Lincoln Electric RANGER SVM120-A Service Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. RANGER SVM120-A
  6. Service manual
Lincoln Electric RANGER SVM120-A Service Manual

Lincoln Electric RANGER SVM120-A Service Manual

Lincoln electric welder user manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

RETURN TO MAIN INDEX
SVM120-A
March 1999
TM
RANGER 10-LX
For use with machine code numbers 9815 and 9816
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.

SERVICE MANUAL

World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric RANGER SVM120-A

Summary of Contents for Lincoln Electric RANGER SVM120-A

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM120-A March 1999 RANGER 10-LX For use with machine code numbers 9815 and 9816 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 .

  • 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: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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 Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Installation Section Table of Contents ...A-1 Technical Specifications ...A-2 Safety Precautions...A-3 Location and Ventilation ...A-3 Pre-operation Engine Service ...A-4 Electrical Output Connections...A-5 Operation...Section B Safety Instructions ...B-2 General Description ...B-2 Recommended Applications ...B-3 Design Features and Advantages...B-3 Welding Capability ...B-3...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Safety Precautions...A-3 Location and Ventilation ...A-3 Storing ...A-3 Stacking...A-4 Tilting ...A-4 Lifting ...A-4 High Altitude Operation...A-4 Pre-operation Engine Service ...A-4 Oil ...A-4 Fuel ...A-4 Engine Coolant ...A-4 Battery Connections...A-4 Muffler Relocation ...A-5 Spark Arrester ...A-5 Electrical Output Connections...A-5 Welding Cable Connections ...A-6...

  • Page 8: Installation

    23 HP @ 3600 RPM Duty Cycle 100% Duty Cycle 100% Duty Cycle 100% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges Max. Open Circuit Voltage 45- 250 Amps Height 37.4 in. 949 mm Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity.

  • Page 9: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions;...

  • Page 10: Pre-Operation Engine Service

    HIGH ALTITUDE OPERATION It may be necessary to derate welder output at higher altitudes. Derate the welder output 0.4% for every 100 ft (30 m) above 500 ft (150 m). Some engine adjust- ment may be required.

  • Page 11: Electrical Output Connections

    FIGURE A.1 - RANGER 10-LX OUTPUT CONNECTIONS MUFFLER RELOCATION WARNING Shut off the machine and allow the muffler to cool before touching the muffler. The RANGER 10-LX is shipped with the exhaust directed toward the rear. It can be changed to the right side by loosening the clamp that holds the exhaust deflector in place and rotating the deflector to the desired direction.

  • Page 12: Welding Cable Connections

    INSTALLATION welder. Cable diameters are increased for long cable lengths to reduce voltage drops. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the Acces- sories section of this manual for more information. Cable Size for 250 Amp...

  • Page 13: Auxiliary Power Receptacles, Plugs, And Hand-Held Equipment

    When the RANGER 10-LX is mounted on a truck or a trailer, the machine generator ground stud MUST be securely connect- ed to the metal frame of the vehicle. See Figure A.1. The ground stud is marked with the ground symbol. If the RANGER 10-LX is connected to premises wiring such as a home or shop, it must be properly connect- ed to the system earth ground.
  • Page 14 FIGURE A.2 - CONNECTION OF RANGER 10-LX TO PREMISES WIRING 230 VOLT 230 Volt POWER 60 Hz. COMPANY 3-Wire METER Service DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 115/230 VOLT PLUG NEMA TYPE 14-50 50 AMP, 115/230 VOLT...
  • Page 15 Welder ...B-3 Generator ...B-3 Design Features and Advantages...B-3 Welding Capability ...B-3 Limitations ...B-3 Controls and Settings ...B-4 Welder/Generator Controls ...B-4 Diesel Engine Controls ...B-6 Engine Operation ...B-7 Before Starting the Engine ...B-7 Starting the Engine ...B-8 Stopping the Engine ...B-8 Break-in Period ...B-8...

  • Page 16: Operation

    AC power tools, battery chargers, and light- ing; it can also be used to provide standby power. As a welder it provides 250 amps of AC current for weld- ing with AC stick electrodes or 250 amps of DC cur- rent for DC stick welding.

