View Safety Info SVM120-A TM RANGER 10-LX March 1999 For use with machine code numbers 9815 and 9816 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN INDEX 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.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii SAFETY 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Installation Section Table of Contents ........................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Location and Ventilation ........................................................................................................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 10-LX INPUT - DIESEL ENGINE Manufacturer Description KUBOTA DH850B-88 3 cyl., liquid-cooled diesel 23 HP @ 3600 RPM Speed Displacement Ignition Capacities 3600 RPM Full load 52.17 cu. in. (855 cc) Electric Fuel: 10 gal. (38 l) Oil: 3.9 qt. (3.7 l) 3750 RPM High idle Cooling system: 5.4 qts. (5.
Return to Master TOC INSTALLATION 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; and parts lists. Return to Master TOC Return to Section TOC Return to Section TOC A-3 ELECTRIC SHOCK can kill.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-4 INSTALLATION STACKING OIL RANGER 10-LX machines CANNOT be stacked. The RANGER 10-LX is shipped with the engine filled with SAE 10W-30 oil (API class CC/DO). CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an added precaution. When full, the oil level should be up to but not over the FULL mark on the dipstick. If it is not full, add enough oil to fill it to the full mark.
Return to Master TOC Return to Section TOC A-5 A-5 INSTALLATION FIGURE A.1 - RANGER 10-LX OUTPUT CONNECTIONS 2 1. 2. 3. 4. 5. 1 115/230 VOLT, 50 AMP RECEPTACLE 115 VOLT, 20 AMP RECEPTACLES (2) WELD OUTPUT TERMINALS (2) GROUND STUD (LOCATION) CIRCUIT BREAKERS (CSA machines only) Return to Master TOC Return to Section TOC 5 Return to Master TOC Return to Section TOC 4 3 Standard mufflers and deflectors (like the ones included with the RANGER 10-LX) do not act as spark arresters.
Return to Master TOC Return to Section TOC A-6 INSTALLATION WELDING CABLE CONNECTIONS CABLE SIZE AND LENGTH Be sure to use welding cables that are large enough. The correct size and length becomes especially important when you are welding at a distance from the welder. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle.
Return to Master TOC Return to Section TOC A-7 A-7 INSTALLATION When the RANGER 10-LX is mounted on a truck or a trailer, the machine generator ground stud MUST be securely connected 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 connected to the system earth ground. See the Premises Wiring section of this manual for details.
Return to Master TOC Return to Section TOC A-8 A-8 INSTALLATION FIGURE A.2 - CONNECTION OF RANGER 10-LX TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 115 VOLT 115 VOLT NEUTRAL BUS Return to Master TOC Return to Section TOC LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION WARNING OPERATING INSTRUCTIONS Read and understand this entire section before operating your RANGER 10-LX. ARC RAYS can burn. SAFETY INSTRUCTIONS • Wear eye, ear, and body protection. WARNING Return to Master TOC Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine.
Return to Master TOC Return to Section TOC B-3 OPERATION RECOMMENDED APPLICATIONS WELDER GENERATOR Return to Master TOC Return to Section TOC The RANGER 10-LX gives AC generator output for medium use demands. For more details on operating the generator, see Auxiliary Power in the Operation section of this manual.
Return to Master TOC Return to Section TOC B-4 OPERATION B-4 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 controls are also on the case front. See Figure B.1 and the explanations that follow. FIGURE B.1 – OUTPUT PANEL CONTROLS 2 1 14 3 4 Return to Master TOC 7 Return to Section TOC 1. 2. 3. 4. 5. 5 6 6 7. 8. 9. 10. 11. 12. 13. 14.
