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Lincoln Electric RANGER SVM168-B manual

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Table of contents for the manual

  • Page 1

    ® RANGER 10,000 /10,000 PLUS SVM168-B April, 2010 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS [...]

  • Page 2

    RANGER® 10,000 & RANGER® 10,000 PLUS i SAFETY i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes out[...]

  • Page 3

    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 gases away from the breathing zone. When weldin[...]

  • Page 4

    RANGER® 10,000 & RANGER® 10,000 PLUS SAFETY iii iii Jan ʻ09 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ʼs recommendations. 8.c. Gr[...]

  • Page 5

    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: Sûr eté Pour Soudage A L’Arc 1. P rotegez-vous cont[...]

  • Page 6

    RANGER® 10,000 & RANGER® 10,000 PLUS v v MASTER T ABLE OF CONTENTS FOR ALL SECTIONS S a f e t y ........................................................ i - i v I n s t a l l a t i o n .................................................... S e c t i o nA O p e r a t i o n ..................................................... S e c t i o n B A c[...]

  • Page 7

    RANGER® 10,000 & RANGER® 10,000 PLUS Section A-1 Section A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ..............................................................................................................Section A T echnical Specifications ..............................................................................[...]

  • Page 8

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-2 A-2 TECHNICAL SPECIFICA TIONS - RANGER® 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1) INPUT - GASOLINE ENGINE RA TED 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 505 lbs. (229kg) K2160-3 528 lbs. (240kg[...]

  • Page 9

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-3 A-3 TECHNICAL SPECIFICA TIONS - RANGER 10,000 PLUS (K1419-5 ), (K2468-2) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg) K1419-5 770 mm 485 mm 1067 mm 528 lbs. (240kg) K2468-2 505 lbs. (229kg) K2160-4 RA[...]

  • Page 10

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION 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 (your home, shop, etc.). T o prevent dangerous [...]

  • Page 11

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION 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. Check the oil level before start- ing the eng[...]

  • Page 12

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-6 A-6 WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary . Loose connections will result in overheating of the output studs. When welding at a considerable dis[...]

  • Page 13

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-7 A-7 LOCA TION / VENTILA TION 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 the welder so that engine exhaust fumes are [...]

  • Page 14

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-8 A-8 120 V DUPLEX RECEPT ACLES The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current load through the as[...]

  • Page 15

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-9 A-9 T ABLE lll ELECTRICAL DEVICE USE WITH THE RANGER® 10,000 or RANGER® 10,000 PLUS. T ype Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker . Capacitive TV sets, radios, microwaves, V [...]

  • Page 16

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-10 A-10 ST ANDBY POWER CONNECTIONS The RANGER® 10,000 or RANGER® 10,000 PLUS is suitable for temporary , standby , or emergency power using the engine manufacturer ʼs recommended mainte- nance schedule. The RANGER® 10,000 or RANGER® 10,000 PLUS can be permanently installed as a standb[...]

  • Page 17

    RANGER® 10,000 & RANGER® 10,000 PLUS INST ALLA TION A-11 A-11 240 Volt 60 Hz. 3-Wire Service P OWER COMPANY M ETER 2 40 VOLT 1 20 VOLT 1 20 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N 4 CONDUCTOR COPPER CABLE SEE NATIONAL ELECTRICAL CODE FOR WIRE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 40 A[...]

  • Page 18

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES A-12 A-12 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 19

    RANGER® 10,000 & RANGER® 10,000 PLUS Section B-1 Section B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ................................................................................................................Section B S a f e t y P r e c a u t i o n s ................................................... B - 2 G e n e r a l D e[...]

  • Page 20

    RANGER® 10,000 & RANGER® 10,000 PLUS OPERA TION B-2 B-2 WELDER CONTROLS - FUNCTION AND OPERA TION ENGINE SWITCH The engine switch is used to Start the Engine, Select High Idle or Auto Idle while the engine is running, and stop the Engine. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine. When[...]

