Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ________________________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter l...
Page 4 - iii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de s...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v RANGER 10-LX Page Safety .................................................................................................................................................i-iv Installation .....................................................................
Page 7 - TABLE OF CONTENTS; Installation; Tilting
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 RANGER 10-LX Installation Technical Specifications .................................................................................................
Page 8 - INSTALLATION; INPUT - DIESEL ENGINE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 RANGER 10-LX TECHNICAL SPECIFICATIONS - RANGER 10-LX INPUT - DIESEL ENGINE Manufacturer Description...
Page 9 - SAFETY PRECAUTIONS; LOCATION AND VENTILATION; STORING
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They includeimportant safety precautions; detailed engine starting,operating,...
Page 10 - PRE-OPERATION ENGINE SERVICE
STACKING RANGER 10-LX machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev-er you use it or store it. Any surfaces you place it onother than the ground must be firm, non-skid, andstructurally sound. The diesel engine is designed to run in a level positionfor best p...
Page 12 - WELDING CABLE CONNECTIONS; CABLE SIZE AND LENGTH; TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH; Tighten the flanged nuts securely.; MACHINE GROUNDING; CAUTION
WELDING CABLE CONNECTIONS CABLE SIZE AND LENGTH Be sure to use welding cables that are large enough.The correct size and length becomes especially impor-tant when you are welding at a distance from thewelder. Table A.1 lists recommended cable sizes and lengthsfor rated current and duty cycle. Length...
Page 15 - Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section B-1 Section B-1 RANGER 10-LX TABLE OF CONTENTS - OPERATION SECTION - Operation ................................................................................................................................
Page 16 - GENERAL DESCRIPTION; OPERATION
OPERATING INSTRUCTIONS Read and understand this entire section before oper-ating your RANGER 10-LX. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They includeimportant safety precautions; de...
Page 17 - RECOMMENDED APPLICATIONS; WELDER; WELDING CAPABILITY
RECOMMENDED APPLICATIONS WELDER The RANGER 10-LX provides excellent constant cur-rent AC/DC welding output for stick (SMAW) weldingand for TIG welding, and it offers constant voltage out-put for DC semiautomatic wire feed welding. For moredetails on using the machine as a welder, see WeldingOperatio...
Page 18 - FIGURE B.1 – OUTPUT PANEL CONTROLS; WELDER/GENERATOR CONTROLS; CONTROLS AND SETTINGS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-4 B-4 RANGER 10-LX FIGURE B.1 – OUTPUT PANEL CONTROLS 1. OUTPUT RANGE SELECTOR2. FINE OUTPUT CONTROL3. POLAR...
Page 20 - DIESEL ENGINE CONTROLS; GLOW PLUG PUSHBUTTON:; FIGURE B.2 – ENGINE CONTROLS
DIESEL ENGINE CONTROLS See Figure B.2 for the location of the following fea-tures: 1. GLOW PLUG PUSHBUTTON: Acti- vates glow plugs to preheat engine forstarting. 2. IDLER CONTROL SWITCH: Adjusts the runningspeed of the engine. The switch has two posi-tions, HIGH and AUTO. In HIGH, theengine runs con...
Page 21 - ENGINE OPERATION; BEFORE STARTING THE ENGINE; Check and fill the engine oil level:
6. OIL PRESSURE LIGHT: Remains off with proper oil pressure. If light turnson, the engine protection system willstop the engine. The light will go onwhen the “Engine” switch is switched to the “ON”position with engine not running. It will go off afterone minute if the engine is not started. 7. WATER...
Page 22 - STARTING THE ENGINE; Set “IDLER” switch to “AUTO”.; STOPPING THE ENGINE; FIGURE B.3 – FUEL SHUTOFF VALVE
STARTING THE ENGINE NOTE: Remove all loads connected to the AC powerreceptacles before starting the diesel engine. 1. Open the engine compartment door and checkthat the fuel shutoff valve located above the clearplastic fuel filter housing is in the open position(lever in the vertical position). See ...