Return to Master TOC Return to Section TOC B-5 OPERATION 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 RECEPTACLE: 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. Return to Master TOC Return to Section TOC 10.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-6 OPERATION FIGURE B.2 – ENGINE CONTROLS Return to Master TOC 4 8 2 9 1 3 1. 2. 3. 4. 5. 6. 7. 8. 9. ENGINE GLOW PLUG PUSHBUTTON IDLER CONTROL SWITCH START PUSHBUTTON ENGINE HOUR METER BATTERY CHARGER LIGHT OIL PRESSURE LIGHT WATER TEMPERATURE LIGHT FUEL LEVEL GAUGE ENGINE ON-OFF SWITCH 7 6 5 DIESEL ENGINE CONTROLS See Figure B.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-7 B-7 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. 7.
Return to Master TOC Return to Section TOC B-8 OPERATION 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). See Figure B.3. 2. Check for proper level of coolant in the plastic reserve overflow tank. The level should be between the full and the low marks. 3.
Return to Master TOC OPERATION TABLE B.1 TYPICAL RANGER 10-LX FUEL CONSUMPTION KUBOTA DH850-B-88 Low Idle – No Load, 2150 RPM .30 Gallons/hour (1.0 liters/hour) High Idle – No Load, 3750 RPM .60 Gallons/hour (2.2 liters/hour) AC CC Weld Output, 250 Amps @ 25 Volts 1.1 Gallons/hour (4.2 liters/hour) DC CC Weld Output, 250 Amps @ 25 Volts 1.2 Gallons/hour (4.6 liters/hour) DC CV Weld Output, 250 Amps @ 30 Volts .90 Gallons/hour (3.6 liters/hour) Auxiliary Power, 10,000 kVA 1.3 Gallons/hour (4.
Return to Master TOC Return to Section TOC B-10 OPERATION WELDING OPERATION To use the RANGER 10-LX for AC/DC Constant Current Stick Welding: GENERAL INFORMATION WARNING • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Do not breathe welding fumes or gases. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC • Use ventilation or exhaust to remove welding fumes from the breathing area.
Return to Master TOC Return to Section TOC B-11 B-11 OPERATION 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 provided with the kit. Also be sure to follow the special machine grounding instructions given in the manual. After you finish welding: 1. Stop the diesel engine. See Engine Operation in this section of the manual. 2. Allow the electrode and work to cool completely. 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-12 OPERATION 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 instructions in the Accessories section of this manual. 2. Some recommended Innershield electrodes are: NR-211MP, NR-311, NR-203 series, as well as Lincore® 33 and 55 hardfacing electrodes. Diameters from .035 (0.
Return to Master TOC Return to Section TOC B-13 B-13 OPERATION SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS Table B.3 summarizes the requirements for various welding processes you can perform with the RANGER 10-LX. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TABLE B.
Return to Master TOC Return to Section TOC B-14 OPERATION AUXILIARY POWER B-14 Powering Motors WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation. You can start most 1.5 HP, single-phase electric motors if there is no load on the motor or other load connected to the RANGER 10-LX. After starting, the motor may be run at full load.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-15 B-15 OPERATION TABLE B.4 - SIMULTANEOUS WELDING AND AUXILIARY POWER Output Selector Setting Welding Output Permissible Power in Watts (Unity Power Factor) 250 200 250 200 None 3000 — 26 — 13 160 120 160 120 3500 5500 30 48 15 24 90 65 45 90 65 45 6500 7500 8500 56 65 74 28 32.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-16 B-16 OPERATION TABLE B.
Return to Master TOC Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-2 TIG Welding..........................................................................................................................
Return to Master TOC Return to Section TOC C-2 ACCESSORIES 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 towing 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.
Return to Master TOC Return to Section TOC C-3 ACCESSORIES TIG WELDING SEMIAUTOMATIC FCAW AND MIG WELDING TIG Module (K930-1) - The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications. It provides contactor control of constant current welding power sources having an internal contactor. LN-25 Wire Feeder – This portable unit provides CC/CV for flux-cored arc welding (FCAW) and metal inert gas welding (MIG).
Return to Master TOC Return to Section TOC C-4 C-4 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING NOTE: Welding cable must be sized for current and duty cycle of application. ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGATIVE (-) BATTERY LEAD before servicing. • Do not touch electrically live parts. 3. Connect the K867 Universal Adapter to the 14 pin amphenol of the RANGER 10-LX as shown in Figure C.1.