  • Page 21

    RANGER® 10,000 & RANGER® 10,000 PLUS OPERA TION 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

    RANGER® 10,000 & RANGER® 10,000 PLUS OPERA TION B-4 B-4 ST ARTING/SHUTDOWN INSTRUCTIONS ST ARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ʼs Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER E[...]

  • Page 23

    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 (CONST ANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity” switch to the desired polar[...]

  • Page 24

    RANGER® 10,000 & RANGER® 10,000 PLUS OPERA TION B-6 B-6 Summary of Welding Processes CONTROL ELECTRODE PROCESS CABLE IDLE WHEN NOT TO ST ART USED MODE WELDING WELDING STICK No AUTO Hot T ouch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger , LN-25 INTERNAL CONT A[...]

  • Page 25

    RANGER® 10,000 & RANGER® 10,000 PLUS Section C-1 Section C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C Optional Equipment ...........................................................................................[...]

  • Page 26

    ACCESSORIES RANGER® 10,000 & RANGER® 10,000 PLUS C-2 C-2 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEA VY DUTY , TWO WHEEL TRAILER FOR SMALL WELDERS - For road, of f-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 T r[...]

  • Page 27

    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 A WG work cable with lugs, headshield, filter plate, work clamp, and electrode holder . 400 amp capacity . K875 Accessory Kit - For stick weldin[...]

  • Page 28

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES C-4 C-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    RANGER® 10,000 & RANGER® 10,000 PLUS Section D-1 Section D-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...........................................................................................................Section D S a f e t y P r e c a u t i o n s .................................................. D - 2 R o u t i n e M a i [...]

  • Page 30

    RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-2 D-2 Have qualified personnel do the maintenance work. T urn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their[...]

  • Page 31

    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 SER VICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tempera- ture use, -5 F to 104 F (-20[...]

  • Page 32

    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 personal injury and damage to the machine can resu[...]

  • Page 33

    RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-5 D-5 KOHLER C20S HONDA GX620KI ROBIN / SUBARU EH64 KOHLER 1205001 HONDA ROBIN / SUBARU Oil Filter FRAM PH3614 * 15410-ZJ4-999A 248-65801-00, FRAM PH4967 Air Filter KOHLER 4708303 HONDA ROBIN / SUBARU Element FRAM CA79 17210-ZJ1-841 263-32610-A1 Air Filter KOHLER 2408302 HONDA N/A Pre-Cleaner[...]

  • Page 34

    RANGER® 10,000 & RANGER® 10,000 PLUS MAINTENANCE D-6 D-6 FIGURE D.1 - MAJOR COMPONENT LOCA TION 4 4 1 1 3 3 5 5 2 2 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBL Y 3. BASE/UNDERCARRIAGE ASSEMBL Y 4. ENGINE/ROTOR/ST A TOR ASSEMBL Y 5. CASE TOP & SIDES Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return[...]

  • Page 35

    RANGER® 10,000 & RANGER® 10,000 PLUS ST ARTER ENGINE BA TTER Y IDLER SOLENOID OUTPUT CONTROL MECHANICAL RO T A T ION FIELD CAP ACITOR ROT OR SLIP RINGS 1 15 & 230VA C RECEPT A CLES ROT OR ST A T OR ST A T OR REACT OR RANGE SWITCH OUTPUT BRIDGE CHOKE AC AC POLARITY SWITCH ELECTRODE TERMINAL WORK TERMINAL FL YWHEEL AL TERNA TOR CV TA P PRIN[...]

  • Page 36

    RANGER® 10,000 & RANGER® 10,000 PLUS THEOR Y OF OPERA TION E-2 E-2 BA TTER Y , ST ARTER, ENGINE, ROT OR, ST A TOR, AND IDLER SOLENOID The 12VDC battery powers the starter motor . When the engine is started and running, the battery circuit voltage is fed, through the printed cir cuit board, to the rotating field coil in the r otor via a brush [...]

  • Page 37

    RANGER® 10,000 & RANGER® 10,000 PLUS THEOR Y OF OPERA TION E-3 E-3 ROT OR FIELD FEEDBACK AND AUXILIAR Y POWER The AC voltage developed in the field winding is fed to the full wave field bridge. The DC output of the bridge is filtered by the field capacitor and contr olled by the printed circuit boar d according to the output contr ol setting.[...]

