes. See Figure F.9.
(continued)
13. Snap the plastic retainer back onto the
brush holder. The brushes may need
some repositioning; wiggle them slightly to
help them seat properly on the slip rings.
14. To reinstall the brushes, depress the
spring-loaded brushes into the holder and
slip a suitable non-metallic, fairly stiff
retainer through the slots at the top and
bottom of the holder. A cable tie works
well; See Figure F.9. This will hold the
brushes up so that you can easily install
the holder.
15. Slide the brush holder assembly back into
the bracket and, with the 5/16” open end
wrench, install the two screws that hold it
in place.
16. With the 7/16” wrench, install the brush
holder assembly bracket to the stator
frame.
9. With the 7/16” wrench, remove the brush
holder assembly bracket from the stator
frame.
10. With the 5/16” open end wrench, remove
the two screws that secure the brush holder assembly to the bracket. Slide the
brush holder assembly out of the bracket.
11. To change the brushes, use the slot head
screw driver to pop off the plastic retainer
on the back of the brush holder assembly.
12. Remove the old brushes and insert the
new ones. One corner of the terminal clip
is beveled so that the brush can go in only
one way.
17. Slowly remove the non-metallic retainer
from the brush holder and let the brushes
snap back against the slip rings.
18. With the needle nose pliers, connect the
red and the black wires to the appropriate
terminals on the brushes. The red wire is
inboard.
19. Check the wire connections for clearance
and tightness.
20. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wires.
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F-45 F-45
Cable
Tie
7/16" Brush
Assembly
Bracket Bolts
Brushes
TROUBLESHOOTING & REPAIR
BRUSH REMOVAL AND REPLACEMENT
SLIP RINGS
A slight amount of darkening and wear of the
slip rings and brushes is normal. Brushes
should be inspected when a general overhaul is
necessary. If brushes are to be replaced, clean
slip rings with a fine emery paper.
FIGURE F.9 - BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE
(continued)
CAUTION
Do not attempt to polish slip rings while engine
is running.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-46 F-46
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-47 F-47
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL
AND REPLACEMENT
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 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the printed circuit board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
Phillips Head Screwdriver
Diagonal cutters
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-48 F-48
1
2 Pin Plug
4 Pin Plug
4 Self Tapping Screws (at corners)
1/4" Q.C. Tabs
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT
(continued)
FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION
PROCEDURE
Before starting the following procedure, refer to
the topic “PC Board Troubleshooting
Procedures” at the beginning of this section.
1. Remove the engine spark plug wires.
2. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
5. Remove the case top, then reinstall the
fuel cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
7. Remove the right case side by lifting up and
out.
8. Remove the 12-pin molex plug from the
Printed circuit board.
9. Remove 4-pin molex from the current
sensing leads.
10. Remove leads from two 1/4” Q.C. connectors.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-49 F-49
TROUBLESHOOTING & REPAIR
PRINTED CIRCUIT BOARD REMOVAL
AND REPLACEMENT
(continued)
CAUTION
Be sure to follow the recommended staticfree methods for handling printed circuit
boards. Failure to do so can result in permanent damage to the equipment.
12. With the 1/4” phillips head screw driver,
remove four self tapping screws holding
the printed circuit board.
13. Replace the old printed circuit board with
a new one.
14. Connect the 12-pin molex plug.
15. Connect the 4-pin molex plug.
16. Connect two 1/4” Q.C. wires to P.C.
Board.
17. Replace any cable ties that were cut during the removal procedure.
18. Replace 4 self tapping screws previously
removed.
19. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wires.
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-50 F-50
NOTES
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-51 F-51
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
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 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the output rectifier bridge for
maintenance or replacement.
MATERIALS NEEDED
1/2” wrench
7/16” wrench
3/8” wrench
Dow Corning 340
Wiring Diagram
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RANGER® 10,000 & RANGER® 10,000 PLUS
F-52 F-52
(-)
(+)
(+)
(+)
(
-)
(-)
ENGINE
NO NUT
TO POLARITY SWITCH
#8
L1 TO CHOKE
(4) 7/16"
MOUNTING
SCREWS
W1
TO S2
TO S2
TO S1
254
(3) 1/2"
MOUNTING
SCREWS
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS
(continued)
PROCEDURE
1. Remove the engine spark plug wires.
2. With the 5/16” nut driver, remove the 6 sheet
metal screws from the case top.