Return to Master TOC Return to Section TOC C-5 C-5 ACCESSORIES 7. Place the WIRE FEEDER switch in the “WITH CONTROL CABLE” position. 8. Adjust wire feed speed at the wire feeder and set the welding voltage with the output “CONTROL” to a CV (constant voltage) position at the welder. NOTE: If optional remote control is used, place the output control switch in the “CONTROL REMOTE” position. CONNECTION OF THE LN-25 TO THE RANGER 10-LX “ACROSS THE ARC” (SEE FIGURE C.2.) 6.
Return to Master TOC Return to Section TOC C-6 ACCESSORIES CONNECTION OF THE LN-7 TO THE RANGER 10-LX USING K584 INPUT CABLE ASSEMBLY (SEE FIGURE C.3.) NOTE: If your LN-7 comes equipped with a K291 or K404 Input cable, refer to Connection of the LN-7 Using K867 Universal Adapter, rather than this discussion, to connect your RANGER 10-LX for wire feed welding. 1. Shut the welder off. 2.
Return to Master TOC Return to Section TOC C-7 C-7 ACCESSORIES CONNECTION OF THE LN-7 TO THE RANGER 10-LX USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-7 to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder. CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage.
Return to Master TOC Return to Section TOC C-8 ACCESSORIES CONNECTION OF THE LN-8 TO THE RANGER 10-LX (SEE FIGURE C.5.) CAUTION 1. Shut the welder off. 2. Connect the electrode cable from the LN-8 to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder. Return to Master TOC NOTE: Welding cable must be sized for current and duty cycle of application. Return to Section TOC C-8 3.
Return to Master TOC Return to Section TOC C-9 ACCESSORIES CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE RANGER 10-LX (SEE FIGURE C6.) 5. Set the welder “polarity” switch to the desired polarity, either DC (-) or DC (+). 1. Shut the welder off. 7. Place the “IDLER” switch in the “HIGH” position. 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.
Return to Master TOC Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Routine and Periodic Maintenance ............................................................................................D-2 Engine Maintenance....
Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. Return to Master TOC Return to Section TOC • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. • If covers or guards are missing from the machine, get replacements from a Lincoln Distributor.
D-3 MAINTENANCE Return to Master TOC Return to Section TOC D-3 FIGURE D.1 – OIL DRAIN AND REFILL LOCATION 4 1 Return to Master TOC Return to Section TOC 3 2 1. DIPSTICK 2. OIL DRAIN PLUG 3. OIL FILTER 4. OIL FILL CAP Return to Master TOC Return to Section TOC 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.
D-4 MAINTENANCE Return to Master TOC Return to Section TOC D-4 FIGURE D.2 – FUEL FILTER 5 1. 2. 3. 4. 5. COCK - CLOSED COCK - OPEN POSITION RING SCREW FILTER POT (ELEMENT INSIDE) VENT PLUGS 1 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 2 3 4 4. Carefully place the element back into the fuel pot. Be careful not to allow any dirt to stick to the element. CAUTION 5. Reassemble the filter pot and tighten the ring screw at the top.
Return to Master TOC Return to Section TOC D-5 D-5 MAINTENANCE FIGURE D.3 – FUEL SYSTEM BLEEDING 1. AIR VENT COCK 2. FUEL FEED PUMP LEVER Return to Master TOC Return to Section TOC 1 2 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: Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 1. Remove the dust cup from the bottom of the air cleaner housing.
Return to Master TOC FIGURE D.4 – COOLING SYSTEM RADIATOR CAP RESERVE TANK Return to Master TOC Return to Master TOC D-6 MAINTENANCE RADIATOR DRAIN COCK CHECKING/ADDING/DRAINING RADIATOR COOLANT: 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” mark.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC D-7 MAINTENANCE TABLE D.1 KUBOTA ENGINE MAINTENANCE SCHEDULE FREQUENCY Daily or Before Starting Engine MAINTENANCE REQUIRED • • • • 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 • Check fuel lines and clamps.
