Lincoln Electric Welder SVM120 A User Manual
RETURN TO MAIN INDEX  
SVM120-A  
March 1999  
TM  
RANGER 10-LX  
For use with machine code numbers 9815 and 9816  
Safety Depends on You  
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. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
SERVICE MANUAL  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
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. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn 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’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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iv  
iv  
SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
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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........................................................................................A-1  
Technical Specifications .............................................................................................................A-2  
Safety Precautions......................................................................................................................A-3  
Location and Ventilation .............................................................................................................A-3  
Pre-operation Engine Service.....................................................................................................A-4  
Electrical Output Connections....................................................................................................A-5  
Operation...............................................................................................................................Section B  
Safety Instructions......................................................................................................................B-2  
General Description....................................................................................................................B-2  
Recommended Applications ......................................................................................................B-3  
Design Features and Advantages...............................................................................................B-3  
Welding Capability......................................................................................................................B-3  
Limitations .................................................................................................................................B-3  
Controls and Settings.................................................................................................................B-4  
Engine Operation........................................................................................................................B-7  
Welding Operation ....................................................................................................................B-10  
Summary of Welding Processes...............................................................................................B-13  
Auxiliary Power .........................................................................................................................B-14  
Accessories...........................................................................................................................Section C  
Maintenance .........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Routine and Periodic Maintenance ............................................................................................D-2  
Major Component Locations....................................................................................................D-10  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair.................................................................................................Section F  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual.................................................................................................................................P-217  
RANGER 10-LX  
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Section A-1  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation  
Technical Specifications .............................................................................................................A-2  
Safety Precautions......................................................................................................................A-3  
Location and Ventilation .............................................................................................................A-3  
Storing .................................................................................................................................A-3  
Stacking................................................................................................................................A-4  
Tilting .................................................................................................................................A-4  
Lifting .................................................................................................................................A-4  
High Altitude Operation........................................................................................................A-4  
Pre-operation Engine Service.....................................................................................................A-4  
Oil ........................................................................................................................................A-4  
Fuel.......................................................................................................................................A-4  
Engine Coolant .....................................................................................................................A-4  
Battery Connections.............................................................................................................A-4  
Muffler Relocation ................................................................................................................A-5  
Spark Arrester ......................................................................................................................A-5  
Electrical Output Connections....................................................................................................A-5  
Welding Cable Connections.................................................................................................A-6  
Cable Size and Length............................................................................................A-6  
Cable Installation.....................................................................................................A-6  
Machine Grounding..............................................................................................................A-6  
Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment .......................................A-7  
Circuit Breakers....................................................................................................................A-7  
Premises Wiring....................................................................................................................A-7  
RANGER 10-LX  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - RANGER 10-LX  
INPUT - DIESEL ENGINE  
Manufacturer Description  
Speed  
Displacement  
Ignition  
Capacities  
KUBOTA  
DH850B-88  
3 cyl.,  
liquid-cooled  
diesel  
3600 RPM  
Full load  
52.17 cu. in.  
(855 cc)  
Electric  
Fuel: 10 gal. (38 l)  
Oil: 3.9 qt. (3.7 l)  
23 HP @  
3600 RPM  
3750 RPM  
High idle  
Cooling system:  
5.4 qts. (5.1 l)  
2150 RPM  
Low idle  
RATED OUTPUT - WELDER  
Duty Cycle  
Amps  
Volts at Rated Amperes  
100% Duty Cycle  
100% Duty Cycle  
100% Duty Cycle  
250 AC Constant Current  
250 DC Constant Current  
250 DC Constant Voltage  
25  
25  
30  
OUTPUT - WELDER AND GENERATOR  
Auxiliary Power for  
Wire Feeders  
Welding Ranges Max. Open Circuit Voltage Auxiliary Power(1)  
45- 250 Amps  
80 Volts RMS  
@ 3700 RPM  
10000 Continuous Watts 42V, 60 Hz, 8 Amps  
87 Amps @ 115 V  
43.5 Amps @ 230 V  
115V, 60 Hz, 8 Amps  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
37.4 in.  
949 mm  
24.8 in.  
629 mm  
60.5 in.  
1529 mm  
1100 lb.  
499 kg  
(1)Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity.  
When welding, available auxiliary power will be reduced.  
RANGER 10-LX  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
LOCATION AND VENTILATION  
Whenever you use the RANGER 10-LX, be sure that  
clean cooling air can flow through the machine’s diesel  
engine and the machine case. Avoid dusty, dirty  
areas. Also, keep the machine away from heat  
sources. Do not place the back end of the generator  
anywhere near hot engine exhaust from another  
machine. And of course, make sure that engine  
exhaust is ventilated to an open, outside area.  
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.  
The RANGER 10-LX may be used outdoors. Do not  
set the machine in puddles or otherwise submerge it in  
water. Such practices pose safety hazards and cause  
improper operation and corrosion of parts.  
Always operate the RANGER 10-LX with the case roof  
on and all machine components completely assem-  
bled. This will protect you from the dangers of moving  
parts, hot metal surfaces, and live electrical devices.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts or electrodes with your  
skin or wet clothing.  
• Insulate yourself from the work  
and ground.  
STORING  
• Always wear dry insulating  
gloves.  
1. Store the machine in a cool, dry place when it’s  
not in use. Protect it from dust and dirt. Keep it  
where it can’t be accidentally damaged from con-  
struction activities, moving vehicles, and other  
hazards.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated  
areas or vent exhaust to the out-  
side.  
2. Drain the engine oil and refill with fresh 10W30 oil.  
Run the engine for about five minutes to circulate  
oil to all the parts. See the Maintenance section  
of this manual for details on changing oil.  
• Do not stack anything on or near  
the engine.  
3. If you are storing the machine for more than 30  
days, drain the coolant from the radiator. Open the  
cock at the bottom of the radiator and remove the  
pressure cap so that the coolant drains complete-  
ly. Attach a note that says “NO WATER” on the  
radiator.  
MOVING PARTS can injure.  
• Do not operate this equipment  
with any of its doors open or  
guards off.  
4. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
• Stop the engine before servicing  
it.  
5. If the engine is not used for a long period of time,  
every two to three months fill the radiator and run  
the engine for about five minutes to keep it free  
from rust.  
• Keep away from moving parts.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
RANGER 10-LX  
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A-4  
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.  
TILTING  
Place the machine on a secure, level surface whenev-  
er you use it or store it. Any surfaces you place it on  
other than the ground must be firm, non-skid, and  
structurally sound.  
For more oil fill and service information, see the  
Maintenance section of this manual.  