3. Remove the rubber gasket (cover seal) from
the lift bail.
4. Remove the fuel cap. The rubber gasket for
the fill tube will come off with the case top.
5. Remove the case top, then reinstall the fuel
cap.
6. With the 5/16” nut driver, remove the 5
screws holding the right case side.
7. Remove the right case side by lifting up and
out.
For the remaining steps, refer to Figure F.11.
8. With the 1/2” wrench, remove the choke
lead.
9. With the 1/2” wrench, remove the heavy
cable and the #8 lead (White) from the rectifier negative heat sink.
10. WIth the 7/16” wrench, remove the W1 lead
and the heavy lead going to the S2 Polarity
switch.
11. With the 7/16” wrench, remove the S2 lead,
the heavy lead going to the S1 Range
switch, and 254 (White) lead to sense turroid.
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F-53 F-53
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE REMOVAL
AND REPLACEMENT
(continued)
12. With the 1/2” wrench remove the three
mounting nuts. Note the placement of the
nylon insulators.
13. Remove the rectifier assembly by tilting it
up and lifting it toward the side of the
machine.
14. Reassembly: Refer to the Wiring Diagram
for proper connections to the positive and
negative sides of the rectifier assembly.
The two sides of the bridge are marked +
and -, respectively.
NOTE: Use Dow Corning 340 on all aluminum
electrical connection surfaces.
15. With the 1/2” wrench install the three
mounting nuts.
16. With the 7/16” socket wrench, install the
S2 lead and the heavy lead going to the S1
Range switch. Note the order of fasteners:
flat washer at the bottom followed by pigtails, heavy leads, flat washer, lock washer, and nut.
17. With the 7/16” socket wrench, install the
W1 lead and the heavy lead going to the
S2 Polarity switch. Note the order of fasteners: flat washer at the bottom followed
by pigtails, heavy leads, flat washer, lock
washer, and nut.
18. With the 1/2” socket wrench, install the
heavy cable and the #8 lead (White) to the
rectifier negative heat sink. Note the order
of fasteners.
19. With the 1/2” socket wrench, install the
choke lead and the #10 lead and note the
order of fasteners.
20. Reinstall the case side, fuel cap, lift bail
gasket, case top, and spark plug wire.
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F-54 F-54
NOTES
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F-55 F-55
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND REPLACEMENT
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 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the engine and/or rotor for maintenance or replacement of either component.
NOTE: The procedures described here are for a Kohler engine. The same basic procedures
apply to the other engines, although there may be a few slight wiring variations.
MATERIALS NEEDED
Lincoln Electric Rotor Removal Kit (S20788) - FOR ROTOR REMOVAL ONLY
1/4” nut driver
5/16” nut driver
Slot head screw driver
3/8” wrench
7/16” wrench
1/2” wrench
9/16” wrench
5/8” wrench
Locking pliers
Needle nose pliers
Diagonal cutters
Impact wrench
Torque wrench (ft lbs)
Feeler gauge (.017)
INSTRUCTIONS
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For Engine and Rotor removal only, follow steps 1-25 under ENGINE AND ROTOR REMOVAL
PROCEDURE. For reassembly of engine and rotor go to REASSEMBLY PROCEDURE.
For rotor removal, follow the ENGINE AND ROTOR REMOVAL PROCEDURE and ROTOR
REMOVAL PROCEDURE.
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F-56 F-56
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND
REPLACEMENT
FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL
3
1
(continued)
5
6
8
7
1
2
9
1. STATOR COWLING COVER
4
2. BLOWER FAN
3. IDLE LINKAGE
4. BRUSH HOLDER BRACKET
5. ENGINE LIFT BAILS
6. STATOR/ENGINE MOUNTING BOLTS
7. ROTOR
8. ROTOR SHAFT BEARING
9. ROTOR THRU-BOLT
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F-57 F-57
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL
AND REPLACEMENT
(continued)
ENGINE AND ROTOR
REMOVAL PROCEDURE
1. Refer to Figure F.12 for component loca-
tions.
