Lincoln Electric RANGER 10,000 Service Manual
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Lincoln Electric RANGER 10,000 Service Manual

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RANGER 10,000 /10,000 PLUS
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
All manuals and user guides at all-guides.com
®
For use with machine code numbers: Kohler 11041, 11151, 11394
SERVICE MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
SVM168-B
Honda 11095, 11398
Robin/Subaru 11253. 11395
Copyright © Lincoln Global Inc.
April, 2010

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  • Page 1 All manuals and user guides at all-guides.com SVM168-B April, 2010 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.

  • Page 2: Safety

    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.
  • Page 3 All manuals and user guides at all-guides.com SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 All manuals and user guides at all-guides.com SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. 7.a. Use only compressed cylinders containing the correct shielding gas for the explosion. 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and...
  • Page 5 All manuals and user guides at all-guides.com SAFETY zones où lʼon pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque dʼincendie dû aux étincelles. et les précautions de sûreté...

  • Page 6: Table Of Contents

    All manuals and user guides at all-guides.com RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ............i-iv Installation .
  • Page 7 All manuals and user guides at all-guides.com Section A-1 TABLE OF CONTENTS Section A-1 - 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...

  • Page 8: Installation

    All manuals and user guides at all-guides.com INSTALLATION TECHNICAL SPECIFICATIONS - RANGER® 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1) INPUT - GASOLINE ENGINE Description Operating Displacement Capacities Make/Model Horsepower Starting Speed (RPM) cu. in. System (cu.cm.) 38(624) Fuel: (K1419-4) 20 HP @ Kohler 9 Gal (34 L) Kohler...
  • Page 9 All manuals and user guides at all-guides.com INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 10,000 PLUS (K1419-5 ), (K2468-2) INPUT - GASOLINE ENGINE Description Operating Displacement Capacities Make/Model Horsepower Starting Speed (RPM) cu. in. System (cu.cm.) 41(674) Fuel: (K1419-5) 12VDC 23 HP @...

  • Page 10: Safety Precautions

    All manuals and user guides at all-guides.com INSTALLATION When this welder is mounted on a truck or trailer, itʼs frame must be electrically bonded to the metal frame of SAFETY PRECAUTIONS the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the frame of WARNING the vehicle.

  • Page 11: Pre-Operation Service

    All manuals and user guides at all-guides.com INSTALLATION 3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when FUEL being moved and when standing by itself while Fill the fuel tank with clean, fresh, lead-free gasoline. being operated or serviced.

  • Page 12: Welding Output Cables

    All manuals and user guides at all-guides.com INSTALLATION WELDING OUTPUT CABLES WARNING With the engine off, connect the electrode and work • Lift only with equipment of ade- cables to the studs provided. These connections quate lifting capacity. should be checked periodically and tightened if neces- sary.

  • Page 13: Location/Ventilation

    RANGER® 10,000 machines cannot be stacked. 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 LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF K930-2 TIG MODULE TO THE WARNING RANGER®...

  • Page 14: Auxiliary Power

    All manuals and user guides at all-guides.com INSTALLATION AUXILIARY POWER The RANGER® 10,000 can provide up to 9,000 watts of 120/240 volts AC, single phase 60Hz power for con- tinuous use, and up to 10,000 watts of 120/240 volts AC, single phase 60Hz power peak use. The RANGER®...
  • Page 15 DO NOT USE THESE DEVICES WITH A RANGER® 10,000 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the RANGER® 10,000 or RANGER® 10,000 PLUS. RANGER® 10,000 & RANGER® 10,000 PLUS...

  • Page 16: Auxiliary Power While Welding

    All manuals and user guides at all-guides.com INSTALLATION A-10 A-10 1. Install a double pole, double throw switch between the power company meter and the premises AUXILIARY POWER WHILE WELDING disconnect. Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown Switch rating must be the same or greater than assume that current is being drawn from either the the customerʼs premises disconnect and service...

  • Page 17: Connection Of Ranger® 10,000 To Premises Wiring (Drawing

    All manuals and user guides at all-guides.com INSTALLATION A-11 A-11 Figure A.1 CONNECTION OF RANGER® 10,000 OR RANGER® 10,000 PLUS TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW...
  • Page 18 All manuals and user guides at all-guides.com NOTES A-12 A-12 RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 19 All manuals and user guides at all-guides.com Section B-1 TABLE OF CONTENTS Section B-1 - OPERATION SECTION - Operation ........................Section B Safety Precautions ...........B-2 General Description .