  • Page 17: Recommended Applications

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

  • Page 18: Controls And Settings

    CONTROLS AND SETTINGS All generator/welder controls are located on the Output Control Panel of the machine case front. Diesel engine glow plug, idler control, and start/stop FIGURE B.1 – OUTPUT PANEL CONTROLS WELDER/GENERATOR CONTROLS See Figure B.1 for the location of the following fea- tures: 1.
  • Page 19 7. 20 AMP, 115 VOLT DUPLEX RECEPTACLES: Connection point for supplying 115 volt power to operate one or two electrical devices. 8. 50 AMP, 230/115 VOLT Connection point for supplying 230 volt power to operate one electrical device. 9. WELD OUTPUT TERMINAL (TO WORK) WITH FLANGE NUT: Provides the connection point for the work cable.
  • Page 20 1. ENGINE GLOW PLUG PUSHBUTTON 2. IDLER CONTROL SWITCH 3. START PUSHBUTTON 4. ENGINE HOUR METER 5. BATTERY CHARGER LIGHT 6. OIL PRESSURE LIGHT 7. WATER TEMPERATURE LIGHT 8. FUEL LEVEL GAUGE 9. ENGINE ON-OFF SWITCH DIESEL ENGINE CONTROLS See Figure B.2 for the location of the following fea- tures: 1.

  • Page 21: Engine Operation

    6. OIL PRESSURE LIGHT: Remains off with proper oil pressure. If light turns on, the engine protection system will stop the engine. The light will go on when the “Engine” switch is switched to the “ON” position with engine not running. It will go off after one minute if the engine is not started.
  • Page 22 STARTING THE ENGINE NOTE: Remove all loads connected to the AC power receptacles before starting the diesel engine. 1. Open the engine compartment door and check that the fuel shutoff valve located above the clear plastic fuel filter housing is in the open position (lever in the vertical position).
  • Page 23 TYPICAL RANGER 10-LX FUEL CONSUMPTION Low Idle – No Load, 2150 RPM High Idle – No Load, 3750 RPM AC CC Weld Output, 250 Amps @ 25 Volts DC CC Weld Output, 250 Amps @ 25 Volts DC CV Weld Output, 250 Amps @ 30 Volts Auxiliary Power, 10,000 kVA OPERATION TABLE B.1...

  • Page 24: Welding Operation

    B-10 WELDING OPERATION GENERAL INFORMATION WARNING • 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. •...
  • Page 25 B-11 To Use the RANGER 10-LX for AC/DC TIG (Constant Current) Welding: 1. Connect the K930-1 TIG Module to the RANGER 10-LX. Follow the installation instructions provid- ed with the kit. Also be sure to follow the special machine grounding instructions given in the man- ual.
  • Page 26 B-12 To Use the RANGER 10-LX for DC Wire Feed Welding (Constant Voltage): 1. Connect one of the following: the LN-25, LN-7 or LN-8 Wire Feeder. Follow the installation instruc- tions in the Accessories section of this manual. 2. Some recommended Innershield electrodes are: NR-211MP, NR-311, NR-203 series, as well as Lincore ®...

  • Page 27: Summary Of Welding Processes

    LN-25 with internal contactor Wire Feed - CV, High LN-7 or LN-8 OPERATION Output Wire Electrode Control Feeder State When Switch Switch Not Welding At Welder Control Cable Remote With Cold Control Cable Remote With Cold Control Cable At Welder Cold...

  • Page 28: Auxiliary Power

    B-14 AUXILIARY POWER WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation. GENERAL INFORMATION The RANGER 10-LX generator is rated at 10,000 con- tinuous watts. It provides both 115 volt and 230 volt power.
  • Page 29 B-15 TABLE B.4 - SIMULTANEOUS WELDING AND AUXILIARY POWER Output Selector Welding Setting Output CV Low CV Medium Low CV Medium High CV High OPERATION Permissible Power in Watts Permissible Auxiliary Current (Unity Power Factor) None 3000 3500 5500 6500 7500 8500 7000...
  • Page 30 *Submersible Pump - 1 HP *Sump Pump Toaster Weed Trimmer Lincoln 100 or 125 Amp Wire Feeder/Welder NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in the table, multiply RUNNING WATTS by 2.