Page 23 - TYPICAL RANGER 10-LX FUEL CONSUMPTION; Low Idle – No Load, 2150 RPM
OPERATION B-9 B-9 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE B.1 TYPICAL RANGER 10-LX FUEL CONSUMPTION KUBOTA DH850-B-88 Low Idle – No Load, 215...
Page 24 - WELDING OPERATION; GENERAL INFORMATION; After you finish welding:; FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
WELDING OPERATION GENERAL INFORMATION • Do not touch electrically live parts or elec- trodes with your skin or wet clothing. • Do not breathe welding fumes or gases. • Use ventilation or exhaust to remove welding fumes from the breathing area. • Keep flammable material away. • Wear eye, ear, and bod...
Page 25 - Allow the electrode and work to cool completely.
To Use the RANGER 10-LX for AC/DC TIG(Constant Current) Welding: 1. Connect the K930-1 TIG Module to the RANGER10-LX. Follow the installation instructions provid-ed with the kit. Also be sure to follow the specialmachine grounding instructions given in the man-ual. 2. Refer to the instruction manual...
Page 26 - Remove the work clamp from the work.
To Use the RANGER 10-LX for DC WireFeed Welding (Constant Voltage): 1. Connect one of the following: the LN-25, LN-7 orLN-8 Wire Feeder. Follow the installation instruc-tions in the Accessories section of this manual. 2. Some recommended Innershield electrodes are:NR-211MP, NR-311, NR-203 series, as...
Page 28 - AUXILIARY POWER; Powering Motors; To use the generator as an auxiliary power supply:; NOTE: The 115 volt auxillary power receptacles
AUXILIARY POWER Be sure that any electrical equipment plugged into thegenerator AC power receptacles can withstand a±10% voltage and a ±3% frequency variation. GENERAL INFORMATION The RANGER 10-LX generator is rated at 10,000 con-tinuous watts. It provides both 115 volt and 230 voltpower. You can dr...
Page 29 - None
OPERATION B-15 B-15 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE B.4 - SIMULTANEOUS WELDING AND AUXILIARY POWER Output Selector Welding Permissibl...
Page 31 - Accessories
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories................
Page 32 - ACCESSORIES
OPTIONS/ACCESSORIES The following options/accessories are available foryour RANGER 10-LX from your local LincolnDistributor. Two-Wheel Trailer (K768) – For in-plant or yard tow-ing of the RANGER 10-LX. (Not intended for highwaytowing as equipped. For highway use of this trailer,consult applicable fe...
Page 33 - Gas-shielded welding requires a Magnum
TIG WELDING TIG Module (K930-1) - The TIG Module is an acces-sory that provides high frequency and shielding gascontrol for AC and DC GTAW (TIG) welding applica-tions. It provides contactor control of constant currentwelding power sources having an internal contactor. The K930-1 TIG Module is suppli...
Page 34 - FIGURE C.1 – RANGER 10-LX/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM; CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGATIVE (-) BATTERYLEAD before servicing. • Do not touch electrically live parts. MOVING PARTS can injure. • Keep guards in place. • Keep away from moving parts. • Only qualified personnel should install, use or service this e...
Page 36 - NOTE: If your LN-7 comes equipped with a K291 or
ACCESSORIES C-6 C-6 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONNECTION OF THE LN-7 TO THERANGER 10-LX USING K584 INPUTCABLE ASSEMBLY (SEE FIGURE C....
Page 37 - NOTE: Welding cable must be sized for current and
ACCESSORIES C-7 C-7 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONNECTION OF THE LN-7 TO THERANGER 10-LX USING K867 UNIVERSALADAPTER (SEE FIGURE C.4.)...
Page 40 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 RANGER 10-LX TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D...
Page 41 - ENGINE MAINTENANCE; CHANGE THE OIL; MAINTENANCE
SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when themaintenance requiring their removal is complete. • If cove...