The diesel engine is designed to run in a level position  
for best performance. It can operate at an angle, but  
this should never be more than 20 degrees in any  
direction. If you do operate it at a slight angle, be sure  
to check the oil regularly and keep the oil level at the  
FULL mark as it would be in its normal level condition.  
Also, fuel capacity will be a little less at an angle.  
FUEL  
Fill the fuel tank with clean, diesel fuel only.  
The RANGER 10-LX has a 10 gallon (38 litre)  
fuel tank with a top fill and fuel gauge  
mounted on the control panel. See the  
Operation and Maintenance sections of this manual  
for more details about fuel.  
LIFTING  
The RANGER 10-LX weighs 1100 lbs/499 kg. A lift bail  
is mounted to the machine frame and should always  
be used when lifting the machine.  
ENGINE COOLANT  
WARNING  
HIGH ALTITUDE OPERATION  
HOT COOLANT can burn  
skin.  
It may be necessary to derate welder output at higher  
altitudes. Derate the welder output 0.4% for every 100  
ft (30 m) above 500 ft (150 m). Some engine adjust-  
ment may be required. Contact a Kubota Service  
Representative.  
• Do not remove cap if radiator is hot.  
The welder is shipped with the engine and radiator  
filled with a 50% mixture of ethylene glycol and water.  
The recovery bottle should be partially filled. See the  
Maintenance section and the engine Operator’s  
Manual for more information on coolant.  
PRE-OPERATION ENGINE SERVICE  
Read and understand the information about the diesel  
engine in the Operation and Maintenance sections of  
this manual before you operate the RANGER 10-LX.  
WARNING  
BATTERY CONNECTIONS  
• Keep hands away from the engine muffler or HOT  
engine parts.  
The RANGER 10-LX is shipped with the  
–
+
negative battery cable disconnected.  
Before you operate the machine, make  
• Stop the engine when fueling.  
• Do not smoke when fueling.  
sure the Engine Switch is in the STOP position and  
attach the disconnected cable securely to the battery  
terminal. If the battery is discharged and won’t start  
the engine, see the battery charging instructions in the  
Maintenance section.  
• Remove the fuel cap slowly to release pressure.  
• Do not overfill the fuel tank.  
• Wipe up spilled fuel and allow the fumes to clear  
before starting the engine.  
• Keep sparks and flame away from the fuel tank.  
RANGER 10-LX  
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A-5  
A-5  
INSTALLATION  
FIGURE A.1 - RANGER 10-LX OUTPUT CONNECTIONS  
2
1
1. 115/230 VOLT, 50 AMP RECEPTACLE  
2. 115 VOLT, 20 AMP RECEPTACLES (2)  
3. WELD OUTPUT TERMINALS (2)  
4. GROUND STUD (LOCATION)  
5. CIRCUIT BREAKERS (CSA machines only)  
5
4
3
Standard mufflers and deflectors (like the ones includ-  
ed with the RANGER 10-LX) do not act as spark  
arresters. When local laws require it, a spark arrester  
must be installed on the machine and properly main-  
tained. An optional spark arrester kit (K903-1) is avail-  
able for your RANGER 10-LX. See the Accessories  
section of this manual for more information.  
MUFFLER RELOCATION  
WARNING  
Shut off the machine and allow the muffler to cool  
before touching the muffler.  
CAUTION  
An incorrect spark arrester may lead to damage to the  
engine or reduce performance.  
The RANGER 10-LX is shipped with the exhaust  
directed toward the rear. It can be changed to the right  
side by loosening the clamp that holds the exhaust  
deflector in place and rotating the deflector to the  
desired direction.  
ELECTRICAL OUTPUT  
CONNECTIONS  
SPARK ARRESTER  
See Figure A.1 for the location of the 115 and 230 volt  
receptacles, weld output terminals, circuit breakers  
and ground stud.  
Diesel engine mufflers may emit sparks when the  
engine is running. Some federal, state, or local laws  
require spark arresters in locations where unarrested  
sparks could present a fire hazard.  
RANGER 10-LX  
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A-6  
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 impor-  
tant when you are welding at a distance from the  
welder.  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
Lincoln Electric offers a welding accessory kit with the  
properly specified welding cables. See the Acces-  
sories section of this manual for more information.  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH  
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES  
Cable Size for 250 Amp  
40% Duty Cycle  
Cable Size for 250 Amp  
Cable Length  
100% Duty Cycle  
0-50 feet (0-15 meters)  
50-100 feet (15-39 meters)  
100-150 feet (30-46 meters)  
150-200 feet (46-61 meters)  
200-250 feet (61-76 meters)  
2 AWG  
2 AWG  
1 AWG  
1 AWG  
1/0 AWG  
1 AWG  
1 AWG  
1 AWG  
1 AWG  
1/0 AWG  
CABLE INSTALLATION  
MACHINE GROUNDING  
Install the welding cables to your RANGER 10-LX as  
follows. See Figure A.1 for the location of parts.  
Because the RANGER 10-LX creates  
its own power from its diesel-engine  
driven generator, you do not need to  
connect the machine frame to an earth  
ground. However, for best protection  
1. The diesel engine must be OFF to install welding  
cables.  
2. Remove the flanged nuts from the output termi-  
nals.  
against electrical shock, connect a heavy gauge wire  
(#8 AWG or larger) from the ground stud located on  
the bottom of the output panel (see Figure A.1) to a  
suitable earth ground such as a metal pipe driven into  
the ground.  
3. Connect the electrode holder and work cables to  
the weld output terminals. The terminals are iden-  
tified on the case front.  
4. Tighten the flanged nuts securely.  
WARNING  
5. Be certain that the metal piece you are welding  
(the “work”) is properly connected to the work  
clamp and cable.  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
6. Check and tighten the connections periodically.  
CAUTION  
• Loose connections will cause the output terminals to  
overheat. The terminals may eventually melt.  
• Do not cross the welding cables at the output termi-  
nal connection. Keep the cables isolated and sepa-  
rate from one another.  
RANGER 10-LX  
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A-7  
A-7  
INSTALLATION  
When the RANGER 10-LX is mounted on  
PREMISES WIRING  
a truck or a trailer, the machine generator  
ground stud MUST be securely connect-  
ed to the metal frame of the vehicle. See  
Figure A.1. The ground stud is marked  
The RANGER 10-LX is suitable for temporary, standby,  
or emergency power using the engine manufacturer’s  
recommended maintenance schedule. With its three-  
wire grounded neutral generator, it can be permanent-  
ly installed as a standby power unit for 230 volt, three-  
wire, single phase 43 ampere service.  
with the ground symbol.  
If the RANGER 10-LX is connected to premises wiring  
such as a home or shop, it must be properly connect-  
ed to the system earth ground. See the Premises  
Wiring section of this manual for details.  