  • Page 38

    RANGER® 10,000 & RANGER® 10,000 PLUS THEOR Y OF OPERA TION E-4 E-4 WELD WINDING, REACT OR, AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch. The inductance in the reactor of fers an impedance to current flow . The reactor coil is tapped at various points. As the range switch is ro- tated, differ ent amount[...]

  • Page 39

    RANGER® 10,000 & RANGER® 10,000 PLUS THEOR Y OF OPERA TION E-5 E-5 OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding is delivered, thr ough the reactor and range switch, to the output bridge and polarity switch. Depending upon the setting of the polarity switch, either AC volt- age[...]

  • Page 40

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES E-6 E-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 41

    RANGER® 10,000 & RANGER® 10,000 PLUS Section F-1 Section F-1 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - T roubleshooting & Repair Section ........................................................................Section F How to Use T roubleshooting Guide ....................................................................[...]

  • Page 42

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-2 F-2 HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory [...]

  • Page 43

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of y[...]

  • Page 44

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for elec[...]

  • Page 45

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for elec[...]

  • Page 46

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for elec[...]

  • Page 47

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-7 F-7 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for elec[...]

  • Page 48

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for elec[...]

  • Page 49

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for elec[...]

  • Page 50

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 pr ocedures or ar e unable to perform the test/repairs safely , con- tact the Lincoln Electric Service Department for el[...]

  • Page 51

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-11 F-11 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- tact the Lincoln Electric Service Department for el[...]

  • Page 52

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR 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 cranks very slow . 1. Check for loose or faulty batt[...]

  • Page 53

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-13 F-13 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS The welding arc is “cold.” Engine runs normally (3700 RPM no load). Auxi[...]

  • Page 54

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-14 F-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 55

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-15 F-15 ROT OR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . F[...]

  • Page 56

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-16 F-16 ROTOR VOL T AGE TEST (c o n t i n u ed ) FIGURE F .1 - LOCA TION OF LEAD 200A AND 219 FOR ROTOR VOL T AGE TEST Slip Rings Brushes Lead 219 + - Lead 200A TEST PROCEDURE 1. With the 5/16” nut driver , remove the 6 sheet metal screws fr om the case top. 2. Remove the [...]

  • Page 57

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-17 F-17 ROT OR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty .[...]

  • Page 58

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-18 F-18 ROT OR RESIST ANCE TEST (c o n t i n u ed ) FIGURE F .2 – LOCA TION OF ROTOR SLIP RINGS Lead 219 Lead 200A + - TEST PROCEDURE 1. With the 5/16” nut driver , remove the 6 sheet metal screws fr om the case top. 2. Remove the rubber gasket (cover seal) from the lift[...]

  • Page 59

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-19 F-19 13. Measure the resistance to gr ound. A. Set the ohmmeter on the high scale (X100,000). B. Place one probe on either of the slip rings. Place the other probe on any good, unpainted ground. The machine ground stud works well. C. Check the resistance. It should read v[...]

  • Page 60

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-20 F-20 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 61

    AUXILIAR Y AND FIELD WINDING TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 safe[...]

  • Page 62

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-22 F-22 AUXILIAR Y AND FIELD WINDING TEST (c o n t i n u ed ) FIGURE F .3 – LOCA TION OF LEADS #3 AND #5 Lead #3 Lead #5 1 15V Receptacle Machine C ase F ront TEST PROCEDURE T o test the 1 15 V AC winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16?[...]

  • Page 63

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-23 F-23 AUXILIAR Y AND FIELD WINDING TEST (c o n t i n u ed ) T o test the field winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver , remove the case top and left side; then reinstall the fuel cap. 2. Connect the volt/ohmmeter probes to [...]

  • Page 64

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-24 F-24 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 65

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-25 F-25 W ARNING OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your fact[...]