Return to Master TOC Return to Section TOC D-8 MAINTENANCE BATTERY MAINTENANCE CHECKING ELECTROLYTE LEVEL If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks. WARNING GASES FROM BATTERY can explode. • Keep sparks, flame, and cigarettes away from battery.
Return to Master TOC Return to Section TOC D-9 MAINTENANCE 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. RECEPTACLES: Keep the electrical receptacles in good condition. Remove any dirt, oil, or other debris from their surfaces and holes.
Return to Master TOC Return to Section TOC D-10 D-10 MAINTENANCE FIGURE D.6 - MAJOR COMPONENT LOCATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. OUTPUT TERMINALS (LOCATION) ENGINE CONTROLS (on Control Panel) AUXILIARY POWER RECEPTACLES OUTPUT CONTROL PANEL REACTOR ASSEMBLY FUEL TANK DIESEL ENGINE ROTOR/STATOR ASSEMBLY BATTERY (not shown) BASE WELDED ASSEMBLY P.C.
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory 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-2 THEORY OF OPERATION Return to Master TOC FIGURE E.
E-3 THEORY OF OPERATION Return to Master TOC FIGURE E.
E-4 THEORY OF OPERATION Return to Master TOC FIGURE E.
E-5 THEORY OF OPERATION FIGURE E.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshooting Guide ......................................................................................F-2 PC Board Troubleshooting Procedures ................................................................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) F-4 POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. 1. Contact your local Lincoln Authorized Field Service Facility. 1. Contact The Lincoln Electric Service Dept.
Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-5 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No weld output, the auxiliary power (230-115VAC) is operating normally. Engine operates normally. 1. If the Polarity mode switch (S1) is in a constant voltage (CV) position, make sure the CV output contactor is activating. 2.
Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No auxiliary power at receptacles – welding output is normal – engine runs normally. 1.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has low welding output and low auxiliary output. 1. If a remote control unit is NOT connected to the machine, make sure the REMOTE switch is in the proper position – “MACHINE CONTROL.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS No DC welding output. AC welding output and auxiliary power are normal. 1. Make sure the Polarity mode switch (S1) is in the proper position and is “seated” correctly. Return to Master TOC Return to Section TOC 2.
Return to Master TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-9 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No constant voltage (CV) welding output. Constant current (CC) and the auxiliary power are operating normally. Return to Master TOC Return to Section TOC Return to Section TOC F-9 1.
Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC POSSIBLE AREAS OF MISADJUSTMENT(S) ENGINE PROBLEMS Engine will not idle down to low speed. Machine has normal weld output and auxiliary power. Return to Section TOC F-10 1.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS 1. Make sure the welding cables and connections are tight. Return to Master TOC Engine will not go to high idle when attempting to weld. Welding output is normal when Idler switch is in “HIGH” position.
Return to Master TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS The engine will not go to high idle when attempting to weld or when the auxiliary power is loaded. Welding output and auxiliary power output are normal when idler switch is in the “HIGH” position.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC POSSIBLE AREAS OF MISADJUSTMENT(S) ENGINE PROBLEMS The engine cranks but will not start. Return to Section TOC F-13 1. The engine may be low on or out of fuel. 1.
Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure there is NOT an external load (auxiliary or weld) connected to the RANGER 10LX. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-15 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Output control on welder not functioning. 1.
Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The wire feeder does not work when connected to the welder amphenol. Return to Section TOC F-16 1. Check circuit breaker CB2.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The CV output contactor does not pull in when using a wire feeder with a control cable connected to the RANGER 10-LX amphenol. Return to Section TOC F-17 1.
Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure the wire feeder is connected correctly to the RANGER 10-LX. Return to Master TOC Return to Master TOC 1. Check the Wire Feeder switch (S8) and associated leads. See Wiring Diagram. 3. Check the Idler switch (S5) and associated leads. See Wiring Diagram. 4. The control board may be faulty.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The CV output contactor does not deactivate (drop out) when a wire feeder without a control cable is connected to the RANGER 10-LX. 1. Make sure the wire feeder is connected properly to the RANGER 10-LX. 2.
Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS The welding arc is “cold.” The engine runs normally (3700 RPM no load). The auxiliary power is functioning normally. 1. Check for loose or faulty connections at the weld output terminals and welding cable connections.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-22 F-22 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Return to Master TOC Return to Section TOC TEST PROCEDURE 1. With the 5/16” and 3/8” nut driver, remove the sheet metal screws from the right hand case side. 2. Carefully remove the right case side. 3. Set the volt/ohmmeter to the DC volts position. 4.
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-24 TROUBLESHOOTING & REPAIR F-24 ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LEADS 200A AND 219 REMOVED Return to Master TOC Return to Section TOC 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. Conduct the test with the engine OFF. 4.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING & REPAIR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-26 TROUBLESHOOTING & REPAIR F-26 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 Return to Master TOC Return to Section TOC TEST PROCEDURE To test the 115 VAC winding: To test the 230 VAC winding: 1. With the 5/16” and 3/8” nut drivers, remove the sheet metal screws from the left case side. 1.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-27 TROUBLESHOOTING & REPAIR F-27 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER Field Bridge Rectifier (see inset) Return to Master TOC Return to Section TOC Capacitor 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. 2. Carefully remove the right case side. 3.
Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR F-28 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4A – 14 PIN AMPHENOL PIN ASSIGNMENTS C Return to Section TOC F-28 Z D B Y L M AJ K E W N I F G H X 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. Carefully remove the right case side. Return to Master TOC Return to Section TOC 3.
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING & REPAIR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-30 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS Left side (–) Right 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. 7. With an ohmmeter or diode tester, check each of the four diodes from their pigtails to their respective heat sinks. 2.
Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-32 TROUBLESHOOTING & REPAIR CHARGING CIRCUIT TEST (continued) FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR 5J 234 236 224A 222D Return to Master TOC 233 Return to Section TOC F-32 TEST PROCEDURE Return to Master TOC Return to Section TOC 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. Locate the engine alternator and regulator. See Figure F.6. 4.
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING & REPAIR PROTECTION RELAY (CR1) 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-34 TROUBLESHOOTING & REPAIR F-34 PROTECTION RELAY (CR1) TEST (continued) FIGURE F.7 – CR1 LEAD CONNECTIONS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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. Conduct this test with the engine OFF. 4.
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-36 F-36 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 – MARK LOCATION, STROBE/TACH METHOD Return to Master TOC Return to Section TOC Flywheel Chalk mark TEST PROCEDURE Return to Master TOC Return to Section TOC 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. 2. Carefully remove the right case side. 3.
Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING & REPAIR F-37 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.9 – HIGH IDLE ADJUSTMENT NUT Lock Nut Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Adjustment Screw Lock Nut Adjustment Screw 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.
Return to Master TOC Return to Section TOC F-38 TROUBLESHOOTING & REPAIR F-38 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.10 – LOW IDLE ADJUSTMENT NUT Return to Master TOC Return to Section TOC 7/16” Lock Nut 1/2” Adjustment Nut Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Oscilloscope Method: 1. Connect the oscilloscope to the 115 VAC receptacle, according to the manufacturer’s instructions.
Return to Master TOC Return to Section TOC F-39 F-39 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 15.8 ms Return to Master TOC Return to Section TOC CH1 0 volts Return to Master TOC Return to Section TOC 50 volts This is the typical auxiliary output voltage generated from a properly operating machine.
Return to Master TOC Return to Section TOC F-40 F-40 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP) MACHINE LOADED Return to Master TOC Return to Section TOC CH1 0 volts 5 ms 20 volts Return to Master TOC Return to Section TOC MACHINE LOADED TO 250 AMPS AT 30VDC This is the typical CV output voltage generated from a properly operating machine.
Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED Return to Master TOC Return to Section TOC CH1 0 volts 5 ms 20 volts Return to Master TOC Return to Section TOC MACHINE LOADED TO 250 AMPS AT 25 VDC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-42 TROUBLESHOOTING & REPAIR TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CH1 0 volts 5 ms 20 volts Return to Master TOC Return to Section TOC MACHINE LOADED TO 250 AMPS AT 25VDC 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.
Return to Master TOC Return to Section TOC F-43 F-43 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING Return to Master TOC Return to Section TOC CH1 0 volts Return to Master TOC Return to Section TOC 50 volts This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-44 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM OUTPUT CAPACITOR BANK NOT FUNCTIONING CH1 0 volts Return to Master TOC Return to Section TOC 50 volts SCOPE SETTINGS Return to Master TOC 5 ms This is NOT the typical CV output voltage waveform. The capacitor bank is not functioning. Note the “ripple” in the waveform.
Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts 5 ms Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-46 F-46 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts 5 ms Return to Master TOC Return to Section TOC 50V 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.
Return to Master TOC Return to Section TOC F-47 F-47 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-48 TROUBLESHOOTING & REPAIR BRUSH 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.
Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 3. Carefully remove the right case side. 4. Using the needle nose pliers, gently remove the red and white wires from the brush holder. Note lead placement. See Figure F.11. 5.
Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR 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. If brushes are to be replaced, clean slip rings with a fine emery paper. CAUTION Do not attempt to polish slip rings while engine is running. FIGURE F.11 - BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE 200A 1. BRUSHES 2. CABLE TIE 3. RETAINER CLIP Return to Master TOC 1.
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-52 F-52 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.12 RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR Capacitor Field Bridge Rectifier (see inset) Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Jumper PROCEDURE 1. Perform this procedure with the engine OFF. 2.
Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 3. Carefully remove the right case side. 4.
Return to Master TOC Return to Section TOC F-54 TROUBLESHOOTING & REPAIR CONTROL BOARD 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR F-55 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.13 - CONTROL BOARD LOCATION J1 #5C Return to Master TOC Return to Section TOC #222 #213 CONTROL BOARD COVER CONTROL J2 Return to Master TOC Return to Section TOC PROCEDURE Before starting the following procedure, refer to the topic “PC Board Troubleshooting Procedures” at the beginning of this section. 1. Perform this procedure with the engine OFF. 2.
Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 18. Connect the three individual leads #213, #222 and #5C. 19.
Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-58 TROUBLESHOOTING & REPAIR F-58 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.14 - OUTPUT RECTIFIER CONNECTIONS Left Side (–) Right 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.
Return to Master TOC Return to Section TOC 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: Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC When reassembling, use Dow Corning 340 on all aluminum electrical connection surfaces.
Return to Master TOC Return to Section TOC F-60 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR BANK 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-61 F-61 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR BANK EMOVAL AND REPLACEMENT (continued) FIGURE F.15 - OUTPUT CAPACITOR BANK/PRINTED CIRCUIT BOARD LOCATION 1. 2. 3. 4. PC BOARD COVER VERTICAL BAFFLE CAPACITOR (4) BUSS BAR (2) 1 4 2 3 Return to Master TOC Return to Section TOC PROCEDURE 1. Perform this procedure with the engine OFF. 2.
Return to Master TOC Return to Section TOC F-62 TROUBLESHOOTING & REPAIR OUTPUT CONTACTOR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-63 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – OUTPUT CONTACTOR LOCATION 1. 2. 3. 4. 5. Return to Master TOC Return to Section TOC 1 4 4 5 PROCEDURE 7. To reinstall the output contactor, use the slot head screw driver and 3/8” nut driver to attach the three mounting screws, nuts and associated washers that hold the contactor to the vertical baffle. 1.