  • Page 31: Accessories

    Options/Accessories...C-2 TIG Welding...C-3 Semiautomatic FCAW and MIG Welding ...C-3 Connection of Lincoln Electric Wire Feeders...C-4 Connection of the K867 Universal Adapter ...C-4 Connection of the LN-25 “Across the Arc” ...C-5 Connection of the LN-7 Using the K584 Input Cable Assembly...C-6 Connection of the LN-7 Using the K867 Universal Adapter ...C-7...
  • Page 32 OPTIONS/ACCESSORIES The following options/accessories are available for your RANGER 10-LX from your local Lincoln Distributor. Two-Wheel Trailer (K768) – For in-plant or yard tow- ing of the RANGER 10-LX. (Not intended for highway towing as equipped. For highway use of this trailer, consult applicable federal, state, and local laws about possible requirements for brakes, lights, fenders, etc.) Power Plug Kit (K802-N) –...
  • Page 33 TIG WELDING TIG Module (K930-1) - The TIG Module is an acces- sory that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applica- tions. It provides contactor control of constant current welding power sources having an internal contactor. The K930-1 TIG Module is supplied without accessories.

  • Page 34: Connection Of Lincoln Electric Wire Feeders

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGATIVE (-) BATTERY LEAD before servicing. • Do not touch electrically live parts. MOVING PARTS can injure. • Keep guards in place.
  • Page 35 NOTE: Welding cable must be sized for current and duty cycle of application. 3. Set the welder “polarity” switch to the desired polarity, either DC (-) or DC (+). 4. Set the “RANGE” switch to the “WIRE FEED” posi- tion.
  • Page 36 1. Shut the welder off. 2. Connect the electrode cable from the K584-XX Input Cable Assembly to the “ELECTRODE” termi- nal of the welder and to the LN-7 wire feeder. Connect the work cable to the “TO WORK” termi- nal of the welder.
  • Page 37 Figure C.4 and the following NOTES, indicated on the figure. 4. Set the welder “polarity” switch to the desired polarity, either DC (-) or DC (+). 5. Set the “RANGE” switch to the “WIRE FEED” posi- tion.
  • Page 38 NOTE: If K595 control cable assembly is available, K867 universal adapter is not required. 4. Set the welder “polarity” switch to the desired polarity, either DC (-) or DC (+). 5. Set the “RANGE” switch to the “WIRE FEED” posi- tion.
  • Page 39 1. Shut the welder off. 2. Connect the electrode cable from the SG Control Module to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.

  • Page 40: Maintenance

    Clean Spark Arrester Screen ...D-6 Engine Maintenance Schedule ...D-7 Battery Maintenance ...D-8 Cleaning the Battery ...D-8 Checking Electrolyte Level...D-8 Charging the Battery ...D-8 Welder/Generator Maintenance ...D-8 Storage...D-8 Cleaning ...D-8 Brush Removal and Replacement ...D-8 Receptacles ...D-9 Cable Connections...D-9 Major Component Locations ...D-10...

  • Page 41: Safety Precautions

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. •...

  • Page 42: Change The Oil Filter

    FIGURE D.1 – OIL DRAIN AND REFILL LOCATION 1. DIPSTICK 2. OIL DRAIN PLUG CHANGE THE OIL FILTER Change the oil filter the first time after 50 hours of operation. Then, under normal operating conditions, change the oil filter after every 200 hours of operation. If the engine is operated under heavy load or in high ambient temperatures, change the oil filter more fre- quently.

  • Page 43: 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.
  • Page 44 FIGURE D.3 – FUEL SYSTEM BLEEDING AIR CLEANER: The Kubota diesel engine is equipped with a dry type air filter. Never apply oil to it. Service the air cleaner as follows: 1. Remove the dust cup from the bottom of the air cleaner housing.

  • Page 45: Checking/Adding/Draining Radiator Coolant

    CHECKING/ADDING/DRAINING RADIATOR COOL- ANT: Check the level of coolant in the reserve tank. The level is sufficient if it is between the “FULL” and the “LOW” marks. If the level is below the “LOW” mark, add fresh, water/antifreeze mixture to the “FULL”...
  • Page 46 KUBOTA ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. • Check oil level. • Check air cleaner for dirty, loose, or damaged parts. • Check air intake and cooling areas, clean as necessary. Every 50 Hours •...