  • Page 66

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-26 F-26 OUTPUT RECTIFIER BRIDGE TEST (c o n t i n u ed ) FIGURE F .4 – LOCA TION OF OUTPUT RECTIFIER LEADS (-) (+) (+) (+) ( -) (-) OUTPUT RECTIFIER ENGINE TEST PROCEDURE 1. Remove the spark plug wires to prevent accidental engine kickback or starting. 2. With the 5/16” [...]

  • Page 67

    CHARGING CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

  • Page 68

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-28 F-28 CHARGING CIRCUIT TEST (c o n t i n u ed ) FIGURE F .5 – LOCA TION OF VOL T AGE REGULA TOR V oltage 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. Set the voltmeter for AC volts [...]

  • Page 69

    ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

  • Page 70

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-30 F-30 ENGINE THROTTLE ADJUSTMENT TEST (c o n t i n u ed ) FIGURE F .6 – BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD Blower Paddle TEST PROCEDURE This test can be conducted by any one of four methods. Strobe-tach Method: 1. With the 5/16” nut driver , r emove the 6 sh[...]

  • Page 71

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-31 F-31 ENGINE THROTTLE ADJUSTMENT TEST (continued) Throttle linkage Choke Cable 3/8" High Idle Adjustment Nut Solenoid Housing 3/8" Low Idle Adjustment Nut Rod Muffler 11. If either of the readings is incorr ect, adjust the throttle as follows: Adjust HIGH IDLE: U[...]

  • Page 72

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-32 F-32 ENGINE THROTTLE ADJUSTMENT TEST (c o n t i n u ed ) Oscilloscope Method: 1. Connect the oscilloscope to the 115 V AC receptacle, accor ding to the manufactur- er’ s instructions. At 3700 RPM, the wave- form should exhibit a period of 16.2 mil- liseconds. At 2200 RP[...]

  • Page 73

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-33 F-33 CH1 16.2 ms 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Coupling ............................DC T rigger .........................Internal This is the typical AC output voltage generated from a pr ope[...]

  • Page 74

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-34 F-34 SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep.....5 ms/Div . Coupling ............................DC T rigger .........................Internal CH1 0 volts 5 ms 20 volts This is the typical CV output voltage generated from a pr operly oper[...]

  • Page 75

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-35 F-35 This is the typical DC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents 20 volts and that each horizontal division repr esents 5 milliseconds in time. The machine was loaded with a resistance grid bank. Note: S[...]

  • Page 76

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-36 F-36 This is the typical AC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents 20 volts and that each horizontal division repr esents 5 milliseconds in time. The machine was loaded with a resistance grid bank. Note: S[...]

  • Page 77

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-37 F-37 This is NOT the typical CV output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was disconnected to simulate an open or nonfunctioning output diode. Each vertical division repr esents 20 volts and each hor[...]

  • Page 78

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-38 F-38 This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was disconnected to simulate an open or nonfunctioning output diode. Each vertical division repr esents 50 volts and each[...]

  • Page 79

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-39 F-39 This is the typical CV output voltage generated from a pr operly operating machine. Note that each vertical division repr esents 20 volts and that each horizontal division repr esents 5 milliseconds in time. Note: Scope probes connected at machine output terminals. S[...]

  • Page 80

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-40 F-40 This is the typical DC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents 50 volts and that each horizontal division repr esents 5 milliseconds in time. Note: Scope probes connected at machine output terminals. S[...]

  • Page 81

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-41 F-41 This is the typical AC output voltage generated from a pr operly operating machine. Note that each vertical division repr esents 50 volts and that each horizontal division repr esents 5 milliseconds in time. Note: Scope probes connected at machine output terminals. S[...]

  • Page 82

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-42 F-42 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 83

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-43 F-43 BRUSH REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained person- nel. Unauthorized r epairs performed on this equipment may result in danger to the tech- nician or machine operator and will invalidate you[...]

  • Page 84

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-44 F-44 BRUSH REMOV AL AND REPLACEMENT (c o n t i n u ed ) PROCEDURE 1. Remove the spark plug wires. 2. With the 5/16” nut driver , remove the 6 sheet metal screws fr om the case top. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. Remove the fuel cap. The [...]