WARNING  
AUXILIARY POWER RECEPTACLES,  
PLUGS, AND HAND-HELD EQUIPMENT  
Only a licensed, certified, trained electrician should  
install the machine to a premises or residential electri-  
cal system. Be certain that:  
The control panel of the RANGER 10-LX features three  
auxiliary power receptacles: See Figure A.1.  
• The installation complies with the National Electrical  
Code and all other applicable electrical codes.  
• Two 20 amp, 125 volt duplex (double outlet) recep-  
tacles.  
• The premises is isolated and no feedbacking into  
the utility system can occur. Certain state and local  
laws require the premises to be isolated before the  
generator is linked to the premises. Check your  
state and local requirements.  
• One 50 amp 115/230 volt simplex (single outlet)  
receptacle.  
Through these receptacles the machine can supply up  
to 10,000 rated continuous watts of single-phase, 60  
Hz AC power. The machine output voltages fall within  
± 10% of the rated voltage.  
• A double pole, double throw transfer switch in con-  
junction with the properly rated double throw circuit  
breaker is connected between the generator power  
and the utility meter.  
For further protection against electric shock, any elec-  
trical equipment connected to the generator recepta-  
cles must use a three-blade, grounded type plug or an  
Underwriter’s Laboratories (UL) approved double insu-  
lation system with a two-blade plug. Lincoln offers an  
accessory plug kit that has the right type of plugs. See  
the Accessories section of this manual for details.  
The following information and the connection diagram,  
Figure A.2, can be used as a guide by the electrician  
for most applications to premises wiring.  
1. Install a double pole, double throw switch between  
the power company meter and the premises dis-  
connect. The switch rating must be the same as  
or greater than the premises disconnect and  
service overcurrent protection.  
If you need ground fault protection for hand-held  
equipment, refer to the Accessories section of this  
manual for the K896-1 GFCI Receptacle kit.  
2. Take the necessary steps to assure that the load is  
limited to the capacity of the RANGER 10-LX by  
installing a 45 amp 230 volt double pole circuit  
breaker. Maximum rated load for the 230 volt aux-  
iliary is 43 amperes. Loading above 43 amperes  
will reduce output voltage below the allowable  
– 10% of rated voltage. This may damage appli-  
ances or other motor-driven equipment.  
CIRCUIT BREAKERS  
Canadian Standards Association  
(CSA) versions of the RANGER 10-LX  
are equipped with 50 amp circuit  
breakers on the 115/230 V receptacle  
and 15 amp circuit breakers on the 115 V receptacles  
for overload protection. Under high heat a breaker  
may tend to trip at lower loads than it would normally.  
3. Install a 50 amp 115/230 volt plug (NEMA type 14-  
50) to a double pole circuit breaker using No. 6, 4  
conductor cable of the desired length. (The 50  
amp 115/230 volt plug is available in the optional  
power plug kit. See the Accessories section for  
details.)  
CAUTION  
Never bypass the circuit breakers. Without overload  
protection, the RANGER 10-LX could overheat and/or  
cause damage to the equipment being used.  
4. Plug this cable into the 50 amp 115/230 volt  
receptacle on the RANGER 10-LX case front.  
RANGER 10-LX  
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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  
115 VOLT  
COMPANY  
115 VOLT  
METER  
NEUTRAL  
BUS  
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
45 AMP  
SYSTEM  
EARTH  
230 VOLT  
GROUND  
PER THE U.S.  
NATIONAL  
ELECTRICAL  
CODE  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 115/230  
VOLT PLUG  
230 VOLTS  
NEMA TYPE 14-50  
GND  
N
50 AMP, 115/230 VOLT  
NOTE: No. 6 COPPER 4 CONDUCTOR CABLE.  
RECEPTACLE  
SEENATIONALELECTRICCODEFOR
LOCATED ON  
FRONT OF MACHINE  
ALTERNATE WIRE SIZE RECOMMENDATIONS.  
RANGER 10-LX  
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Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Safety Instructions......................................................................................................................B-2  
General Description....................................................................................................................B-2  
Recommended Applications ......................................................................................................B-3  
Welder .................................................................................................................................B-3  
Generator .............................................................................................................................B-3  
Design Features and Advantages...............................................................................................B-3  
Welding Capability......................................................................................................................B-3  
Limitations .................................................................................................................................B-3  
Controls and Settings ................................................................................................................B-4  
Welder/Generator Controls ..................................................................................................B-4  
Diesel Engine Controls.........................................................................................................B-6  
Engine Operation........................................................................................................................B-7  
Before Starting the Engine ..................................................................................................B-7  
Starting the Engine ..............................................................................................................B-8  
Stopping the Engine ............................................................................................................B-8  
Break-in Period ....................................................................................................................B-8  
Welding Operation ....................................................................................................................B-10  
General Information............................................................................................................B-10  
AC/DC Constant Current Stick Welding ......................................................................B-10  
AC/DC TIG (Constant Current) Welding.......................................................................B-11  
DC Wire Feed Welding.................................................................................................B-12  
Summary of Welding Processes and Machine Settings ..........................................................B-13  
Auxiliary Power .........................................................................................................................B-14  
General Information............................................................................................................B-14  
RANGER 10-LX  
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B-2  
B-2  
OPERATION  
WARNING  
OPERATING INSTRUCTIONS  
Read and understand this entire section before oper-  
ating your RANGER 10-LX.  
ARC RAYS can burn.  
SAFETY INSTRUCTIONS  
WARNING  
• Wear eye, ear, and body protection.  
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.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust to the outside.  
• Do not stack anything on or near the  
engine.  
ELECTRIC SHOCK can kill.  
MOVING PARTS can injure.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
• Do not operate this equipment with  
any of its doors open or guards off.  
• Stop the engine before servicing it.  
• Keep away from moving parts.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
FUMES AND GASES can be dan-  
gerous.  
• Keep your head out of fumes.  
GENERAL DESCRIPTION  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
The RANGER 10-LX is a diesel-engine driven, multi-  
process AC and DC arc welder and AC power genera-  
tor for commercial and residential applications. As a  
generator it can supply up to 10,000 continuous watts  
of 115/230 volt, 60 Hz, single-phase AC power to  
operate AC power tools, battery chargers, and light-  
ing; it can also be used to provide standby power. As  
a welder it provides 250 amps of AC current for weld-  
ing with AC stick electrodes or 250 amps of DC cur-  
rent for DC stick welding. The RANGER 10-LX can  
also perform AC/DC TIG welding and DC semiauto-  
matic wire feed welding.  
WELDING SPARKS can cause  
fire or explosion.  
• Keep flammable material away.  
