Page 2 - SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS
RANGER® 10,000 & RANGER® 10,000 PLUS i SAFETY i FOR ENGINEpowered 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-ventila...
Page 3 - ii; FUMES AND GASES
RANGER® 10,000 & RANGER® 10,000 PLUS SAFETY ii ii 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...
Page 4 - iii; CYLINDER may explode; Refer to
RANGER® 10,000 & RANGER® 10,000 PLUS SAFETY iii iii Jan ʻ09 FOR ELECTRICALLYpowered 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 t...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR
SAFETY RANGER® 10,000 & RANGER® 10,000 PLUS iv iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudag...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Accessories; RETURN TO MAIN INDEX; RETURN TO MAIN MENU
RANGER® 10,000 & RANGER® 10,000 PLUS v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 7 - TABLE OF CONTENTS
RANGER® 10,000 & RANGER® 10,000 PLUS Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation ..............................................................................................................Section A Technical Specifications .....................................
Page 8 - INSTALLATION; INPUT - GASOLINE ENGINE
RANGER® 10,000 & RANGER® 10,000 PLUS INSTALLATION A-2 A-2 TECHNICAL SPECIFICATIONS - RANGER® 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1) INPUT - GASOLINE ENGINE RATED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-4 770 mm 485 mm 1067 mm...
Page 10 - CAUTION
RANGER® 10,000 & RANGER® 10,000 PLUS INSTALLATION A-4 A-4 SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or genera- tor creates itʼs own power, it is not necessary to con- nect itʼs frame to an earth ground, unless the machine is connected to premises wiring (you...
Page 11 - BATTERY CONNECTIONS; PRE-OPERATION SERVICE; • Do not leave unattended while; GASOLINE FUEL ONLY; GASOLINE
RANGER® 10,000 & RANGER® 10,000 PLUS INSTALLATION A-5 A-5 FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL The RANGER® 10,000 and the RANGER® 10,000 PLUS are shipped with the engine crankcase filled with SAE 10W-30 oil. C...
Page 13 - INSTRUCTIONS
RANGER® 10,000 & RANGER® 10,000 PLUS INSTALLATION A-7 A-7 LOCATION / VENTILATION The welder should be located to provide an unrestrict- ed 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 ...
Page 14 - 20 V DUPLEX RECEPTACLES; RANGER® 10,000 Extension Cord Length Recommendations; AUXILIARY POWER; Do not connect any plugs that connect to the
RANGER® 10,000 & RANGER® 10,000 PLUS INSTALLATION A-8 A-8 120 V DUPLEX RECEPTACLES 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 l...
Page 17 - Connection of RANGER® 10,000 to premises
RANGER® 10,000 & RANGER® 10,000 PLUS INSTALLATION A-11 A-11 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRALBUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N 4 CONDUCTOR COPPER CABLE SEE NATIONAL ELECTRICAL CODE FOR WIRE RECOMMEND...
Page 18 - NOTES
RANGER® 10,000 & RANGER® 10,000 PLUS NOTES A-12 A-12 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
Page 19 - Controls Dial
RANGER® 10,000 & RANGER® 10,000 PLUS Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation ................................................................................................................Section B Safety Precautions . . . . . . . . . . . . . . . . . . . . . . ...
Page 20 - OPERATION; ENGINE SWITCH; GENERAL DESCRIPTION
RANGER® 10,000 & RANGER® 10,000 PLUS OPERATION B-2 B-2 W E L D E R C O N T R O L S - F U N C T I O N A N DOPERATION 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 ...
Page 21 - POLARITY SWITCH; RANGER® 10,000 AND RANGER® 10,000 PLUS APPROXIMATE FUEL CONSUMPTION
RANGER® 10,000 & RANGER® 10,000 PLUS OPERATION B-3 B-3 “ 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. Never change the “RANGE” Switch setting while welding. This will damage the switch...
Page 22 - STARTING/SHUTDOWN INSTRUCTIONS
RANGER® 10,000 & RANGER® 10,000 PLUS OPERATION B-4 B-4 STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Ownerʼs Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles....
Page 23 - WELDING PROCESS
WELDING PROCESS For any electrodes the procedures should be kept with- in 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 &#...
Page 25 - Wirefeed
RANGER® 10,000 & RANGER® 10,000 PLUS Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C Optional Equipment ...............................................