Page 42 - CHANGE THE OIL FILTER; FIGURE D.1 – OIL DRAIN AND REFILL LOCATION
CHANGE THE OIL FILTER Change the oil filter the first time after 50 hours ofoperation. Then, under normal operating conditions,change the oil filter after every 200 hours of operation.If the engine is operated under heavy load or in highambient temperatures, change the oil filter more fre-quently. S...
Page 43 - BLEEDING THE FUEL SYSTEM:; FIGURE D.2 – FUEL FILTER
4. Carefully place the element back into the fuel pot. Be careful not to allow any dirt to stick to the ele-ment. 5. Reassemble the filter pot and tighten the ring screw at the top. 6. Open the fuel cock and loosen the two air vent plugs a few turns. When bubbles no longer appeararound the plugs, sc...
Page 44 - FIGURE D.3 – FUEL SYSTEM BLEEDING
AIR CLEANER: The Kubota diesel engine is equippedwith a dry type air filter. Never apply oil to it. Servicethe air cleaner as follows: 1. Remove the dust cup from the bottom of the air cleaner housing. Clean out any accumulated dust. 2. If dust is sticking to the element, blow compressed air through...
Page 45 - FIGURE D.4 – COOLING SYSTEM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE D-6 D-6 RANGER 10-LX FIGURE D.4 – COOLING SYSTEM CHECKING/ADDING/DRAINING RADIATOR COOL-ANT: Check the level...
Page 46 - KUBOTA ENGINE MAINTENANCE SCHEDULE; • Check fuel lines and clamps.
MAINTENANCE D-7 D-7 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE D.1 KUBOTA ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Be...
Page 47 - CLEANING THE BATTERY
CAUTION BATTERY MAINTENANCE GASES FROM BATTERY can explode. • Keep sparks, flame, and cigarettes away from battery. To prevent EXPLOSION when: • INSTALLING A NEW BATTERY - Disconnect the negative cable from the old battery first and connectto the new battery last. • CONNECTING A BATTERY CHARGER - Re...
Page 48 - Keep the electrical receptacles in; FIGURE D.5 - BRUSH REMOVAL AND REPLACEMENT
To reinstall the brushes, press them upward and slidea cable tie or wooden stick through the brush holdertabs. See Figure D.5. Install the brush holder intoposition and secure with the screws previouslyremoved. Remove the cable tie or wooden stick andthe brushes will seat onto the slip rings. RECEPT...
Page 50 - FIGURE E.1 – RANGER 10-LX BLOCK LOGIC DIAGRAM
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 Theory of Operation ............................................................................................................. Section E Battery, Starter, Engine, Glow Plugs, Engine Pro...
Page 51 - THEORY OF OPERATION; ROTOR, STATOR AND IDLER SOLENOID
BATTERY, STARTER, ENGINE,GLOW PLUGS, ENGINEPROTECTION, ROTOR, STATORAND IDLER SOLENOID The 12VDC battery powers the starter motor and glowplugs. The glow plugs are used to preheat the dieselengine to enhance starting., When the engine isstarted and running, the battery circuit voltage is fedthrough ...
Page 52 - FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER
ROTOR FIELD FEEDBACK,AUXILIARY, AND WIRE FEEDERPOWER The AC voltage developed in the field winding is fed tothe full wave field bridge. The DC output of the fieldbridge is filtered by the field capacitor and controlledby the printed circuit board according to the output orremote control setting. Thi...
Page 54 - OUTPUT TERMINALS
OUTPUT BRIDGE, CHOKE,POLARITY SWITCH, CVCONTACTOR AND OUTPUTTERMINALS The AC voltage developed in the stator weld windingis delivered, through the reactor and range switch, tothe output bridge and polarity switch. Dependingupon the setting of the polarity switch, either AC volt-age or DC voltage is ...
Page 55 - Test Procedures
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section F-1 Section F-1 RANGER 10-LX Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshooting Guide .................
Page 56 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...
Page 57 - PC BOARD TROUBLESHOOTING PROCEDURES
ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connections. ...
Page 58 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Contact The Lincoln Electric
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 RANGER 10-LX Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 59 - With the Polarity mode switch
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-5 F-5 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginn...