• Do not weld on containers that have held  
combustibles.  
The RANGER 10-LX is powered by the Kubota  
DH850B-88 water-cooled, three-cylinder diesel  
engine.  
RANGER 10-LX  
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B-3  
B-3  
OPERATION  
• Top-mounted 10 gallon (38.0 litre) fuel tank with  
convenient top fil.  
RECOMMENDED APPLICATIONS  
WELDER  
• Front-panel mounted fuel gauge.  
The RANGER 10-LX provides excellent constant cur-  
rent AC/DC welding output for stick (SMAW) welding  
and for TIG welding, and it offers constant voltage out-  
put for DC semiautomatic wire feed welding. For more  
details on using the machine as a welder, see Welding  
Operation in the Operation section of this manual.  
• Quiet engine muffler and insonorized case for  
extremely quiet operation.  
• All copper alternator windings and high quality insu-  
lation for dependable long life.  
• Automatic engine shutdown protection for low oil  
pressure.  
GENERATOR  
• Automatic engine idler goes to low idle 10 to 14  
seconds after welding for greater fuel economy;  
includes high idle switch.  
The RANGER 10-LX gives AC generator output for  
medium use demands. For more details on operat-  
ing the generator, see Auxiliary Power in the  
Operation section of this manual.  
• Standard Remote Control Receptacle provides  
interface for Lincoln remote control accessories.  
Both 6 pin and 14 pin amphenols are provided for  
ease in hooking up wire feeders.  
DESIGN FEATURES AND  
ADVANTAGES  
• Canadian Standard Association (CSA) approved  
models available; include integrated generator out-  
put overload protection through circuit breakers.  
• 10,000 watts of auxiliary power  
• Enhanced constant voltage capability with low (9-19  
volts), medium low (10-24 volts), medium high (15-  
29 volts) and high (22-40 volts) range settings for  
greater control of wire feed applications.  
WELDING CAPABILITY  
The RANGER 10-LX is rated 250 amps, 25 volts con-  
stant current AC or 250 amps, 25 volts constant cur-  
rent DC (250 amps 30 volts constant voltage DC) at  
100% duty cycle on a ten-minute basis.  
• Built-in contactor with front panel selection of  
“cold” or “hot” welding terminals.  
• Constant current AC/DC Stick welding (SMAW)  
process capability with output range from 45-250  
amps (AC) or 45-250 amps (DC).  
The current is continuously variable from 45 to 250  
amps AC or 45 to 250 amps DC. The RANGER 10-LX  
can weld with all 3/32 and most 1/8 inch and 1/16  
diameter Lincoln AC stick electrodes. Wire feed  
processes using wire diameters from .030 to .068 inch  
are possible, depending on the specific process and  
wire feeder. (See LIMITATIONS.)  
• Constant voltage DC Semiautomatic Wire Feed  
Welding with output range from 45-250 amps.  
• Constant current AC/DC TIG Welding with output  
across the entire range of settings.  
• Polarity switch for selecting DC+, DC-, or AC weld-  
ing output.  
LIMITATIONS  
• Separate ground stud for safe connection of case to  
earth ground.  
• The RANGER 10-LX is not recommended for any  
processes besides those that are normally per-  
formed using stick welding (SMAW), TIG welding  
(GTAW), MIG (GMAW) welding and Innershield®  
(FCAW) welding. Specific limitations on using the  
RANGER 10-LX for these processes are described  
in the Welding Operation section of this manual.  
• Single 50 amp, 230 volt, full 10 kVA auxiliary power  
receptacle.  
• Double duplex 20 amp, 125 volt auxiliary power  
receptacles.  
• Electric starting.  
• The RANGER 10-LX is not recommended for pipe  
thawing.  
• Battery Charging Ammeter.  
• Engine Hour Meter for determining periodic mainte-  
nance.  
• During welding, generator power is limited and out-  
put voltages can drop. Therefore, DO NOT OPER-  
ATE ANY SENSITIVE ELECTRICAL EQUIPMENT  
WHILE YOU ARE WELDING. See Table B.4 for per-  
missible simultaneous welding and auxiliary power  
loads.  
• 23 HP Kubota DH850B-88 diesel engine.  
• Durable, heavy-gauge steel case.  
RANGER 10-LX  
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B-4  
B-4  
OPERATION  
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
5
4
1. OUTPUT RANGE SELECTOR  
2. FINE OUTPUT CONTROL  
3. POLARITY SWITCH  
4. CONTROL AT WELDER/REMOTE CONTROL SWITCH  
5. WIRE FEEDER NO CONTROL CABLE/WIRE FEEDER  
WITH CONTROL CABLE SWITCH  
7
6
6 WIRE FEEDER POWER CIRCUIT BREAKER  
7. 115 VOLT, 20 AMP RECEPTACLES (2)  
8. 115/230 VOLT, 50 AMP RECEPTACLE  
9. WELD OUTPUT TERMINAL (TO WORK)  
10. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER)  
11. GROUND STUD (LOCATION)  
8
12. 14 PIN AMPHENOL  
13. 6 PIN AMPHENOL  
14. VOLTMETER  
13  
10  
11  
12  
9
switch setting while welding since this could  
damage the switch.  
WELDER/GENERATOR CONTROLS  
See Figure B.1 for the location of the following fea-  
tures:  
4. CONTROL AT WELDER/REMOTE CONTROL  
SWITCH: Allows the operator to control welding  
output at the welding control panel or at a remote  
station. Remote connections are made at the 6 pin  
or 14 pin amphenol connector.  
1. OUTPUT RANGE SELECTOR: Selects continu-  
ous current output for constant current stick or  
TIG applications (blue settings) and constant volt-  
age wire feed applications (white settings). The  
amperages on the dial correspond to the maxi-  
mum amperages for each corresponding range  
setting. Never change the range switch setting  
while welding since this could damage the  
switch.  
5. WIRE FEEDER NO CONTROL CABLE/WIRE  
FEEDER WITH CONTROL CABLE SWITCH:  
Allows control of the RANGER 10-LX output con-  
tactor. In the “NO CONTROL CABLE” position, the  
switch closes the output contactor, and welding  
begins when an arc is struck between the electrode  
and the workpiece. In the “WITH CONTROL  
CABLE” position, the switch places control of the  
contactor at the wire feeder. The contactor closes  
when the wire feeder gun trigger or amptrol switch  
closes and opens when it is released.  
2. FINE OUTPUT CONTROL: Allows fine adjust-  
ment of current or voltage within the selected out-  
put range.  