Page 26 - ACCESSORIES; OPTIONAL EQUIPMENT; K893-1 Caster for Undercarriage
ACCESSORIES RANGER® 10,000 & RANGER® 10,000 PLUS C-2 C-2 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 br...
Page 27 - RECOMMENDED EQUIPMENT; STICK
RANGER® 10,000 & RANGER® 10,000 PLUS ACCESSORIES C-3 C-3 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 capaci...
Page 30 - MAINTENANCE; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n
RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-2 D-2 Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary t o r e m o v e s a f e t y g u a r d s t o p e r f o r m r e q u i r e d m a i n t e n a n c e . R...
Page 31 - OIL FILTER CHANGE
RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-3 D-3 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 con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for gen...
Page 32 - ENGINE ADJUSTMENTS
RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-4 D-4 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS 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 pe...
Page 34 - OUTPUT RECTIFIER ASSEMBLY
RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-6 D-6 FIGURE D.1 - MAJOR COMPONENT LOCATION 44 11 33 55 22 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY 3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 5. CASE TOP & SIDES Retur n to Section TOC Retur n to Section TOC Retur n to ...
Page 35 - FIGURE E.1 – RANGER® 10,000 BLOCK LOGIC DIAGRAM
RANGER® 10,000 & RANGER® 10,000 PLUS STARTER ENGINE BATTERY IDLER SOLENOID OUTPUT CONTROL MECHANICAL ROTAT ION FIELD CAPACITOR ROTOR SLIP RINGS 115 & 230VAC RECEPTACLES ROTOR STAT OR STAT OR REACTOR RANGE SWITCH OUTPUT BRIDGE CHOKE AC AC POLARITY SWITCH ELECTRODE TERMINAL WORK TERMINAL FLYWH...
Page 36 - THEORY OF OPERATION; SOLENOID; winding and the field feedback winding.
RANGER® 10,000 & RANGER® 10,000 PLUS THEORY OF OPERATION E-2 E-2 BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOID The 12VDC battery powers the starter motor. Whenthe engine is started and running, the battery circuitvoltage is fed, through the printed circuit board, to therotating fie...
Page 37 - ROTOR FIELD FEEDBACK AND; As the feedback voltage is increased or de-; FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER
RANGER® 10,000 & RANGER® 10,000 PLUS THEORY OF OPERATION E-3 E-3 ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed tothe full wave field bridge. The DC output of the bridgeis filtered by the field capacitor and controlled by theprinted circuit board ac...
Page 38 - RANGE SWITCH; The reactor coil is
RANGER® 10,000 & RANGER® 10,000 PLUS THEORY OF OPERATION E-4 E-4 WELD WINDING, REACTOR, AND RANGE SWITCH The stator weld winding is connected to the reactorand range switch. The inductance in the reactor offersan impedance to current flow. The reactor coil is tapped at various points. As the ran...
Page 39 - POLARITY SWITCH, AND OUTPUT; Depending
RANGER® 10,000 & RANGER® 10,000 PLUS THEORY OF OPERATION E-5 E-5 OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS The AC voltage developed in the stator weld windingis delivered, through the reactor and range switch, tothe output bridge and polarity switch. Depending upon the setting ...
Page 41 - Test Procedures
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 ...........................
Page 42 - TROUBLESHOOTING & REPAIR; HOW TO USE TROUBLESHOOTING GUIDE; Simply follow the three-step procedure; PERFORM EXTERNAL TESTS.; The; Step 3. PERFORM COMPONENT TESTS; Refer to the
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-2 F-2 HOW TO USE TROUBLESHOOTING GUIDE 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...
Page 43 - PC BOARD TROUBLESHOOTING PROCEDURES
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the foll...
Page 44 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; PROBLEMS; Rotor Voltage
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-4 F-4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-tact the L...
Page 45 - gram
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-tact the L...
Page 46 - Auxiliary and
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-6 F-6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-tact the L...
Page 48 - Output Bridge Test
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-8 F-8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-tact the L...
Page 49 - Wiring Diagram
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-9 F-9 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-tact the L...
Page 50 - Wiring
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-10 F-10 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-tact the...
Page 52 - Charging Circuit Test
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-12 F-12 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will not crank or crank...
Page 55 - ROTOR VOLTAGE TEST; TEST DESCRIPTION
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-15 F-15 ROTOR VOLTAGE TEST 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 ormachine operator and ...
Page 56 - FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST; Slip Rings; TEST PROCEDURE; then reinstall the; Rotor Resistance
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-16 F-16 ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Slip Rings Brushes Lead 219 + - Lead 200A TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from...