TROUBLESHOOTING & REPAIRs Return to Master TOC Return to Section TOC F-64 OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-65 TROUBLESHOOTING & REPAIR STATOR AND/OR 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-66 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-66 STATOR AND/OR REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL 11 10 Return to Master TOC Return to Section TOC 9 7 Support engine when removing stator 5 13 12 4 Support rotor when removing Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC 3. If necessary, use the 1/2” wrench to remove the exhaust pipe from the muffler. 4.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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. Return to Master TOC Return to Section TOC 24. Clear all stator leads and cut any necessary cable ties. 25.
Return to Master TOC Return to Section TOC F-69 TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) REASSEMBLY NOTES Front Panel/PC Board 1. Be sure to remove the rotor bearing from the stator frame before reinstalling the rotor/stator Also remove the tolerance ring. n n n 2. Install the rotor to the flex plate and install the flex plate to the engine. Return to Master TOC Return to Section TOC 3. Carefully install the stator. eight bolts finger-tight only.
Return to Master TOC Return to Section TOC F-70 F-70 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components.
TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram Ranger 10 LX Code 9816 . . . . . . . . . . . . . . . . . . . . . . . G-2 Wiring Diagram Ranger 10 LX CSA Code 9821 . . . . . . . . . . . . . . . . . . . G-3 Control PC Board (G2318) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 Control PC Board (G2318) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES RANGER 10LX
Wiring Diagram Ranger 10LX Code 9816 3 TURNS 254A SENSOR 8617 31,000 MFD CAPACITOR 211 252 FLASHING 4 CURRENT } 200B 250 8 6 201A 1 9 7 ENGINE A PROTECTION CR1 RELAY 7 253 4 J1 2 243 6 3 B 5 214 S2 E S1 R4 21 R1 GND S8 R6 R2 WORK ELECTRODE R7 C4 75 5G 75A 5L S2 (SHOWN IN REMOTE SWITCH POSITION) IDLER REMOTE C2 5C POSITION) C1 3 224F CB2 SWITCH (SHOWN IN C3 31 32 42 3 5 9 6 5D 236 5D GND-E GREEN 5B 5E 223 244 GROUND GREEN 77C F 7
Wiring Diagram Ranger 10LX CSA Code 9821 3 TURNS 254A 6 1 Return to Master TOC CLOSED WITH S2, IN C4 B1 5G - 76D 75A 5L S7 S2 W1 (SHOWN IN REMOTE HIGH IDLE SWITCH POSITION) IDLER REMOTE C2 3 224F 31 32 42 3 5 5D 9 6 7 236 SCREW 5D GND-E GREEN 5B 5E 223 GROUND G 75C I 31B K 42 B GREEN 4A 2A REMOTE 75C L 8582 GROUND 1 6 7 4C GND-A 8 5 A 77B B 76B C CONTACTOR 3 2 AMPHENOL 1 CONTROL 5 4 77C 76C 4 D 76B 75B 6 2B 3 4B 4 1 75B 2B E 4B F
Return to Master TOC ELECTRICAL DIAGRAMS G-4 Control PC Board (G2318) Schematic Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-4 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.
X X IDENTIFICATION TP-D X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X TP-A X X X X X X X X 5 X X X X X X X X X X X X X X X X X X X X X X X X X X X TP-G X X X X X X X X X X X TP-H X X X X X X X 222 TP-F TP-B X X X X X X X X X X X X X X 213 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X TP-E X X X X X G2318 X X X X Return to Master TOC PART No. REQ'D.
Return to Master TOC DIAGRAMS G-6 RF BYPASS BOARD SCHEMATIC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-6 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.
N.A. N.B. 5.25 12.02 RANGER 10LX 24.75 24.03 18.00 18.50 17.50 3.94 31.57 Return to Master TOC Return to Master TOC 18.00 Return to Section TOC Return to Section TOC 13.85 N.A. 20.25 60.18 60.50 31.03 34.62 33.81 M16706 3-24-95E 11.00 13.00 Return to Master TOC Return to Section TOC COOLANT CAP CENTER OF GRAVITY N.B. 5.25 46.
Return to Master TOC We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave.