Main
SVM120-A
RANGER 10-LX
March 1999
SERVICE MANUAL
Safety Depends on You
i i
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dangerous.
iii iii
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
WELDING SPARKS can cause fire or explosion.
iv iv
PRCAUTIONS DE SRET
Mar. 93
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
- INSTALLATION SECTION -
TECHNICAL SPECIFICATIONS - RANGER 10-LX INPUT - DIESEL ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
OUTPUT - WELDER AND GENERATOR
SAFETY PRECAUTIONS
LOCATION AND VENTILATION
STORING
STACKING
TILTING
PRE-OPERATION ENGINE SERVICE
OIL
FUEL
ENGINE COOLANT HOT COOLANT can burn skin.
BATTERYCONNECTIONS
ELECTRICAL OUTPUT CONNECTIONS
WELDING CABLE CONNECTIONS
MACHINE GROUNDING
AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT
CIRCUIT BREAKERS
PREMISES WIRING
A-8 A-8
RANGER 10-LX
FIGURE A.2 - CONNECTION OF RANGER 10-LX TO PREMISES WIRING
- OPERATION SECTION -
OPERATING INSTRUCTIONS
SAFETY INSTRUCTIONS
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dan- gerous.
WELDING SPARKS can cause fire or explosion.
RECOMMENDED APPLICATIONS
WELDER
GENERATOR
DESIGN FEATURES AND ADVANTAGES
WELDING CAPABILITY
CONTROLS AND SETTINGS
Page
DIESEL ENGINE CONTROLS
ENGINE OPERATION
BEFORE STARTING THE ENGINE
STARTING THE ENGINE
STOPPING THE ENGINE
BREAK-IN PERIOD
Page
WELDING OPERATION
GENERAL INFORMATION
To use the RANGER 10-LX for AC/DC Constant Current Stick Welding:
To Use the RANGER10-LX for AC/DC TIG (Constant Current) Welding:
To Use the RANGER 10-LX for DCWire Feed Welding (Constant Voltage):
SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS
AUXILIARY POWER
GENERAL INFORMATION
Page
Page
- ACCESSORIES -
OPTIONS/ACCESSORIES
Page
CONNECTION OF THE RANGER 10-LX TO WIRE FEEDERS USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1)
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
CONNECTION OF THE LN-25 TO THE RANGER 10-LX ACROSS THE ARC (SEE FIGURE C.2.)
CONNECTION OF THE LN-7 TO THE RANGER 10-LX USING K584 INPUT CABLE ASSEMBLY(SEE FIGURE C.3.)
CONNECTION OF THE LN-7 TO THE RANGER 10-LX USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.4.)
CONNECTION OF THE LN-8 TO THE RANGER 10-LX (SEE FIGURE C.5.)
Page
-MAINTENANCE-
SAFETY PRECAUTIONS
ROUTINE AND PERIODIC MAINTENANCE
ENGINE MAINTENANCE
Page
Page
Page
Page
Page
BATTERY MAINTENANCE
WELDER/GENERATOR MAINTENANCE
Page
D-10 D-10
RANGER 10-LX
5/96
FIGURE D.6 - MAJOR COMPONENT LOCATIONS
-THEORY OF OPERATION SECTION-
FIGURE E.1 RANGER 10-LX BLOCK LOGIC DIAGRAM
BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION, ROTOR, STATOR AND IDLER SOLENOID
ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER
WELD WINDING, REACTOR, AND RANGE SWITCH
OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, CV CONTACTOR AND OUTPUT TERMINALS
TROUBLESHOOTING & REPAIR SECTION
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
WELDING PROBLEMS
ROTOR VOLTAGE TEST
ROTOR VOLTAGE TEST (continued)
ROTOR RESISTANCE TEST
ROTOR RESISTANCE TEST (continued)
AUXILIARY AND FIELD WINDING TEST
Page
Page
Page
OUTPUT RECTIFIER BRIDGE TEST
OUTPUT RECTIFIER BRIDGE TEST (continued)
CHARGING CIRCUIT TEST
CHARGING CIRCUIT TEST (continued)
PROTECTION RELAY (CR1) TEST
PROTECTION RELAY (CR1) TEST (continued)
ENGINE THROTTLE ADJUSTMENT TEST
Page
Page
Page
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)
MACHINE LOADED TO 250 AMPS AT 30VDC
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP)
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM
MACHINE LOADED TO 250 AMPS AT 25VDC
TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)
OUTPUT CAPACITOR BANK NOT FUNCTIONING
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
BRUSH REMOVAL AND REPLACEMENT
Page
BRUSH REMOVAL AND REPLACEMENT (continued)
Page
AND REPLACEMENT (continued)
PROCEDURE - RECTIFIER BRIDGE REMOVALAND REPLACEMENT
CONTROL BOARD REMOVAL AND REPLACEMENT
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
Page
Page
Page
OUTPUT CAPACITOR BANK REMOVAL
OUTPUT CAPACITOR BANK EMOVAL
OUTPUT CONTACTOR REMOVAL
OUTPUT CAPACITOR REMOVAL
TROUBLESHOOTING & REPAIRs
OUTPUT CAPACITOR REMOVAL
STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT
STATOR AND/OR REMOVAL AND REPLACEMENT (continued)
FIGURE F.18 COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL
STATOR AND/OR ROTOR REMOVAL
PROCEDURE (Stator Removal)
ROTOR REMOVALPROCEDURE
REASSEMBLYNOTES
LEAD RECONNECTION CHECKLIST Engine
Front Panel/PC Board
RETEST AFTER REPAIR
ENGINE OUTPUT
WELDER DC OUTPUT
WELDER AC OUTPUT
WELDER CV OUTPUT
Page
Page
ELECTRICAL DIAGRAMS
}
NOTE: COMPONENTS SHOWN
J8
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L
CLEVELAND, OHIO U.S.A.
THE LINCOLN ELECTRIC CO.
ENGINE WELDER (RANGER 10-LX)
}
}
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L
CLEVELAND, OHIO U.S.A.
THE LINCOLN ELECTRIC CO.
J4 J1, J5 J2
Control PC Board (G2318) Schematic
G-5
Control PC Board (G2318) Layout
G2318
2318
G
G-5
DIAGRAMS
RF BYPASS BOARD SCHEMATIC
DIAGRAMS
DIMENSION PRINT
M16706
3-24-95E
SVM ERROR REPORTING FORM