Page 57 - ROTOR RESISTANCE TEST
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-17 F-17 ROTOR RESISTANCE TEST 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 ormachine operator a...
Page 58 - FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS; then replace the
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-18 F-18 ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS Lead 219 Lead 200A + - TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gask...
Page 61 - AUXILIARY AND FIELD WINDING TEST
AUXILIARY AND FIELD WINDING TEST 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 ormachine operator and will invalidate your factory warranty. For your safety and to avoi...
Page 62 - To test the 115 VAC winding:
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-22 F-22 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 Lead #3 Lead #5 115V Receptacle Machine Case Front TEST PROCEDURE To test the 115 VAC winding: 1. Remove the fuel cap and lift bail ru...
Page 63 - To test the field winding:
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-23 F-23 AUXILIARY AND FIELD WINDING TEST (continued) To test the field winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver, removethe case top and left side; then reinstall the fuel cap. 2. Con...
Page 66 - OUTPUT RECTIFIER BRIDGE TEST; FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS; OUTPUT RECTIFIER; ENGINE; then replace the fuel
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-26 F-26 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS (-) (+) (+) (+) (-) (-) OUTPUT RECTIFIER ENGINE TEST PROCEDURE 1. Remove the spark plug wires to prevent accidental engine kickback...
Page 67 - CHARGING CIRCUIT TEST
CHARGING CIRCUIT TEST 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 ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-tric...
Page 68 - FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-28 F-28 CHARGING CIRCUIT TEST (continued) FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR Voltage Regulator Ground Lead (Green) Engine AC Lead DC Lead AC Lead TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. ...
Page 69 - ENGINE THROTTLE ADJUSTMENT TEST
ENGINE THROTTLE ADJUSTMENT TEST 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 ormachine operator and will invalidate your factory warranty. For your safety and to avoid...
Page 70 - FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD; Blower Paddle
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-30 F-30 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Blower Paddle TEST PROCEDURE This test can be conducted by any one of fourmethods. Strobe-tach Method: 1. With the 5/16...
Page 71 - Frequency Counter Method
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-31 F-31 ENGINE THROTTLE ADJUSTMENT TEST (continued) Throttle linkage Choke Cable 3/8" High IdleAdjustment Nut Solenoid Housing 3/8" Low Idle Adjustment Nut Rod Muffler 11. If either of the readings is incorrect, adjust t...
Page 72 - NORMAL OPEN CIRCUIT
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-32 F-32 ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 115 VAC receptacle, according to the manufactur-er’s instructions. At 3700 RPM, the wave-form should exhibit a period of...
Page 73 - volts; SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY); HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-33 F-33 CH1 16.2 ms 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div .....................50V/Div.Horizontal Sweep.....5 ms/Div.Coupling ............................DCTrigger .........................Internal This is the typical A...
Page 74 - TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE); MACHINE LOADED; MACHINE LOADED TO 200 AMPS AT 20 VDC
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-34 F-34 SCOPE SETTINGS Volts/Div .....................20V/Div.Horizontal Sweep.....5 ms/Div.Coupling ............................DCTrigger .........................Internal CH1 0 volts 5 ms 20 volts This is the typical CV output...
Page 75 - TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-35 F-35 This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 20 volts and thateach horizontal division represents 5milliseconds in time. The machinewas loade...
Page 76 - TYPICAL AC WELD OUTPUT WAVEFORM
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-36 F-36 This is the typical AC output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 20 volts and thateach horizontal division represents 5milliseconds in time. The machinewas loade...
Page 77 - ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE); HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-37 F-37 This is NOT the typical CV outputvoltage waveform. One output diodeis not functioning. Note the “gap” inthe waveform. One output diode wasdisconnected to simulate an open ornonfunctioning output diode. Eachvertical divis...
Page 78 - ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-38 F-38 This is NOT the typical DC (+) outputvoltage waveform. One output diodeis not functioning. Note the “gap” inthe waveform. One output diode wasdisconnected to simulate an open ornonfunctioning output diode. Eachvertical d...
Page 79 - NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-39 F-39 This is the typical CV output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 20 volts and thateach horizontal division represents 5milliseconds in time. Note: Scope probes c...
Page 80 - NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-40 F-40 This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 50 volts and thateach horizontal division represents 5milliseconds in time. Note: Scope probes c...