Page 60 - If the machine is equipped with
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 RANGER 10-LX Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 61 - If a remote control unit is NOT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-7 F-7 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginn...
Page 64 - ENGINE PROBLEMS; is in the “Auto” position.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 RANGER 10-LX Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the begi...
Page 65 - Make sure the welding cables
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 67 - The engine may be low on or
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-13 F-13 RANGER 10-LX Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the begi...
Page 68 - Make sure there is NOT an
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-14 F-14 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 69 - FUNCTION PROBLEMS; Make sure the Remote switch
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-15 F-15 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 70 - The wire feeder control cable
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-16 F-16 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 71 - Make sure the Wire Feeder
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-17 F-17 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 72 - Make sure the wire feeder is
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-18 F-18 RANGER 10-LX TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 74 - WELDING PROBLEMS; The welding cables may be too
TROUBLESHOOTING & REPAIR F-20 F-20 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the begi...
Page 75 - ROTOR VOLTAGE TEST; TEST DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-21 F-21 RANGER 10-LX ROTOR VOLTAGE TEST Service and repair should be performed by only Li...
Page 76 - FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST; TEST PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-22 F-22 RANGER 10-LX ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST ...
Page 77 - ROTOR RESISTANCE TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ROTOR RESISTANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthor...
Page 80 - To test the 115 VAC winding:; AUXILIARY AND FIELD WINDING TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TEST PROCEDURE To test the 115 VAC winding: 1. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from t...
Page 81 - FIGURE F.4 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-27 F-27 RANGER 10-LX AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4 – LOCATION O...
Page 82 - FIGURE F.4A – 14 PIN AMPHENOL PIN ASSIGNMENTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 RANGER 10-LX AUXILIARY AND FIELD WINDING TEST (continued) Z W Y X K B I H N L C D...
Page 84 - OUTPUT RECTIFIER BRIDGE TEST; FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-30 F-30 RANGER 10-LX OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.5 – LOCATION OF OU...
Page 86 - CHARGING CIRCUIT TEST; FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-32 F-32 RANGER 10-LX CHARGING CIRCUIT TEST (continued) FIGURE F.6 – LOCATION OF VOLTAGE R...
Page 88 - FIGURE F.7 – CR1 LEAD CONNECTIONS; Conduct this test with the engine OFF.
TROUBLESHOOTING & REPAIR F-34 F-34 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PROTECTION RELAY (CR1) TEST (continued) FIGURE F.7 – CR1 LEAD CONNEC...
Page 90 - ENGINE THROTTLE ADJUSTMENT TEST
TROUBLESHOOTING & REPAIR F-36 F-36 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 – MARK LOCATI...
Page 91 - Frequency Counter Method; Plug the frequency counter into one of the; FIGURE F.9 – HIGH IDLE ADJUSTMENT NUT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-37 F-37 RANGER 10-LX ENGINE THROTTLE ADJUSTMENT TEST (continued) Adjust HIGH IDLE: First ...
Page 92 - Connect the oscilloscope to the 115 VAC; FIGURE F.10 – LOW IDLE ADJUSTMENT NUT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-38 F-38 RANGER 10-LX ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. ...
Page 93 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY); HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM; volts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 RANGER 10-LX This is the typical auxiliary outputvoltage generated from a properl...
Page 94 - TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP); MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-40 F-40 RANGER 10-LX This is the typical CV output voltagegenerated from a properly opera...
Page 95 - TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM; MACHINE LOADED TO 250 AMPS AT 25 VDC
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-41 F-41 RANGER 10-LX This is the typical DC output voltagegenerated from a properly opera...
Page 96 - TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-42 F-42 RANGER 10-LX This is the typical AC output voltagegenerated from a properly opera...
Page 97 - ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM; HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-43 F-43 RANGER 10-LX This is NOT the typical DC (+) outputvoltage waveform. One output di...
Page 98 - ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-44 F-44 RANGER 10-LX This is NOT the typical CV outputvoltage waveform. The capacitorbank...
