Ranger 10,000 /10,000 Plus
Safety
Powered equipment
For Engine
Fumes and Gases
ARC Rays can burn
Welding and Cutting Sparks can cause fire or Explosion
Cylinder may explode If damaged
Iii
Précautions DE Sûreté
Master Table of Contents for ALL Sections
Table of Contents
Installation Section
Section A-1
Height Width Depth Weight
Installation
Horsepower Operating Speed RPM
Towing
Safety Precautions
Spark Arrester
Machine Grounding
Can cause fire or explosion
PRE-OPERATION Service
Gasoline
Vehicle Mounting
Lifting
Welding Output Cables
Total Combined Length of Electrode and Work Cables
Angle of Operation
Welder Operation
Connection of Lincoln Electric Wire Feeders
Instructions
Stacking
Motor Starting
Auxiliary Power
120/240 Volt Dual Voltage Receptacle
Duplex Receptacles
Not USE These Devices With a Ranger 10,000
These Devices Without Additional Resistive Type Loads
Standby Power Connections
Simultaneous Welding and Power
Figure A.1
Ranger 10,000 & Ranger 10,000 Plus
Operation Section
Section B-1
Operation
Engine Switch
Operation
Welder Controls Function and Operation
Control Dial
Polarity Switch
Range Switch
Kohler Honda Robin / Subaru 20 H.P. Command
Stopping the Engine
STARTING/SHUTDOWN Instructions
BREAK-IN Period
Starting the Engine
Wire Feed Welding Processes Constant Voltage
Stick Constant Current Welding
TIG Constant Current Welding
Summary of Welding Processes
Start Switch Wire FEED, LN-15
Section C-1
Accessories Section
Optional Equipment Field Installed
Accessories
Plasma Cutting
Recommended Equipment
Stick
TIG Welding
Ranger 10,000 & Ranger 10,000 Plus
Section D-1
Maintenance Section
Maintenance
Safety Precautions
Kohler Honda
OIL Filter Change
AIR Cleaner and Other Maintenance
Slip Rings
Engine Adjustments
Battery
Overspeed is Hazardous
Element
Pre-Cleaner
Oil Filter
Air Filter
Figure D.1 Major Component Location
Theory of Operation Section
Section E-1
Theory of Operation
Theory of Operation
BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler Solenoid
Figure E.3 Rotor Field Feedback and Auxiliary Power
Rotor Field Feedback and Auxiliary Power
Figure E.4 Weld WINDING, REACTOR, and Range Switch
Weld WINDING, REACTOR, Range Switch
Output BRIDGE, Choke Polarity SWITCH, and Output Terminals
Ranger 10,000 & Ranger 10,000 Plus
Section F-1
Troubleshooting & Repair Section
HOW to USE Troubleshooting Guide
Troubleshooting & Repair
Electric Shock
PC Board Troubleshooting Procedures
Output Problems
Troubleshooting Guide
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 Description
Materials Needed
Test Procedure
Rotor Resistance Test
Figure F.2 Location of Rotor Slip Rings
Rotor Resistance Test
Troubleshooting & Repair
Ranger 10,000 & Ranger 10,000 Plus
Auxiliary and Field Winding Test
Auxiliary and Field Winding Test
To test the 115 VAC winding
To 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 Test
Figutpure F.4 Locationctifof Output Rectifier Leads
Charging Circuit Test
Figure F.5 Location of Voltage Regulator
Charging Circuit Test
Engine Throttle Adjustment Test
Figure F.6 Blower Paddle Marked for STROBE-TACH Method
Engine Throttle Adjustment Test
Figure F.7
Oscilloscope Method
Scope Settings
Normal Open Circuit Voltage Waveform 115 VAC Supply
High Idle no Load Output Control AT Maximum
Typical DC Weld Output Waveform CV Mode
Machine Loaded
Machine Loaded to 200 Amps AT 20 VDC
Machine Loaded to 200 Amps AT 26 VDC
Typical DC Weld Output Waveform CC Mode
Machine Loaded to 225 Amps AT 25 VDC
Typical AC Weld Output Waveform
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
Description
Brush Removal and Replacement
Procedure
Brush Removal and Replacement
Figure F.9 Brush LEADS/BRUSHES Retained with Cable TIE
Slip Rings
Ranger 10,000 & Ranger 10,000 Plus
Printed Circuit Board Removal Replacement
Figure F.10 Printed Circuit Board Location
Printed Circuit Board Removal and Replacement
Printed Circuit Board Removal
Replacement
Ranger 10,000 & Ranger 10,000 Plus
Output Rectifier Bridge Removal Replacement
Output Rectifier Bridge Removal
Remove the case top, then reinstall the fuel cap
Section TOC
Ranger 10,000 & Ranger 10,000 Plus
Instructions
ENGINE/ROTOR Removal and Replacement
Figure F.12 Component LOCATIONS, ENGINE/ROTOR Removal
ENGINE/ROTOR Removal
Engine and Rotor Removal Procedure
Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT
Rotor Removal Procedure
Reassembly Procedure
Replacement KIT S20788
Retest After Repair
Electrical Diagrams Section
Electrical Diagrams
Section G-1
Wiring Diagram Code 11041 only -M20226
Electrical Diagrams
Ranger 10,000 Honda
Wiring Diagram Code 11095 only M20301
Ranger 10,000
Wiring Diagram Code 11398 M21269
Ranger 10,000 Plus
L13105
Schematic Entire Machine Codes 11395 and 11398 L13105
L13103
Schematic Entire Machine CDE 11394 L13103
Schematic Entire Machine Code 11095 & 11253 only L12257
L12249
Schematic Entire Machine Code 11151 only L12249-1
Electrical Diagrams
Electrical Diagrams