Page 81 - NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-41 F-41 This is the typical AC output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 50 volts and thateach horizontal division represents 5milliseconds in time. Note: Scope probes c...
Page 83 - BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-43 F-43 BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained person-nel. Unauthorized repairs performed on this equipment may result in danger to the tech-nician o...
Page 84 - PROCEDURE
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-44 F-44 BRUSH REMOVAL AND REPLACEMENT (continued) 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 ...
Page 85 - SLIP RINGS; Brushes; Cable
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-45 F-45 SLIP RINGS A slight amount of darkening and wear of theslip rings and brushes is normal. Brushes should be inspected when a general overhaul isnecessary. If brushes are to be replaced, cleanslip rings with a fine emery p...
Page 88 - PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT; FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION; PC
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-48 F-48 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION 12 Pin Plug 4 Pin Plug 4 Self Tapping Screws (at corners) 1/4" Q.C. Tabs PROCEDURE Before starting the following ...
Page 89 - Replace the old printed circuit board with; PRINTED CIRCUIT BOARD REMOVAL
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-49 F-49 Be sure to follow the recommended static-free methods for handling printed circuitboards. Failure to do so can result in perma-nent damage to the equipment. 12. With the 1/4” phillips head screw driver, remove four self ...
Page 92 - OUTPUT RECTIFIER BRIDGE REMOVAL; FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS; metal screws from the case top.; then reinstall the fuel; screws holding the right case side.
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-52 F-52 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS (-) (+) (+) (+) (-) (-) ENGINE NO NUT TO POLARITY SWITCH #8 L1 TO CHOKE (4) 7/16" MOUNTING SCREWS W1 TO S2 TO S2 ...
Page 95 - ENGINE/ROTOR REMOVAL AND REPLACEMENT; Lincoln Electric Rotor Removal Kit (S20788)
ENGINE/ROTOR REMOVAL AND REPLACEMENT 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 ormachine operator and will invalidate your factory warranty. For your safety and to ...
Page 96 - ENGINE/ROTOR REMOVAL AND; STATOR COWLING COVER
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-56 F-56 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL 3 1 9 2 4 1 8 7 6 5 1. STATOR COWLING COVER 2. BLOWER FAN 3. IDLE LINKAGE 4. BRUSH HOLDER BRACKET 5. ENGINE LIFT BA...
Page 97 - AND REPLACEMENT
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-57 F-57 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 she...
Page 98 - ROTOR REMOVAL PROCEDURE; double check that the; FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-58 F-58 ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the engine spark plug wires are disconnect- ed. You will be turning the rotor during this procedure, and this could accidentally causeengine kickback. 2. ...
Page 99 - REASSEMBLY PROCEDURE; Brush
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-59 F-59 REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installedwhen you replace the rotor and blower assem-bly. 1. Clean the tapered engine crankshaft. Slide the rotor onto...
Page 100 - RETEST AFTER REPAIR
RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REPAIR F-60 F-60 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 repla...
Page 101 - Assembly drawings of these boards are no longer provided.
RANGER® 10,000 & RANGER® 10,000 PLUS Section G-1 Section G-1 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams................................................................................................Section G Wiring Diagram - Entire Machine - Code 11041 Only - (M20226)...
Page 102 - ELECTRICAL DIAGRAMS; ENGINE COMPONENTS; ELECTRICAL SYMBOLS PER E1537; ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL DIAGRAMS G-2 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 11041 ONLY -(M20226) STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID BATTERY AC AC B+ SWI TCH REGULATOR FLYWHEEL A LTERNATOR B- HOUR METER 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1...
Page 103 - ALL CASE FRONT COMPONENTS SHOW N VIEW ED FROM REAR.; HONDA ENGINE COMPONENTS
ELECTRICAL DIAGRAMS G-3 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 11095 ONLY - (M20301) IDLER SOLENOID HOUR METER 5E 5D 224 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 J2 209A M20301 215 + ELECTRICAL SYMBOLS PER E1537 STATOR REACTOR S1 W ORK ELECTRODE CHOKE D1 S2 ROTOR PCB1 S...
Page 104 - OFF
ELECTRICAL DIAGRAMS G-4 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 11150 T0 11393 - (M20431) CR1 STARTER SOLENOID AC AC B+ REGULATOR FLYWHEEL ALTERNATOR B- 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 J2 209A 209A 224C 210 GENERATOR LEAD END(NOT...
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