  • Page 47: Battery Maintenance

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

  • Page 48: Brush Removal And Replacement

    To reinstall the brushes, press them upward and slide a cable tie or wooden stick through the brush holder tabs. See Figure D.5. Install the brush holder into position and secure with the screws previously removed. Remove the cable tie or wooden stick and the brushes will seat onto the slip rings.
  • Page 49 D-10 FIGURE D.6 - MAJOR COMPONENT LOCATIONS 1. OUTPUT TERMINALS (LOCATION) 2. ENGINE CONTROLS (on Control Panel) 3. AUXILIARY POWER RECEPTACLES 4. OUTPUT CONTROL PANEL 5. REACTOR ASSEMBLY 6. FUEL TANK 7. DIESEL ENGINE 8. ROTOR/STATOR ASSEMBLY 9. BATTERY (not shown) 10.
  • Page 50 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E Battery, Starter, Engine, Glow Plugs, Engine Protection, Rotor, Stator, and Idler Solenoid...E-2 Rotor Field Feedback, Auxiliary and Wire Feeder Power ...E-3 Weld Winding, Reactor, and Range Switch...E-4 Output Bridge, Choke, Polarity Switch, CV Contactor, and Output Terminals ...E-5 SHUTDOWN SOLENOID GLOW PLUGS...

  • Page 51: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION, ROTOR, STATOR AND IDLER SOLENOID SHUTDOWN SOLENOID STARTER MOTOR ALTERNATOR BATTERY ENGINE PROTECTION RELAY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE...
  • Page 52 THEORY OF OPERATION FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER SHUTDOWN SOLENOID STARTER MOTOR ALTERNATOR BATTERY ENGINE PROTECTION RELAY BY-PASS BOARD CONTROL CLOSURE CONTACTOR CLOSURE OUTPUT CONTROL 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER The AC voltage developed in the field winding is fed to...
  • Page 53 THEORY OF OPERATION FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH SHUTDOWN SOLENOID STARTER MOTOR ALTERNATOR BATTERY ENGINE PROTECTION RELAY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL WELD WINDING, REACTOR, AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch.
  • Page 54 THEORY OF OPERATION FIGURE E.5 – OUTPUT BRIDGE, CAPACITOR, CHOKE, POLARITY SWITCH, CV CONTACTOR AND SHUTDOWN SOLENOID STARTER MOTOR ALTERNATOR ENGINE PROTECTION RELAY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, CV CONTACTOR AND OUTPUT TERMINALS...
  • Page 55 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-20 Test Procedures Rotor Voltage Test ...F-21 Rotor Resistance Test ...F-23 Auxiliary and Field Winding Test ...F-25 Output Rectifier Bridge Test...F-29 Charging Circuit Test ...F-31 Protection Relay (CR1) Test ...F-33...

  • Page 56: Troubleshooting & Repair Section

    TROUBLESHOOTING & REPAIR 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 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 57: Pc Board Troubleshooting Procedures

    • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

  • Page 58: Troubleshooting Guide

    Engine operates normally. 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 216-383-2531 or 1-800-833-9353.
  • Page 59 Engine operates normal- 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 216-383-2531 or 1-800-833-9353.
  • Page 60 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 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 61 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 216-383-2531 or 1-800-833-9353.
  • Page 62 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 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 63 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 216-383-2531 or 1-800-833-9353.

  • Page 64: Receptacles

    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 216-383-2531 or 1-800-833-9353.
  • Page 65 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 216-383-2531 or 1-800-833-9353.

  • Page 66: Cable Connections

    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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 67 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 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 68 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 216-383-2531 or 1-800-833-9353.
  • Page 69 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 70 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 71 RANGER 10-LX amphenol. 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 216-383-2531 or 1-800-833-9353.
  • Page 72 RANGER 10-LX. 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 216-383-2531 or 1-800-833-9353.
  • Page 73 The battery does not stay charged. 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 216-383-2531 or 1-800-833-9353.
  • Page 74 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.

  • Page 75: Rotor Voltage Test

    F-21 TROUBLESHOOTING & REPAIR 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 76 F-22 TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST TEST PROCEDURE 1. With the 5/16” and 3/8” nut driver, remove the sheet metal screws from the right hand case side.

  • Page 77: Rotor Resistance Test

    TROUBLESHOOTING & REPAIR 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 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 78 F-24 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LEADS 200A AND 219 REMOVED TEST PROCEDURE 1. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right hand case side. 2. Carefully remove the right case side. 3.