  • Page 20: Operation

    All manuals and user guides at all-guides.com OPERATION SAFETY PRECAUTIONS WELDER CONTROLS - FUNCTION AND OPERATION Do not attempt to use this equipment until you The engine switch is used to Start the Engine, Select have thoroughly read the engine manufacturer’s ENGINE SWITCH manual supplied with your welder.

  • Page 21: Range Switch

    All manuals and user guides at all-guides.com 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 90 Max.

  • Page 22: Starting The Engine

    All manuals and user guides at all-guides.com OPERATION STARTING/SHUTDOWN INSTRUCTIONS STOPPING THE ENGINE Remove all welding and auxiliary power loads and STARTING THE ENGINE allow engine to run at low idle speed for a few minutes to cool the engine. WARNING Stop the engine by placing the Engine switch in the •...

  • Page 23: Welding Process (Stick/Tig

    All manuals and user guides at all-guides.com OPERATION For any electrodes the procedures should be kept with- WELDING PROCESS SETTINGS FOR 1% THORIATED TUNGSTEN in the rating of the machine. For electrode information TUNGSTEN RANGE SWITCH APPROXIMATE see the appropriate Lincoln publication. DIAMETER (in.) SETTINGS CURRENT RANGE...

  • Page 24: Summary Of Welding Processes

    All manuals and user guides at all-guides.com OPERATION Summary of Welding Processes CONTROL ELECTRODE PROCESS CABLE IDLE WHEN NOT TO START USED MODE WELDING WELDING STICK AUTO Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH AUTO Cold...
  • Page 25 All manuals and user guides at all-guides.com Section C-1 TABLE OF CONTENTS Section C-1 - ACCESSORIES SECTION - Accessories ......................Section C Optional Equipment ....................C-2 Recommended Equipment ..................C-3 Wirefeed......................C-3 Stick........................C-3 TIG ........................C-3 Plasma Cutting ....................C-3 RANGER® 10,000 & RANGER® 10,000 PLUS...

  • Page 26: Accessories

    All manuals and user guides at all-guides.com ACCESSORIES K802-R Power Plug Kit- provides four 120V plugs (Field Installed) rated at 15 amps each and one dual voltage, Full KVA OPTIONAL EQUIPMENT plug rated at 120/240V, 50 amps. SMALL WELDERS - For road, off-road and in-plant K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR K802-N Power Plug Kit - Provides four 120V plugs and yard towing.
  • Page 27 All manuals and user guides at all-guides.com ACCESSORIES RECOMMENDED EQUIPMENT PLASMA CUTTING: K1580-1- Pro-Cut 55 (Requires full KVA Adapter K1816-1). STICK K704 Accessory Kit - For Stick Welding. Includes 35 ft (10.7m). • 2/0 AWG electrode cable, 30 ft. (9.1m) •...
  • Page 28 All manuals and user guides at all-guides.com NOTES RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 29 All manuals and user guides at all-guides.com Section D-1 TABLE OF CONTENTS Section D-1 - MAINTENANCE SECTION - Maintenance ......................Section D Safety Precautions ..........D-2 Routine Maintenance .

  • Page 30: Maintenance

    All manuals and user guides at all-guides.com MAINTENANCE SAFETY PRECAUTIONS CAUTION WARNING Make certain that the oil filler cap is securely tight- Have qualified personnel do the maintenance ened after checking or adding oil. If the cap is not work. Turn the engine off before working inside tight, oil consumption can increase significantly the machine.
  • Page 31 All manuals and user guides at all-guides.com MAINTENANCE Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. AIR CLEANER AND OTHER MAINTENANCE Always check the API SERVICE label on the oil con- •...

  • Page 32: Engine Adjustments

    All manuals and user guides at all-guides.com MAINTENANCE ENGINE ADJUSTMENTS WARNING GASES FROM BATTERY can explode. OVERSPEED IS HAZARDOUS • Keep sparks, flame and cigarettes away from battery. To prevent EXPLOSION when: WARNING • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last.

  • Page 33: Engine Maintenance Parts

    All manuals and user guides at all-guides.com MAINTENANCE ENGINE MAINTENANCE PARTS KOHLER C20S HONDA GX620KI ROBIN / SUBARU EH64 KOHLER 1205001 HONDA ROBIN / SUBARU FRAM PH3614* 15410-ZJ4-999A 248-65801-00, FRAM PH4967 Oil Filter KOHLER 4708303 HONDA ROBIN / SUBARU FRAM CA79 17210-ZJ1-841 263-32610-A1 Air Filter...
  • Page 34 All manuals and user guides at all-guides.com MAINTENANCE FIGURE D.1 - MAJOR COMPONENT LOCATION 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY 3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 5. CASE TOP & SIDES RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 35 All manuals and user guides at all-guides.com Section E-1 TABLE OF CONTENTS Section E-1 - 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 .

  • Page 36: Theory Of Operation

    All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID RANGE SWITCH ELECTRODE TERMINAL POLARITY CHOKE OUTPUT SWITCH BRIDGE REACTOR WORK STAT OR TERMINAL MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR...
  • Page 37 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER RANGE SWITCH ELECTRODE TERMINAL POLARITY CHOKE OUTPUT SWITCH BRIDGE REACTOR WORK STAT OR TERMINAL MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR RINGS FLYWHEEL...
  • Page 38 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH RANGE SWITCH ELECTRODE TERMINAL CHOKE POLARITY OUTPUT SWITCH BRIDGE REACTOR WORK STAT OR TERMINAL MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR RINGS FLYWHEEL...
  • Page 39 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS RANGE SWITCH ELECTRODE TERMINAL POLARITY OUTPUT CHOKE SWITCH BRIDGE REACTOR WORK STAT OR TERMINAL MECHANICAL ROTAT ION ROTOR STARTER ENGINE SLIP ROTOR...
  • Page 40 All manuals and user guides at all-guides.com NOTES RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 41 All manuals and user guides at all-guides.com Section F-1 TABLE OF CONTENTS Section F-1 - 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...

  • Page 42: Troubleshooting And 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.

  • Page 43: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - 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 prop- er failure analysis.

  • Page 44: Troubleshooting Guide

    CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 45 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 46 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 47 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 48 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 49 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 50 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 51 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 52 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 53 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 54 All manuals and user guides at all-guides.com NOTES F-14 F-14 RANGER® 10,000 & RANGER® 10,000 PLUS...

  • Page 55: Rotor Voltage Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 56 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-16 F-16 ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Brushes Slip Rings Lead 200A Lead 219 TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 9.

  • Page 57: Rotor Resistance Test

    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 elec-...
  • Page 58 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-18 F-18 ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS Lead 200A Lead 219 TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 9. Isolate the rotor electrically by removing sheet metal screws from the case top.
  • Page 59 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR 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.
  • Page 60 All manuals and user guides at all-guides.com NOTES F-20 F-20 RANGER® 10,000 & RANGER® 10,000 PLUS...

  • Page 61: Auxiliary And Field Winding Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 62 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-22 F-22 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 Machine Case 115V Front Receptacle Lead #3 Lead #5 TEST PROCEDURE To test the 115 VAC winding: To test the 230 VAC winding: 1.
  • Page 63 All manuals and user guides at all-guides.com 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 If the voltage readings are within specifica- gasket. With the 5/16” nut driver, remove tions, then the windings are good and func- the case top and left side;...
  • Page 64 All manuals and user guides at all-guides.com NOTES F-24 F-24 RANGER® 10,000 & RANGER® 10,000 PLUS...

  • Page 65: Output Rectifier Bridge Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 66 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-26 F-26 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS OUTPUT RECTIFIER ENGINE TEST PROCEDURE 10. With the 7/16” wrench or socket wrench 1. Remove the spark plug wires to prevent and 6”...

  • Page 67: Charging Circuit Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 68 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-28 F-28 CHARGING CIRCUIT TEST (continued) FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR Engine Ground Lead (Green) Voltage Regulator AC Lead DC Lead AC Lead TEST PROCEDURE 1. Start the engine and run it at high idle 5.

  • Page 69: Engine Throttle Adjustment Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 70 All manuals and user guides at all-guides.com 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 four 8.
  • Page 71 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-31 F-31 (continued) ENGINE THROTTLE ADJUSTMENT TEST FIGURE F.7 FIGURE F.8 HIGH IDLE ADJUSTMENT NUT LOW IDLE ADJUSTMENT NUT Solenoid 3/8" Low Idle Adjustment Muffler Housing Throttle linkage Choke Cable 3/8"...
  • Page 72 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-32 F-32 ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: Vibratach Method: 1. Connect the oscilloscope to the 115 VAC 1. Place the vibratach as close to the engine receptacle, according to the manufactur- as possible.