3. POLARITY SWITCH: Selects DC+, DC- or AC  
welding output. Color codings aid in the proper  
selection of stick (blue) or wire feed (white) polari-  
ty setting. The color setting of the polarity switch  
must match the color setting of the OUTPUT  
6. WIRE FEEDER POWER CIRUIT BREAKER:  
Opens the wire feeder circuit and disables the  
feeder if a fault is detected in the circuit.  
RANGE SELECTOR. Never change the polarity  
RANGER 10-LX  
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B-5  
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.  
10. WELD OUTPUT TERMINAL (TO ELECTRODE  
HOLDER) WITH FLANGE NUT: Provides the  
connection point for the electrode holder.  
11. GROUND STUD: Provides a connection point for  
connecting the machine case to earth ground for  
the safest grounding procedure.  
12. 14 PIN AMPHENOL: For attaching wire feeder  
control cables to the RANGER 10-LX. (Includes  
contactor closure circuit, remote control circuit,  
wire feeder 115/42 volt power source.)  
13. 6 PIN AMPHENOL: For attaching optional remote  
control equipment to the RANGER 10-LX.  
(Includes contactor closure circuit & remote con-  
trol circuit.)  
14. VOLTMETER – Displays actual voltage at the out-  
put terminals when welding in CV-mode.  
RANGER 10-LX  
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B-6  
B-6  
OPERATION  
FIGURE B.2 – ENGINE CONTROLS  
4
8
2
9
1
3
1. ENGINE GLOW PLUG PUSHBUTTON  
2. IDLER CONTROL SWITCH  
3. START PUSHBUTTON  
4. ENGINE HOUR METER  
5. BATTERY CHARGER LIGHT  
6. OIL PRESSURE LIGHT  
7. WATER TEMPERATURE LIGHT  
8. FUEL LEVEL GAUGE  
7
6
9. ENGINE ON-OFF SWITCH  
5
3. START PUSHBUTTON: When the  
pushbutton is held, the starter motor  
cranks over the engine – release the  
button once the engine starts.  
DIESEL ENGINE CONTROLS  
See Figure B.2 for the location of the following fea-  
tures:  
1. GLOW PLUG PUSHBUTTON: Acti-  
vates glow plugs to preheat engine for  
starting.  
NOTE: If you press the START pushbutton when  
the engine is running, you may damage the ring  
gear or starter motor.  
2. IDLER CONTROL SWITCH: Adjusts the running  
speed of the engine. The switch has two posi-  
tions, HIGH and AUTO. In HIGH, the  
engine runs continuously at high idle.  
In AUTO, the idler control works as fol-  
lows:  
4. ENGINE HOUR METER: Records engine running  
time. Use the meter to determine when to perform  
required maintenance.  
5. BATTERY LIGHT: Is off when battery charging  
system is functioning normally. If light turns on  
while the engine is running, the fan belt may be  
broken or the alternator or the voltage regulator  
may be defective.  
Stick Welding; Wire Feeder switch in  
“NO CONTROL CABLE” position:  
The engine accelerates to high speed when the  
electrode touches the work and strikes a welding  
arc. The engine returns to low idle approximately  
10-14 seconds after welding stops, as long as no  
auxiliary power is being drawn.  
WARNING  
MOVING PARTS can injure.  
• Have qualified personnel do mainte-  
nanace and troubleshooting work.  
Wire Welding; Wire Feeder switch in “WITH CON-  
TROL CABLE” position: The engine accelerates to  
high speed when the electrode touches the work-  
piece. The engine returns to low idle approxi-  
mately 10-14 seconds after the gun trigger is  
released and the welding stops, provided that no  
auxiliary power is being drawn.  
• If possible, turn the engine off and  
disconnect the battery before work-  
ing inside the machine.  
• Remove guards only when necessary to perform  
maintenance, and replace them when the mainte-  
nance requiring their removal is complete.  
Auxiliary Power: The engine accelerates to high  
speed when power is drawn at the receptacles for  
lights or tools. The engine returns to low idle  
approximately 10-14 seconds after demand for  
auxiliary power stops.  
• If fan guards are missing from a machine, obtain  
replacements from a Lincoln Distributor. (See Parts  
List.)  
RANGER 10-LX  
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B-7  
B-7  
OPERATION  
6. OIL PRESSURE LIGHT: Remains off  
with proper oil pressure. If light turns  
BEFORE STARTING THE ENGINE  
Check and fill the engine oil level:  
on, the engine protection system will  
stop the engine. The light will go on  
1. Be sure the machine is on a level  
surface.  
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.  
2. Remove the engine oil dipstick and wipe it with a  
clean cloth. Reinsert the dipstick and check the  
level on the dipstick. See Figure D.1 in the  
Maintenance section of this manual.  
7. WATER TEMPERATURE LIGHT:  
Remains off under normal operating  
temperatures. If light turns on, the  
engine protection system will stop the  
engine. The light will remain on when the engine is  
over temperature and the “Engine” switch is in the  
“ON” position (engine not running).  
3. Add oil (if necessary) to bring the level up to the  
full mark. Do not overfill.  
Replace the dipstick.  
Check and fill the engine fuel tank:  
WARNING  
WARNING  
HOT COOLANT can burn skin.  
DIESEL fuel can cause fire or  
explosion.  
• Do not remove cap if radiator is hot.  
• Stop engine when fueling.  
• Do not smoke when fueling.  
• Remove cap slowly to release pressure.  
• Do not overfill tank.  
8. FUEL LEVEL GAUGE: Displays the level of diesel  
fuel in the 10-gallon fuel tank.  
9. ENGINE ON-OFF SWITCH: Energizes the fuel  
solenoid in the ON position. In the STOP position,  
stops fuel flow to the injection pump and stops the  
engine.  
• Wipe up spilled fuel and allow fumes to clear before  
starting engine.  
• Keep sparks and flame away from tank.  
1. Remove the fuel tank cap.  
ENGINE OPERATION  
WARNING  
2. Fill the tank approximately 4 inches (100 mm) from  
the top of the filler neck to allow for fuel expansion  
(observe the fuel gauge). DO NOT FILL THE TANK  
TO THE POINT OF OVERFLOW.  
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.  
The maximum allowable high idle speed for the  
RANGER 10-LX is 3750 RPM, no load. Do NOT adjust  
the governor screw on the engine. Severe personal  
injury and damage to the machine can result if it is  
operated at speeds above the maximum rated speed.  
3. Replace the fuel tank cap and tighten securely.  
NOTE: DO NOT allow the RANGER 10-LX to run out  
of fuel. If it does, you will have to bleed the injection  
system.  
NOTE: USE DIESEL FUEL ONLY.  
Read and understand all safety instructions included  
in the Kubota instruction manual that is shipped with  
your RANGER 10-LX.  
NOTE: Purchase diesel fuel in quantities that will be  
used within 30 days, to assure freshness.  
Refer to Pre-Operation Engine Service in the  
Installation section of this manual.  
RANGER 10-LX  
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B-8  
B-8  
OPERATION  
NOTE: If the engine fails to start in 60 seconds or  
stops running, the “ENGINE” switch must be switched  
to “OFF” and then switched back to “ON” before  
attempting to restart the engine. This resets the  
engine protection circuit.  
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.  
If the engine will not start, see the Trouble-  
shooting section of this manual.  
STOPPING THE ENGINE  
2. Check for proper level of coolant in the plastic  
reserve overflow tank. The level should be  
between the full and the low marks.  
1. Remove all welding and generator  
power loads and let the engine cool by  
running it for several minutes at low idle.  
3. Check for proper oil level on the oil dipstick. Close  
engine compartment door.  
2. Stop the engine by placing the Engine Switch in  
the OFF position. This turns off the fuel solenoid.  
You can also stop the engine by turning off the fuel  
valve located on the fuel filter housing.  
4. Set “IDLER” switch to “AUTO”.  
5. Set the “ENGINE” switch to “ON”. Observe that  
both the oil pressure light and battery charger light  
are on. Check the fuel gauge to make sure that  
there is an adequate fuel level (NEVER ALLOW  
THE RANGER 10-LX TO RUN OUT OF FUEL).  
BREAK-IN PERIOD  
Any engine will use a small amount of oil during its  
“break-in” period. For the diesel engine on the  
RANGER 10-LX, break-in is about 50 running hours.  
6. Press the “GLOW PLUG” button for 15  
seconds (30 seconds if below 0°C/32°F)  
and then press the “START BUTTON”.  
Check the oil every four hours during break-in.  
Change the oil after the first 50 hours of operation,  
every 100 hours thereafter. Change the oil filter at the  
second oil change. For more details, see the  
Maintenance section of this manual.  
7. Release both buttons when the engine  
starts.  
8. Check that the indicator lights are off. If not,  
immediately stop the engine and investigate the  
indicated problem.  
CAUTION  
9. Allow the engine to warm up at low idle speed for  
several minutes before applying a load and/or  
switching to high idle. Allow a longer warm up  
time in cold weather.  
During break-in, subject the RANGER 10-LX to mod-  
erate loads. Avoid long periods running at idle. Before  
stopping the engine, remove all loads and allow the  
engine to cool several minutes.  
FIGURE B.3 – FUEL SHUTOFF VALVE  
RANGER 10-LX  
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B-9  
B-9  
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)  
.60 Gallons/hour (2.2 liters/hour)  
1.1 Gallons/hour (4.2 liters/hour)  
1.2 Gallons/hour (4.6 liters/hour)  
.90 Gallons/hour (3.6 liters/hour)  
1.3 Gallons/hour (4.9 liters/hour)  
High Idle – No Load, 3750 RPM  
AC CC Weld Output, 250 Amps @ 25 Volts  
DC CC Weld Output, 250 Amps @ 25 Volts  
DC CV Weld Output, 250 Amps @ 30 Volts  
Auxiliary Power, 10,000 kVA  
RANGER 10-LX  
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B-10  
B-10  
OPERATION  
To use the RANGER 10-LX for AC/DC  
Constant Current Stick Welding:  
WELDING OPERATION  
GENERAL INFORMATION  
1. Remove the flange nuts from output terminals and  
place the work and electrode welding cables over  
the terminals. See Figure B.4. Replace and tight-  
en the flange nuts securely. Be sure the connec-  
tions are tight.  
WARNING  
• Do not touch electrically live parts or elec-  
2. Select the appropriate electrode. See “Welding  
Tips 1” included with your RANGER 10-LX.  
trodes with your skin or wet clothing.  
3. Attach the work clamp securely to the work you  
are welding.  
• Do not breathe welding fumes or gases.  
4. Insert the electrode into the electrode holder.  
• Use ventilation or exhaust to remove  
welding fumes from the breathing area.  
5. Set the IDLER CONTROL to AUTO and start the  
diesel engine. See Engine Operation in this sec-  
tion of the manual.  
6. Set the OUTPUT RANGE dial to a setting equal to  
or slightly higher than the welding current recom-  
mended for the electrode being used.  
• Keep flammable material away.  
• Wear eye, ear, and body protection.  
7. Set the POLARITY SWITCH to the desired polarity.  
8. Set the FINE OUTPUT CONTROL. Use a setting  
that results in the highest output at the lowest set-  
ting of the RANGE switch for the application.  
The RANGER 10-LX can deliver from 45 to 250 amps  
of constant current for AC/DC stick welding or from 45  
to 250 amps of constant voltage current for DC semi-  
automatic wire feed welding. AC/DC TIG welding is  
possible across the entire range from 45 to to maxi-  
mum rated output. Output can be adjusted by setting  
the POLARITY SWITCH, the OUTPUT RANGE dial,  
and the FINE CONTROL dial on the output control  
panel to the settings that are best for your selected  
welding process.  
9. Strike an arc and begin welding.  
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. Remove the work clamp from the work.  
4. Remove any remaining piece of electrode from the  
electrode holder.  
5. If you are finished using the RANGER 10-LX for  
welding, disconnect the welding cables from the  
weld output terminals. Reattach the flange nuts  
and leave them on the terminals.  
FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING  
1. OUTPUT CONTROL PANEL  
2. ELECTRODE CABLE  
3. ELECTRODE HOLDER  
4. ELECTRODE  
5. OUTPUT TERMINALS  
6. WORK  
7. WORK CLAMP  
8. WORK CABLE  
RANGER 10-LX  
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B-11  
B-11  
OPERATION  
After you finish welding:  
To Use the RANGER 10-LX for AC/DC TIG  
(Constant Current) Welding:  
1. Stop the diesel engine. See Engine Operation in  
this section of the manual.  
1. Connect the K930-1 TIG Module to the RANGER  
10-LX. Follow the installation instructions provid-  
ed with the kit. Also be sure to follow the special  
machine grounding instructions given in the man-  
ual.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
2. Refer to the instruction manual with the TIG mod-  
ule (IM 528) for operation with a RANGER 10-LX  
and proper machine settings.  
3. Set the OUTPUT RANGE dial to the appropriate  
setting for the electrode you are using. Refer to  
IM -528 with the TIG module or refer to Table B.2  
for AC TIG welding.  
4. Set the POLARITY SWITCH to the desired polarity.  
5. Do not AC TIG weld on the 250 AC range setting.  
The output current may exceed the rating of the  
RANGER 10-LX.  
6. Start the arc and begin welding.  
NOTE: When using the RANGER 10-LX for AC TIG  
welding of aluminum, the TIG Module is to be  
set for CONTINUOUS HF.  
TABLE B.2 - AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS  
Settings for Pure Tungsten  
Range Switch Settings  
65, 90 or 120(1)  
Tungsten Diameter (inches)  
Appropriate Current Range  
100 - 200 Amps  
1/8  
3/32  
1/16  
45, 65 or 90  
50 - 100 Amps  
45, 65 or 90  
45 - 150 Amps  
Settings for 1% Thoriated Tungsten  
Range Switch Settings  
90, 120, or 160  
Tungsten Diameter (inches)  
Appropriate Current Range  
160 - 250 Amps  
1/8  
3/32  
1/16  
45, 90, or 120  
100 - 180 Amps  
45 or 90  
60 - 120 Amps  
(1) The welding current will be approximately 200 amps with the range switch set at 120 and the OUTPUT CON-  
TROL set at 10. Do not use a range setting higher than 120 for AC TIG welding.  
RANGER 10-LX  
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B-12  
B-12  
OPERATION  
4. Set the OUTPUT RANGE dial to either HIGH,  
MEDIUM HIGH, MEDIUM LOW, or LOW depend-  
ing on your wire size and speed.  
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 instruc-  
tions in the Accessories section of this manual.  
5. Set the POLARITY SWITCH to either WIRE FEED  
DC+ or WIRE FEED DC- (white), depending on the  
electrode.  
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 (0.9mm) up to and including  
5/64” (2.0mm) can be used. 5/64” (2.0mm) NS-  
3M can be used in limited applications. Cable  
length and other conditions can affect the ultimate  
results of this application. Request Lincoln publi-  
cation N-675 for additional information.  
6. Set the FINE OUTPUT CONTROL to a setting that  
gives the most stable arc for the application.  
7. Strike an arc and begin welding.  
After you finish welding:  
1. Stop the engine. See Engine Operation in this  
section of the manual.  
2. Allow the work to cool completely. The wire gun  
and wire are “cold.”  
Recommended Outershield electrodes are .045  
(1.1 mm), .052 (1.3 mm), and 1/16 (1.6 mm)  
Outershield 71 and 1/16 (1.6 mm) Outershield 70.  
Request Lincoln publication GS-200 for additional  
information.  
3. Remove the work clamp from the work.  
For MIG welding, the recommended electrodes  
are .030 (0.8 mm), .035 (0.9 mm) and .045  
(1.1 mm) L-50 and L-56. You must use a blended  
shielding gas such as C25 (75% Argon, 25% CO2).  
Request Lincoln publication GS-100 for additional  
information.  
3. Set the IDLER CONTROL to “AUTO” for the LN-25  
“HIGH” for the LN-7 or LN-8 and start the diesel  
engine. See Engine Operation in this section of  
the manual.  
RANGER 10-LX  
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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.  
TABLE B.3 - SUMMARY OF WELDING PROCESSES  
Process  
Control  
Cable  
Used  
Idle  
Mode  
Output  
Control  
Switch  
Wire  
Feeder  
Switch  
Electrode  
State When  
Not Welding  
To Start Welding  
Stick – CC  
No  
Auto  
At Welder No  
Control  
Hot  
Touch electrode to work.  
Welding starts immed-  
ately and engine goes to  
high idle.  
Cable  
TIG - CC  
K930-1/K936-1  
(With Amptrol)  
Yes  
Yes  
Auto  
Auto  
Remote  
Remote  
With  
Control  
Cable  
Cold  
Cold  
Press Amptrol. Welding  
starts immediately.  
Wire Feed - CV,  
LN-25 with 42V  
Remote Control Kit  
With  
Control  
Cable  
Press gun trigger,  
RANGER 10-LX contactor  
closes. Welding starts  
immediately and engine  
goes to high idle.  
Wire Feed - CV  
LN-25 with internal  
contactor  
No  
Auto  
High  
At Welder No  
Control  
Cold  
Cold  
Press gun trigger, LN-25  
contactor closes. Weld-  
ing starts immediately  
and engine goes to high  
idle.  
Cable  
Wire Feed - CV,  
LN-7 or LN-8  
Yes  
Remote  
With  
Press gun trigger,  
Control  
Cable  
RANGER 10-LX contactor  
closes. Welding starts  
immediately.  
RANGER 10-LX  
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B-14  
B-14  
OPERATION  
Powering Motors  
AUXILIARY POWER  
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. Larger motors (up to 2  
HP) may be started and run as long as you don’t  
exceed the current rating of the receptacle. This may  
mean that only 230 volt motors of this size may be  
operated.  
WARNING  
Be sure that any electrical equipment plugged into the  
generator AC power receptacles can withstand a  
±10% voltage and a ±3% frequency variation.  
Using Auxiliary Power and Welding at the  
Same Time  
GENERAL INFORMATION  
It is possible to weld and use the RANGER 10-LX for  
auxiliary power at the same time. However, the size of  
the loads you can power is reduced when you weld.  
See Table B.4 in this section of the manual for a list of  
permissible simultaneous welding and load ratings.  
The table assumes that power is being drawn from  
either a 115 volt or the 230 volt receptacle, but not  
both at the same time.  
The RANGER 10-LX generator is rated at 10,000 con-  
tinuous watts. It provides both 115 volt and 230 volt  
power. You can draw up to 87 amps total, but no more  
than 20 amps (15 amps CSA) from each 115V recep-  
tacle at once. Up to 43.5 amps can be drawn from the  
single 230 volt receptacle.  
The current rating of any plug used must be at least  
equal to the current load being drawn from the recep-  
tacle. Do not try to connect the receptacles in paral-  
lel.  
NOTE: For simultaneous welding and power, set the  
OUTPUT CONTROL at “10” for maximum auxiliary  
power. At settings below “10,” only incandescent  
loads should be connected to the auxiliary recepta-  
cles.  
Electrical loads in watts are calculated by multiplying  
the voltage rating of the load by the number of amps it  
draws. (This information is given on the load device  
nameplate.) For example, a device rated 115 volts, 2  
amps will need 230 watts of power (115 x 2 = 230).  
To use the generator as an auxiliary power supply:  
1. Start the engine. See Engine Operation in this  
section of the manual.  
You can use Table B.5, GENERATOR POWER APPLI-  
CATIONS, to determine the wattage requirements of  
some common types of loads you can power with the  
RANGER 10-LX. Be sure to read the notes at the bot-  
tom of the table.  
2. Set the IDLER CONTROL to the desired operating  
mode, HIGH or AUTO. Set the OUTPUT CON-  
TROL to “10.” See Figure B.1.  
3. Plug the load(s) into the appropriate 115 volt or  
230 volt power receptacle.  