  • Page 79: Auxiliary And Field Winding Test

    TROUBLESHOOTING & REPAIR 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 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 80 F-26 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 TEST PROCEDURE To test the 115 VAC winding: 1. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the left case side.
  • Page 81 F-27 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER Field Bridge Rectifier (see inset) To test the field winding: 1. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right case side.
  • Page 82 F-28 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4A – 14 PIN AMPHENOL PIN ASSIGNMENTS To test the feeder winding: 1. Using the 5/16” and 1/8” nut drivers, remove the sheet metal screws from the right case side. 2.

  • Page 83: Output Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE 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 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 84 F-30 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS Left side (–) TEST PROCEDURE 1. Using the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right and left case sides. 2.

  • Page 85: Charging Circuit Test

    F-31 TROUBLESHOOTING & REPAIR 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 86 F-32 TROUBLESHOOTING & REPAIR CHARGING CIRCUIT TEST (continued) FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR TEST PROCEDURE 1. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the left case side. 2. Carefully remove the left case side. 3.

  • Page 87: Protection Relay (Cr1) Test

    TROUBLESHOOTING & REPAIR PROTECTION RELAY (CR1) 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 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 88 F-34 TROUBLESHOOTING & REPAIR PROTECTION RELAY (CR1) TEST (continued) FIGURE F.7 – CR1 LEAD CONNECTIONS TEST PROCEDURE 1. Using the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the left case side. 2. Carefully remove the left case side. 3.

  • Page 89: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR 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 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 90 F-36 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 – MARK LOCATION, STROBE/TACH METHOD TEST PROCEDURE This test can be conducted by any one of three methods. Strobe-tach Method: 1. With the 5/16” nut drivers, remove the sheet metal screws from the right case side.
  • Page 91 F-37 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.9 – HIGH IDLE ADJUSTMENT NUT Adjust HIGH IDLE: First make sure there is NOT a load on the machine. Use the 10mm wrench to loosen the lock nut. See Figure F.9 for location of adjustment screw and lock nut.
  • Page 92 F-38 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.10 – LOW IDLE ADJUSTMENT NUT 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 15.8 mil- liseconds.

  • Page 93: Normal Open Circuit Voltage Waveform (115 Vac Supply

    F-39 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 15.8 ms 50 volts This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 5 milliseconds in time.
  • Page 94 F-40 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP) MACHINE LOADED TO 250 AMPS AT 30VDC MACHINE LOADED 5 ms 20 volts This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 95 F-41 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 250 AMPS AT 25 VDC MACHINE LOADED 5 ms 20 volts This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 96 F-42 TROUBLESHOOTING & REPAIR TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 250 AMPS AT 25VDC MACHINE LOADED 5 ms 20 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 97 F-43 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 5 ms 50 volts This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning.

  • Page 98: Abnormal Open Circuit Weld Voltage Waveform (One Diode Open

    F-44 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM OUTPUT CAPACITOR BANK NOT FUNCTIONING (HIGH CV MODE) 5 ms 50 volts This is NOT the typical CV output voltage waveform. The capacitor bank is not functioning.

  • Page 99: Normal Open Circuit Weld Voltage Waveform (High Cv Mode

    F-45 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 5 ms 20 volts This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 100: Normal Open Circuit Dc Weld Voltage Waveform

    F-46 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 101: Normal Open Circuit Ac Weld Voltage Waveform

    F-47 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 102: Brush Removal And Replacement

    TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT 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 103 F-49 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Perform this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right case side. 3. Carefully remove the right case side. 4.
  • Page 104 F-50 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) NOTE: A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary. replaced, clean slip rings with a fine emery paper.

  • Page 105: Field Capacitor And Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL 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 106 F-52 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR Field Bridge Rectifier (see inset) PROCEDURE 1. Perform this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right case side.
  • Page 107 F-53 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE - RECTIFIER BRIDGE REMOVAL AND REPLACEMENT 1. Perform this procedure with the engine OFF. 2. WIth the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right case side.

  • Page 108: Control Board Removal And Replacement

    TROUBLESHOOTING & REPAIR CONTROL BOARD 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 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 109 F-55 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT FIGURE F.13 - CONTROL BOARD LOCATION CONTROL PROCEDURE Before starting the following procedure, refer to topic “PC Board Procedures” at the beginning of this section. 1. Perform this procedure with the engine OFF. 2.