  • Page 85

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-45 F-45 SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary . If brushes are to be r eplaced, clean slip rings with a fine emery paper . Do not attempt to polish slip rings[...]

  • Page 86

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-46 F-46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 87

    PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained per sonnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please ob[...]

  • Page 88

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-48 F-48 PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (c o n t i n u ed ) FIGURE F .10 - PRINTED CIRCUIT BOARD LOCA TION 1 2 Pin Plug 4 Pin Plug 4 Self Tapping Screws (at corners) 1/4" Q.C. Tabs PROCEDURE Before starting the following pr ocedure, r efer to the topic ?[...]

  • Page 89

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-49 F-49 Be sure to follow the r ecommended static- free methods for handling printed cir cuit boards. 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 tapping scr ews holding the printed cir[...]

  • Page 90

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-50 F-50 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 91

    OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please o[...]

  • Page 92

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-52 F-52 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (c o n t i n u ed ) FIGURE F .1 1 - OUTPUT RECTIFIER CONNECTIONS (-) (+) (+) (+) ( -) (-) ENGINE NO NUT TO POLARITY SWITCH #8 L1 TO CHOKE (4) 7/16" MOUNTING SCREWS W1 TO S2 TO S2 TO S1 254 (3) 1/2" MOUNTING S[...]

  • Page 93

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-53 F-53 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (c o n t i n u ed ) 12. With the 1/2” wrench remove the thr ee mounting nuts. Note the placement of the nylon insulators. 13. Remove the rectifier assembly by tilting it up and lifting it toward the side of the machi[...]

  • Page 94

    RANGER® 10,000 & RANGER® 10,000 PLUS NOTES F-54 F-54 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 95

    ENGINE/ROT OR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

  • Page 96

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-56 F-56 ENGINE/ROT OR REMOV AL AND REPLACEMENT (c o n t i n u ed ) FIGURE F .12 – COMPONENT LOCA TIONS, ENGINE/ROTOR REMOV AL 3 1 9 2 4 1 8 7 6 5 1. ST A TOR COWLING COVER 2. BLOWER F AN 3. IDLE LINKAGE 4. BRUSH HOLDER BRACKET 5. ENGINE LIFT BAILS 6. ST A TOR/ENGINE MOUNTI[...]

  • Page 97

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-57 F-57 ENGINE/ROT OR REMOV AL AND REPLACEMENT (c o n t i n u ed ) ENGINE AND ROT OR REMOV AL PROCEDURE 1. Refer to Figure F .12 for component loca- tions. 2. Remove the engine spark plug wires. 3. With the 5/16” nut driver , remove the 6 sheet metal screws fr om the case [...]

  • Page 98

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-58 F-58 ROTOR REMOV AL PROCEDURE 1. T o remove the r otor , double check that the engine spark plug wires are disconnect- ed. Y ou will be tur ning the rotor during this procedur e, and this could accidentally cause engine kickback. 2. With an impact wrench, remove the r oto[...]

  • Page 99

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-59 F-59 REASSEMBL Y PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace the r otor and blower assem- bly . 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft. 2. Insert the rotor thru-bolt,[...]

  • Page 100

    RANGER® 10,000 & RANGER® 10,000 PLUS TROUBLESHOOTING & REP AIR F-60 F-60 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that r equires you to remove any mechanical part which could af fect the machine’ s electrical characteristics. OR • If you repair or r eplace any electrical components. ENGINE[...]

  • Page 101

    RANGER® 10,000 & RANGER® 10,000 PLUS Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams................................................................................................Section G Wiring Diagram - Entire Machine - Code 1 1041 Only - (M20226) . . . . . . . . . . . . . . .G-2 Wiring Diagr[...]

  • Page 102

    ELECTRICAL DIAGRAMS G-2 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 1 1041 ONL Y -(M20226) STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 N.A. B J2 SOLENOID FUEL SHUTOFF OIL PR[...]

  • Page 103

    ELECTRICAL DIAGRAMS G-3 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 1 1095 ONL Y - (M20301) IDLER SOLENOID HO UR ME T ER 5E 5D 224 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 J2 20 9A M2 0301 215 + EL ECTRI CAL S YM BOLS PER E 1537 STAT OR REA CTOR S1 W ORK EL EC T RODE C HOKE D1 S2 ROT OR PCB1 SLIP RING NEA REST LA MIN[...]