Page 99 - NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-45 F-45 RANGER 10-LX This is the typical CV output voltagegenerated from a properly opera...
Page 100 - NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-46 F-46 RANGER 10-LX SCOPE SETTINGS Volts/Div .....................50V/Div.Horizontal Swe...
Page 101 - NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-47 F-47 RANGER 10-LX CH1 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div ....................
Page 102 - BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-48 F-48 RANGER 10-LX BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be p...
Page 103 - PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-49 F-49 RANGER 10-LX BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Perform this ...
Page 106 - FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL; RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-52 F-52 RANGER 10-LX FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (con...
Page 109 - CONTROL BOARD REMOVAL AND REPLACEMENT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-55 F-55 RANGER 10-LX CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.13 - CONT...
Page 110 - Connect current sensing leads #254 and; CONTROL BOARD REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-56 F-56 RANGER 10-LX 16. Connect current sensing leads #254 and #254A. See the Wiring Dia...
Page 112 - OUTPUT RECTIFIER BRIDGE REMOVAL; FIGURE F.14 - OUTPUT RECTIFIER CONNECTIONS; Perform this procedure with the engine OFF.; For the remaining steps refer to FIgure F.14.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-58 F-58 RANGER 10-LX OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F...
Page 113 - Clear the leads and carefully remove the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-59 F-59 RANGER 10-LX OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 9. Clear...
Page 115 - OUTPUT CAPACITOR BANK EMOVAL; FIGURE F.15 - OUTPUT CAPACITOR BANK/PRINTED CIRCUIT BOARD LOCATION
TROUBLESHOOTING & REPAIR F-61 F-61 RANGER 10-LX Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT CAPACITOR BANK EMOVAL AND REPLACEMENT (continued) FIGURE F.15...
Page 117 - OUTPUT CAPACITOR REMOVAL; FIGURE F.16 – OUTPUT CONTACTOR LOCATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-63 F-63 RANGER 10-LX OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – O...
Page 118 - TROUBLESHOOTING & REPAIRs; FIGURE F.17 – CONTACTOR COIL LEAD PLACEMENT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIRs F-64 F-64 RANGER 10-LX OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – ...
Page 120 - STATOR AND/OR REMOVAL AND
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-66 F-66 RANGER 10-LX STATOR AND/OR REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – COMP...
Page 121 - STATOR AND/OR ROTOR REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-67 F-67 RANGER 10-LX STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) PROCEDURE (S...
Page 122 - ROTOR REMOVAL PROCEDURE; FIGURE F.19- ENGINE AND ROTOR REMOVED FROM STATOR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-68 F-68 RANGER 10-LX 23. Using the 5/16” wrench, remove the three sheet metal screws hold...
Page 124 - RETEST AFTER REPAIR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-70 F-70 RANGER 10-LX RETEST AFTER REPAIR Retest a machine: • If it is rejected under test...
Page 126 - NOTES
NOTES RANGER 10LX Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 127 - ELECTRICAL DIAGRAMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-2 RANGER 10LX Wiring Diagram Ranger 10LX Code 9816 W O R K G N D R 5 C 6 C 7 C 8 C 9 S 2 S 2 I D L...
Page 131 - DIAGRAMS; RF BYPASS BOARD SCHEMATIC
DIAGRAMS G-6 G-6 RANGER 10LX NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components arenot available from Lincoln Electric. This information is p...
Page 132 - DIMENSION PRINT
DIAGRAMS G-7 G-7 RANGER 10LX DIMENSION PRINT 18.00 17.50 12.02 5.25 3.94 18.00 18.50 24.03 24.75 N.A. N.B. 13.85 20.25 N.A. 60.18 N.B. CENTER OF GRAVITY 33.81 13.00 11.00 COOLANT CAP 5.25 31.03 34.62 46.00 60.50 31.57 M16706 3-24-95E Retur n to Section TOC Retur n to Section TOC Retur n to Section T...
Page 133 - SVM ERROR REPORTING FORM; Please give detailed description below:; Return to Section TOC
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col-umn troubleshoo...
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