2. Remove the engine spark plug wires.
3. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
4. Remove the rubber gasket (cover seal)
from the lift bail.
5. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
6. Remove the case top, the reinstall the fuel
cap.
7. WIth the 5/16” nut driver, remove the 5
screws holding the right case side and the
5 screws holding the left case side.
8. Remove the case sides by lifting up and
out.
9. WIth the 3/8” wrench, remove the battery
cover.
10. Disconnect the negative battery cable,
then the positive battery cable. BE SURE
TO DISCONNECT THE NEGATIVE BATTERY CABLE FIRST. Remove the battery
and set it aside.
11. With the diagonal cutters, cut the cable
ties around the leads from the starter solenoid and disconnect the leads. Remove
lead 209A from the harness bundle.
15. With the 1/4” nut driver, disconnect the
engine choke cable from the engine. Mark
the location of the retainer for reassembly.
The other end can remain connected.
16. Disconnect the idle linkage by unsnapping
the plastic clip at the engine end of the
idler rod. Snap the clip back onto the rod
to avoid losing it; remove the rod for
reassembly.
17. Disconnect the fuel line from the fuel tank.
Plug the hose and also plug the connection at the fuel tank to prevent the escape
of gasoline fumes.
18. Cut the cable ties and remove leads 224C
and 210 from the oil pressure switch.
19. With the 9/16” wrenches, remove the
ground lead from the right engine foot
mounting bolt.
20. With the 7/16” wrench, remove the brush
holder bracket and leads #219 & 200A
from the stator frame.
21. Support the engine with a chain hoist. Lift
bails are provided on the top of the engine
for this purpose.
22. With the 9/16” wrench, remove the right
and left engine foot mounting bolts.
23. With the 9/16” wrench, remove the four
bolts that hold the stator to the engine.
There is one lock washer per bolt.
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12. Disconnect the large black plug in front of
the fuel tank spout.
13. With the 3/8” wrench, remove the cowling
covers at the rear on the stator, both sides
of the machine.
14. WIth the 3/8” wrench, remove the two
screws that hold the vertical fan baffle in
place. Slide the baffle forward toward the
rectifier bridge heat sink assembly.
15. Hold the rotor shaft with locking pliers and
unscrew the blower fan. Turn the fan
counterclockwise. You do not need to
remove the fan from the machine, but be
sure it is completely unscrewed from the
rotor shaft.
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24. With the chain hoist, unweight the engine
gently. Use a pry bar to carefully pry
between the engine and the stator frame in
order to unseat the bearing on the end of
the rotor shaft. Separate the engine and
rotor from the stator frame, supporting the
rotor by hand to prevent damage to the
rotor core.
25. Move the engine and rotor assembly to a
bench. The engine is off balance with the
rotor still attached; therefore, support the
end of the rotor with a wooden two-byfour before unhooking the chain hoist.
F-58 F-58
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND
REPLACEMENT
FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR
(continued)
1
ROTOR REMOVAL PROCEDURE
1. To remove the rotor, double check that the
engine spark plug wires are disconnected. You will be turning the rotor during this
procedure, and this could accidentally cause
engine kickback.
2. With an impact wrench, remove the rotor
thru-bolt. See Figure F.13. If an impact
wrench is not available, use the 5/8” box
wrench. Hold the rotor with one hand and
shock the wrench with the mallet to loosen
the thru-bolt. The thru-bolt has a star washer and lock washer, beveled to conform to
the rotor shaft. Pull out the thru-bolt.
3. Install the appropriate long thru-bolt (two are
provided) supplied with Lincoln Electric
Rotor Removal Kit S20788. The slot head
must face out. Screw in the bolt with the slot
head screw driver until the bolt bottoms out
on the engine crankshaft, about 3/4”.
2
4. Turning it counterclockwise, screw in the
left-hand thread rotor removal tool from the
kit into the rotor shaft. Support the rotor with
one hand and tighten the tool to approximately 50 ft lbs with the torque or impact
wrench.
5. If the rotor does not pop off, tighten the rotor
removal tool an additional 5 ft lbs. Hold the
rotor with one hand until the rotor pops off
the engine crankshaft.
HINT: If the rotor does not pop off, hit the end of
the rotor removal tool with a hammer.