  • Page 104

    ELECTRICAL DIAGRAMS G-4 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 1 1 150 T0 11393 - (M20431) CR1 ST ART ER SOLENOI D AC AC B+ REG ULA T OR FL Y WHEEL A LT ER NATOR B- 5E 5D 224 ENGINE CO MPO NE NTS 22 4A 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 J2 20 9A 20 9A 22 4C 210 GE NERA TO R LEA D E ND (N OTE C AVITY NUM BE[...]

  • Page 105

    ELECTRICAL DIAGRAMS G-5 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM - CODE 1 1398 - (M21269) IDLER SOLENOID HO UR ME T ER 5E 5D 224 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 J2 20 9A M2 12 69P RI NT 215 + EL ECTRI CAL S YM BOLS PER E 1537 REA CTOR S1 WORK C HOKE D1 B ROT OR PCB1 SLIP RING NEA REST LA MINA T ION W2 C1 S1 R1 R[...]

  • Page 106

    ELECTRICAL DIAGRAMS G-6 RANGER® 10,000 & RANGER® 10,000 PLUS WIRING DIAGRAM CODE 1 1394 AND 1 1395 (M21270) CR1 ST ART ER SOLENOI D AC AC B+ REG ULA T OR FL Y WHEEL A LT ER NATOR B- 5E 5D 224 ENGINE CO MPO NE NTS 22 4A 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 J2 20 9A 20 9A 22 4C 210 GE NERA TO R LEA D E ND (N OTE C AVITY NUM BE R [...]

  • Page 107

    ELECTRICAL DIAGRAMS G-7 SCHEMA TIC - ENTIRE MACHINE - CODES 11395 AND 1 1398 - (L13105) EN-168 L13105 RANGER 10,000 (HONDA), RANGER 10,000 PLUS (SUB ARU ROBIN) MACHINE SCHEMATIC NONE L12257 MAP DJS - UNLESS OTHERWISE SPECI FIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS [...]

  • Page 108

    ELECTRICAL DIAGRAMS G-8 SCHEMA TIC - ENTIRE MACHINE - CDE 11394 - (L13103) EN-168 L13103 RANGER 10,000 PLUS (KOHLER) MACHINE SCHEMATIC NONE L12249-1 MAP DJS - UNLESS OTHERWISE SPECI FIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE WITH PUBLISHED STANDARD[...]

  • Page 109

    ELECTRICAL DIAGRAMS G-9 SCHEMA TIC - ENTIRE MACHINE - CODE 11095 & 1 1253 ONL Y - (L12257) EN-168 L 12257 RANGER 10 , 00 0 HONDA MACHI NE SCHEMATI C NONE L12249 BAM BAM - UNLESS OTHERWISE SPEC IFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE WITH PU[...]

  • Page 110

    ELECTRICAL DIAGRAMS G-10 SCHEMA TIC - ENTIRE MACHINE - CODE 11 151 ONL Y - (L12249-1) EN-168 L 12249-1 RA NG ER 10, 000 KO HLE R MACHI NE SCHEMATI C NONE L11942 BAM BAM - UNLESS OTHERWISE SPEC IFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE WITH PUBLIS[...]

  • Page 111

    ELECTRICAL DIAGRAMS G-1 1 SCHEMA TIC - IDLER/FIELD CONTROL P .C. BOARD - CODE 1 1041 ONL Y - (L12049) G-1 1 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. RANGER® 10,000 & RANGER® 10,000 PLUS Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section TOC Re[...]

  • Page 112

    ELECTRICAL DIAGRAMS G-12 SCHEMA TIC - IDLER/FIELD CONTROL P .C. BOARD - CODES ABOVE 1 1050 ONL Y - (L12197-1) G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. RANGER® 10,000 & RANGER® 10,000 PLUS Return to Section TOC Retur n to Section TOC Return to Section TOC Retur n to Section[...]