Ranger 10,000 & Ranger 10,000 Plus | Lincoln Electric SVM168-B

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A-12	NOTES	A-12

RANGER® 10,000 & RANGER® 10,000 PLUS

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Lincoln Electric SVM168-B service manual Ranger 10,000 & Ranger 10,000 Plus

Contents

Ranger 10,000 /10,000 Plus Safety Powered equipmentFor Engine ARC Rays can burn Fumes and Gases Welding and Cutting Sparks can cause fire or Explosion Cylinder may explode If damagedIii Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation SectionSection A-1 Installation Height Width Depth Weight Horsepower Operating Speed RPM Machine Grounding Safety PrecautionsSpark Arrester Towing Vehicle Mounting PRE-OPERATION ServiceGasoline Can cause fire or explosion Angle of Operation Welding Output CablesTotal Combined Length of Electrode and Work Cables Lifting Stacking Connection of Lincoln Electric Wire FeedersInstructions Welder Operation Duplex Receptacles Auxiliary Power120/240 Volt Dual Voltage Receptacle Motor Starting These Devices Without Additional Resistive Type Loads Not USE These Devices With a Ranger 10,000 Simultaneous Welding and Power Standby Power Connections Figure A.1 Ranger 10,000 & Ranger 10,000 Plus Operation Section Section B-1Operation Engine Switch OperationWelder Controls Function and Operation Kohler Honda Robin / Subaru 20 H.P. Command Polarity SwitchRange Switch Control Dial Starting the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Stopping the Engine Wire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG Constant Current Welding Start Switch Wire FEED, LN-15 Summary of Welding Processes Accessories Section Section C-1 Accessories Optional Equipment Field Installed TIG Welding Recommended EquipmentStick Plasma Cutting Ranger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1 Maintenance Safety PrecautionsKohler Honda AIR Cleaner and Other Maintenance OIL Filter Change Overspeed is Hazardous Engine AdjustmentsBattery Slip Rings Air Filter Pre-CleanerOil Filter Element Figure D.1 Major Component Location Theory of Operation Section Section E-1Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler Solenoid Theory of Operation Rotor Field Feedback and Auxiliary Power Figure E.3 Rotor Field Feedback and Auxiliary Power Weld WINDING, REACTOR, Range Switch Figure E.4 Weld WINDING, REACTOR, and Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Troubleshooting & Repair Section Section F-1 Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Electric Shock Troubleshooting Guide Output Problems Output Problems Field Winding Voltage Test Adjustment Test Troubleshooting Guide Output Problems Engine Problems Make sure the leads are looped Charging Circuit Test Welding Problems Ranger 10,000 & Ranger 10,000 Plus Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Rotor Resistance Test Rotor Resistance Test Figure F.2 Location of Rotor Slip Rings Troubleshooting & Repair Ranger 10,000 & Ranger 10,000 Plus Auxiliary and Field Winding Test Auxiliary and Field Winding Test To test the 115 VAC windingTo test the 230 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test 26TROUBLESHOOTING & REPAIRF-26 Output Rectifier Bridge TestFigutpure F.4 Locationctifof Output Rectifier Leads Charging Circuit Test Charging Circuit Test Figure F.5 Location of Voltage Regulator Engine Throttle Adjustment Test Engine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Figure F.7 Oscilloscope Method Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh Idle no Load Output Control AT Maximum Typical DC Weld Output Waveform CV Mode Machine LoadedMachine Loaded to 200 Amps AT 20 VDC Typical DC Weld Output Waveform CC Mode Machine Loaded to 200 Amps AT 26 VDC Typical AC Weld Output Waveform Machine Loaded to 225 Amps AT 25 VDC Abnormal Open Circuit Weld Voltage Waveform CV Mode Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit Weld Voltage Waveform CV Mode Normal Open Circuit DC Weld Voltage Waveform CC Mode Normal Open Circuit AC Weld Voltage Waveform Ranger 10,000 & Ranger 10,000 Plus Brush Removal and Replacement Description Brush Removal and Replacement Procedure Slip Rings Figure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Ranger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Printed Circuit Board Removal and Replacement Figure F.10 Printed Circuit Board Location Replacement Printed Circuit Board Removal Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Remove the case top, then reinstall the fuel cap Output Rectifier Bridge Removal Section TOC Ranger 10,000 & Ranger 10,000 Plus ENGINE/ROTOR Removal and Replacement Instructions ENGINE/ROTOR Removal Figure F.12 Component LOCATIONS, ENGINE/ROTOR Removal Engine and Rotor Removal Procedure Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Replacement KIT S20788 Reassembly Procedure Retest After Repair Electrical Diagrams Section Electrical DiagramsSection G-1 Electrical Diagrams Wiring Diagram Code 11041 only -M20226 Wiring Diagram Code 11095 only M20301 Ranger 10,000 Honda Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus Schematic Entire Machine Codes 11395 and 11398 L13105 L13105 Schematic Entire Machine CDE 11394 L13103 L13103 Schematic Entire Machine Code 11095 & 11253 only L12257 Schematic Entire Machine Code 11151 only L12249-1 L12249 Electrical Diagrams Electrical Diagrams