6. Slide the rotor the rest of the way off the
crankshaft. Be careful not to lose the washer that fits between the blower fan and the
rotor.
1. THRU-BOLT
2. ROTOR
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F-59 F-59
TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL AND
REPLACEMENT (KIT S20788)
REASSEMBLY PROCEDURE
(continued)
NOTE: Lincoln Electric recommends that a new
bearing (Lincoln part #M9300-85) be installed
when you replace the rotor and blower assembly.
1. Clean the tapered engine crankshaft. Slide
the rotor onto the shaft.
2. Insert the rotor thru-bolt, and with the
torque wrench tighten the bolt to 50 ft lbs.
3. Support the engine/rotor assembly with the
chain hoist. Fit the rotor into the stator
frame, being careful not to damage the
rotor core against the stator. The bearing
will seat into its race about half way.
4. Insert the four bolts and lock washers that
hold the engine to the stator. With the
9/16” wrench, draw the bolts up evenly in
order to seat the bearing properly. Tighten
to 22 ft-lb. moving diagonally from bolt to
bolt.
5. Check the rotor-stator air gap with the .017
feeler gauge. The measurement is taken at
the blower end of the rotor before the fan is
reinstalled. Turn the rotor with a pair of
locking pliers as necessary so that the rotor
“iron” is up to take the measurement. (The
rotor has two flat sides, which are not measured for air gap.) Slide in the gauge. Then
rotate the shaft 180 degrees and measure
again. If the gauge does not clear, loosen
the four engine/stator bolts; retighten the
bolts and recheck the air gap. Repeat until
the proper .017 minimum air gap is
achieved.
6. Fasten the ground lead to the right engine
mounting bolt and install both bolts.
8. Attach leads to the oil pressure switch refer
to wiring diagram. Replace any cut cable
ties.
9. Unplug the fuel tank connection and fuel
hose and connect them.
10. Connect the idle linkage to the idler rod.
Snap the plastic clip back into place.
11. Connect the engine choke cable at the
position marked during disassembly.
12. Screw the blower fan back onto the end of
the rotor shaft. Be sure the washer is in
place and hand tighten the fan only.
13. Reposition the vertical fan baffle and secure
it with the two screws.
14. Install the two cowling covers at the rear of
the stator.
15. Connect the black plug in front of the fuel
tank fill spout.
16. Connect the leads to the starter solenoid
and replace any cable ties cut during disassembly.
17. Install the battery. Connect the positive
battery cable, then the negative battery
cable. BE SURE TO CONNECT THE POSITIVE BATTERY CABLE FIRST.
18. Replace the battery cover.
19. Reinstall the case side, fuel cap, lift bail
gasket, and case top. Connect the spark
plug wires.
20. Conduct the “Retest after Repair” procedure, the following topic in this section of
the manual.
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7. Install the brush holder bracket back into
the stator frame. Refer to the topic “Brush
Removal and Replacement” in this section of the manual.
RANGER® 10,000 & RANGER® 10,000 PLUS
F-60 F-60
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics.
OR
• If you repair or replace any electrical components.
ENGINE OUTPUT
Mode No Load RPM Load RPM
Low Idle 2150-2250 NA
High Idle 3700-3750 3100-3600
WELDER DC OUTPUT
1
Output Control Range Switch Open Circuit Load Volts Load Amps
Volts
Maximum Maximum 65 - 72 21 - 26.5 205 - 240
WELDER AC OUTPUT
1
Output Control Range Switch Open Circuit Load Volts Load Amps
Volts
Maximum Maximum 73 - 80 25 - 32 225 - 275
WELDER CV OUTPUT
1
Output Control Range Switch Open Circuit Load Volts Load Amps
Volts
Maximum Wire Feed CV 29 - 33 19 - 22 200 - 220
AUXILIARY POWER RECEPTACLE OUTPUT
230 Volt Receptacle 115 Volt Receptacle
1
2
Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps
Voltage Voltage
246 - 264 216 - 250 34 - 41.5 123- 132 114 - 126 35 - 42
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FIELD AMPS AND VOLTS
Slip Ring Volts Field Amps
28.0 - 46.0 VDC 6.5 - 7.5 VDC
1
OUTPUT CONTROL switch set at MAXIMUM (position 10).
2
Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.
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