  • Page 73: Normal Open Circuit Voltage Waveform (115 Vac Supply

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-33 F-33 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 16.2 ms 0 volts 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine.
  • Page 74 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-34 F-34 TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE) MACHINE LOADED 0 volts 5 ms 20 volts MACHINE LOADED TO 200 AMPS AT 20 VDC This is the typical CV output voltage generated from a properly operating machine.
  • Page 75 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-35 F-35 TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE) MACHINE LOADED 0 volts 5 ms 20 volts MACHINE LOADED TO 200 AMPS AT 26 VDC This is the typical DC output voltage generated from a properly operating machine.

  • Page 76: Typical Ac Weld Output Waveform - Machine Loaded

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-36 F-36 TYPICAL AC WELD OUTPUT WAVEFORM MACHINE LOADED 0 volts 5 ms 20 volts MACHINE LOADED TO 225 AMPS AT 25 VDC This is the typical AC output voltage generated from a properly operating machine.

  • Page 77: Abnormal Open Circuit Weld Voltage Waveform (Cv Mode, One Diode Open

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-37 F-37 ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 0 volts 5 ms 20 volts This is NOT the typical CV output voltage waveform.

  • Page 78: Abnormal Open Circuit Dc Weld Voltage Waveform

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-38 F-38 ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 0 volts 5 ms 50 volts This is NOT the typical DC (+) output voltage waveform.

  • Page 79: Normal Open Circuit Weld Voltage Waveform (Cv Mode

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-39 F-39 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 0 volts 5 ms 20 volts This is the typical CV output voltage generated from a properly operating machine.

  • Page 80: Normal Open Circuit Dc Weld Voltage Waveform

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-40 F-40 NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 0 volts 5 ms 50 volts This is the typical DC output voltage generated from a properly operating machine.

  • Page 81: Normal Open Circuit Ac Weld Voltage Waveform

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-41 F-41 NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 0 volts 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine.
  • Page 82 All manuals and user guides at all-guides.com NOTES F-42 F-42 RANGER® 10,000 & RANGER® 10,000 PLUS...

  • Page 83: Brush Removal And Replacement

    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 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.
  • Page 84 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-44 F-44 BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wires. 13. Snap the plastic retainer back onto the brush holder. The brushes may need 2. With the 5/16” nut driver, remove the 6 some repositioning;...
  • Page 85 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-45 F-45 BRUSH REMOVAL AND REPLACEMENT (continued) SLIP RINGS A slight amount of darkening and wear of the CAUTION slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary.
  • Page 86 All manuals and user guides at all-guides.com NOTES F-46 F-46 RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 87 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this man- ual.

  • Page 88: Printed Circuit Board Removal And Replacement

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-48 F-48 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION 4 Self Tapping Screws (at corners) 4 Pin Plug 12 Pin Plug 1/4" Q.C. Tabs PROCEDURE 8.
  • Page 89 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-49 F-49 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) CAUTION Be sure to follow the recommended static- free methods for handling printed circuit boards. Failure to do so can result in perma- nent damage to the equipment.
  • Page 90 All manuals and user guides at all-guides.com NOTES F-50 F-50 RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 91 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this man- ual.