  • Page 110: Control Board Removal

    F-56 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 16. Connect current sensing leads #254 and #254A. See the Wiring Diagram for the proper connections. 17. Connect the two molex plugs. 18. Connect the three individual leads #213, #222 and #5C. 19.

  • Page 111: Output Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL 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 112 F-58 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.14 - OUTPUT RECTIFIER CONNECTIONS Left Side (–) PROCEDURE 1. Perform this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the left and right case sides.
  • Page 113 F-59 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 9. Clear the leads and carefully remove the heat sink assembly. 10. Repeat the above procedure to remove the other half of the output rectifier. REASSEMBLY: When reassembling, use Dow Corning 340 on all aluminum electrical connection surfaces.

  • Page 114: Output Capacitor Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR BANK REMOVAL 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 115 F-61 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR BANK EMOVAL AND REPLACEMENT (continued) FIGURE F.15 - OUTPUT CAPACITOR BANK/PRINTED CIRCUIT BOARD LOCATION PROCEDURE 1. Perform this procedure with the engine OFF. 2. WIth the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the right case side.

  • Page 116: Output Contactor Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT CONTACTOR REMOVAL 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 117 F-63 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – OUTPUT CONTACTOR LOCATION PROCEDURE 1. Perform this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the left case side.
  • Page 118 F-64 F-64 TROUBLESHOOTING & REPAIRs OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – CONTACTOR COIL LEAD PLACEMENT 224C 224F Copper Strap 241A RANGER 10-LX...

  • Page 119: Stator And/Or Rotor Removal And Replacement (Kit S20788

    TROUBLESHOOTING & REPAIR STATOR AND/OR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 120 F-66 TROUBLESHOOTING & REPAIR STATOR AND/OR REMOVAL AND FIGURE F.18 – COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL REPLACEMENT (continued) RANGER 10-LX F-66 Support engine when removing stator Support rotor when removing 1. STATOR MOUNTING BRACKET 2. MOUINTING BRACKET BOLT (2) 3. ROTOR BEARING SCREWS (2) 4.
  • Page 121 F-67 TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) PROCEDURE (Stator Removal) 1. Perform this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the case top and left and right case sides. 3.
  • Page 122 F-68 TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.19- ENGINE AND ROTOR REMOVED FROM STATOR 23. Using the 5/16” wrench, remove the three sheet metal screws holding the front vertical baffle to the base of the machine. 24.
  • Page 123 F-69 TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) REASSEMBLY NOTES 1. Be sure to remove the rotor bearing from the stator frame before reinstalling the rotor/stator Also remove the tolerance ring. 2. Install the rotor to the flex plate and install the flex plate to the engine.

  • Page 124: Retest After Repair

    Output values of each receptacle can vary within the range shown but must be within 2 volts of each other. RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 2150-2250 3650-3700 WELDER DC OUTPUT Open Circuit Volts 61 - 68 WELDER AC OUTPUT Open Circuit...
  • Page 125 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagram Section ....... . . Section G Wiring Diagram Ranger 10 LX Code 9816 .
  • Page 126 NOTES RANGER 10LX...

  • Page 127: Wiring Diagram Ranger 10Lx Code 9816

    Wiring Diagram Ranger 10LX Code 9816 242A 241A CV OUTPUT CONTACTOR MODE 224F SWITCH 224K 254A WORK ELECTRODE NO CONTROL CABLE SWITCH S H O W N I N N O C A B L E P O S I T I O N 224F STATOR I N L I N E C O N N E C T O R S...

  • Page 128: Wiring Diagram Ranger 10Lx Csa Code 9821

    Wiring Diagram Ranger 10LX CSA Code 9821 242A 241A CV OUTPUT CONTACTOR MODE SWITCH 224F 224K 254A WORK ELECTRODE NO CONTROL CABLE SWITCH S H O W N I N N O C A B L E P O S I T I O N 224F STATOR I N L I N E C O N N E C T O R S...

  • Page 129: Control Pc Board (G2318) Schematic

    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 are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 130: Control Pc Board (G2318) Layout

    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 are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 131: Rf Bypass Board Schematic

    Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 132: Dimension Print

    DIAGRAMS DIMENSION PRINT RANGER 10LX...
  • Page 133 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

This manual is also suitable for:

Ranger 10-lx

Table of Contents