  • Page 92: Output Rectifier Bridge Removal And Replacement

    All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-52 F-52 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS L1 TO CHOKE TO POLARITY SWITCH (3) 1/2" TO S2 MOUNTING SCREWS ENGINE (4) 7/16" MOUNTING SCREWS TO S2...
  • Page 93 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-53 F-53 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 12. With the 1/2” wrench remove the three 17. With the 7/16” socket wrench, install the mounting nuts. Note the placement of the W1 lead and the heavy lead going to the nylon insulators.
  • Page 94 All manuals and user guides at all-guides.com NOTES F-54 F-54 RANGER® 10,000 & RANGER® 10,000 PLUS...
  • Page 95 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 elec-...
  • Page 96 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-56 F-56 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL 1. STATOR COWLING COVER 2. BLOWER FAN 3. IDLE LINKAGE 4. BRUSH HOLDER BRACKET 5. ENGINE LIFT BAILS 6.
  • Page 97 All manuals and user guides at all-guides.com TROUBLESHOOTING & REPAIR F-57 F-57 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) ENGINE AND ROTOR REMOVAL PROCEDURE 1. Refer to igure .12 for component loca- 15. With the 1/4” nut driver, disconnect the tions. engine choke cable from the engine. Mark the location of the retainer for reassembly.
  • Page 98 6. Slide the rotor the rest of the way off the 3. Install the appropriate long thru-bolt (two are crankshaft. Be careful not to lose the wash- provided) supplied with Lincoln Electric er that fits between the blower fan and the Rotor Removal Kit S20788. The slot head rotor.
  • Page 99 F-59 ENGINE/ROTOR REMOVAL AND REPLACEMENT (KIT S20788) (continued) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new 8. Attach leads to the oil pressure switch refer bearing (Lincoln part #M9300-85) be installed to wiring diagram. Replace any cut cable when you replace the rotor and blower assem- ties.

  • Page 100: Retest After Repair

    All manuals and user guides at all-guides.com 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.
  • Page 101 All manuals and user guides at all-guides.com Section G-1 TABLE OF CONTENTS Section G-1 - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams....................Section G Wiring Diagram - Entire Machine - Code 11041 Only - (M20226) ....G-2 Wiring Diagram - Entire Machine - Code 11095 Only - (M20301) .
  • Page 102 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11041 ONLY -(M20226) RANGER 10,000 (KOHLER) (CSA) LEADS 3 AND 6: 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 1 TURN OUTPUT GROUND SCREW CONTROL 209A ON UPPER CASEFRONT...
  • Page 103 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11095 ONLY - (M20301) RANGER 10,000 (HONDA) LEADS 3 AND 6: 213A 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 1 TURN OUTPUT GROUND SCREW CONTROL 209A ON MIDDLE CASEFRONT...
  • Page 104 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11150 T0 11393 - (M20431) RANGER 10,000 LEADS 3 AND 6: 2 TURNS THRU TOROID IN 1 TURN OPPOSITE DIRECTIONS CHOKE OUTPUT CONTROL GROUND SCREW ON UPPER...
  • Page 105 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11398 - (M21269) RANGER 10,000 (HONDA) LEADS 3 AND 6: 213A 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 1 TURN WORK OUTPUT CONTROL 209A CHOKE NEGATIVE POSITIVE...
  • Page 106 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM CODE 11394 AND 11395 (M21270) RANGER 10,000 PLUS LEADS 3 AND 6: 2 TURNS THRU TOROID IN 1 TURN OPPOSITE DIRECTIONS WORK CHOKE OUTPUT CONTROL ELECTRODE POSITIVE CHOKE NEGATIVE...
  • Page 107 ON 2 PLACE DECIMALS IS ± .02 REFERENCE: SUBJECT: ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: RANGER 10,000 (HONDA), RANGER 10,000 PLUS (SUBARU ROBIN) ON ALL ANGLES IS ± .5 OF A DEGREE SCALE: L12257 MATERIAL TOLERANCE (" ") TO AGREE...
  • Page 108 ON 2 PLACE DECIMALS IS ± .02 DRAWN BY: REFERENCE: SUBJECT: ON 3 PLACE DECIMALS IS ± .002 RANGER 10,000 PLUS (KOHLER) ON ALL ANGLES IS ± .5 OF A DEGREE SCALE: L12249-1 MATERIAL TOLERANCE (" ") TO AGREE ENGINEER:...
  • Page 109 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. RANGER 10,000 HONDA EQUIPMENT TYPE: UNLESS OTHERWISE SPECIFIED TOLERANCE...
  • Page 110 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED running and PC B1 will denergize idle TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. RANGER 10,000 KOHLER solenoid. EQUIPMENT TYPE:...
  • Page 111 All manuals and user guides at all-guides.com G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD - CODE 11041 ONLY - (L12049) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER®...
  • Page 112 All manuals and user guides at all-guides.com G-12 G-12 ELECTRICAL DIAGRAMS SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD - CODES ABOVE 11050 ONLY - (L12197-1) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER®...

This manual is also suitable for:

Ranger 10,000 plusK1419-4K1419-5K2160-3K2160-4K2468-2

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