NOTE: The 115 volt auxillary power receptacles  
should only be used with three-wire grounded  
type plugs or approved double insulated  
devices with two-wire plugs.  
RANGER 10-LX  
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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)  
Permissible Auxiliary Current  
in Amperes  
@ 115V  
@230V  
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  
32.5  
37  
CV Low  
200  
40  
7000  
9500  
60  
82  
30  
41  
CV Medium Low  
CV Medium High  
CV High  
250  
60  
5500  
8500  
48  
74  
24  
37  
250  
80  
3500  
7000  
30  
60  
15  
30  
250  
100  
1500  
6000  
13  
52  
6.5  
26  
RANGER 10-LX  
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B-16  
B-16  
OPERATION  
TABLE B.5  
TYPICAL GENERATOR POWER APPLICATIONS  
Suggested Power Applications  
*Air Compressor - 3/4 HP  
Running Watts  
*Start-up Watts  
1,250  
600  
3,100 - 5,000  
1,500 - 2,400  
*Airless Sprayer - 1/3 HP  
Chain Saw  
1,200  
1,200  
1,000  
500  
Circular Saw  
Coffee Maker  
*Deep Freezer  
750 - 2,000  
*Electric Motor - 1 HP  
Electric Range (1 element)  
Electric Skillet  
1,000  
1,500  
1,250  
1,200  
600  
2,500 - 4,000  
*Furnace Fan - 1/3 HP  
Portable Grinder (4 1/2”)  
Portable Grinder (7”)  
Halogen Work Light  
Hand Drill - 1/4”  
3,000 - 4,800  
2,000  
500  
500  
Hand Drill - 3/8”  
700  
1500 Watt Heater  
Hedge Trimmer  
1,750  
450  
Light Bulb  
100  
Reciprocating Saw  
Radial Arm Saw  
900  
2,600  
50  
Radio  
*Refrigerator/Freezer (small)  
Slow Cooker  
600  
1,500 - 2,400  
200  
*Submersible Pump - 1 HP  
*Sump Pump  
1,000  
600  
2,500 - 4,000  
1,500 - 2,400  
Toaster  
1,100  
500  
Weed Trimmer  
Lincoln 100 or 125 Amp Wire Feeder/Welder  
4,000  
NOTES:  
Wattages listed are approximate. Check your equipment for actual wattage.  
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in the  
table, multiply RUNNING WATTS by 2.  
Multiple loads can be used as long as the total load does not exceed 10,000 watts. Be sure to start the  
largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may  
require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to  
start.  
RANGER 10-LX  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories...........................................................................................................................Section C  
Options/Accessories...................................................................................................................C-2  
TIG Welding..........................................................................................................................C-3  
Semiautomatic FCAW and MIG Welding .............................................................................C-3  
Connection of Lincoln Electric Wire Feeders.......................................................................C-4  
Connection of the K867 Universal Adapter...................................................................C-4  
Connection of the LN-25 “Across the Arc” ...................................................................C-5  
Connection of the LN-7 Using the K584 Input Cable Assembly...................................C-6  
Connection of the LN-7 Using the K867 Universal Adapter .........................................C-7  
Connection of the LN-8 .................................................................................................C-8  
Connection of the K488 SG Control Module and the K487 Magnum Spool Gun ........C-9  
RANGER 10-LX  
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C-2  
C-2  
ACCESSORIES  
Spark Arrester Kit (K903-1) – A field-installed kit for  
the RANGER 10-LX engine muffler exhaust pipe (either  
OPTIONS/ACCESSORIES  
The following options/accessories are available for  
your RANGER 10-LX from your local Lincoln  
Distributor.  
engine option).  
Includes a heavy-gauge steel,  
approved spark arrester, mounting clamp and adapter.  
Remote Control (K857) – Includes a control box with  
25 feet (7.5 meters) of 4-conductor cable. Allows out-  
put voltage to be controlled remotely.  
Two-Wheel Trailer (K768) – For in-plant or yard tow-  
ing 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.)  
GFCI Receptacle Kit (K896-1) – Includes two UL  
approved 115 volt ground fault circuit interrupter  
receptacles (duplex type) with covers and installation  
instructions. Each receptacle is rated 15 amps, but  
the maximum total current from each GFCI duplex is  
limited to 20 amps. The GFCI receptacles replace the  
two factory installed 115 volt duplex receptacles.  
Power Plug Kit (K802-N) – Provides four 20 amp, 115  
volt plugs and one 50 amp, dual voltage (115/230V),  
full kVA plug.  
NOTE: For CSA machines and  
machines with GFCI receptacles, use Power Plug Kit  
K802-R.)  
Power Plug Kit (K802-R) –Provides four 15 amp, 115  
volt plugs and one 50 amp, dual voltage (115/230V),  
full kVA plug.  
Accessory Kit (K702) – Includes the following:  
• Thirty-five feet (10.5 meters) of #2 AWG electrode  
cable  
• Thirty feet (9.1 meters) of #2 AWG work cable  
• Headshield with No. 12 filter.  
• GC300 work clamp  
• Cooltong® 300 insulated electrode holder  
The cables are rated at 250 amps, 40% duty cycle.  
RANGER 10-LX  
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C-3  
C-3  
ACCESSORIES  
TIG WELDING  
SEMIAUTOMATIC FCAW AND MIG WELDING  
TIG Module (K930-1) - The TIG Module is an acces-  
sory that provides high frequency and shielding gas  
control for AC and DC GTAW (TIG) welding applica-  
tions. 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).  
LN-7 or LN-8 Wire Feeder – Semiautomatic, con-  
stant speed wire feeders.  
The K930-1 TIG Module is supplied without accessories.  
Arc Start switches, Amptrols, cables, torches and  
mounting brackets must be purchased separately.  
NOTE: Gas-shielded welding requires a Magnum  
Gun. Gasless welding requires an Innershield Gun.  
Magnum Spool Gun (K487-25) – A lightweight, semi-  
automatic wire feeder for aluminum welding with  
argon gas. Has built-in remote wire speed control in  
the handle. Requires the K488 SG Control Module.  
Includes 50 feet (15.2 meters) of power cable.  
Docking Kit (K939-1) - For mounting the K930-1 TIG  
Module on top of the RANGER 10-LX.  
Control Cable (K936-1) - Control cable for connecting  
the K930-1 TIG Module to a RANGER 10-LX 9-Socket  
(at the TIG Module) to 14-pin (at RANGER 10-LX).  
(Contains circuits 2, 4, 31, 32, 75, 76, 77 and ground.)  
SG Control Module (K488) – Controls wire speed and  
gas flow. Provides the required control interface  
between the RANGER 10-LX and the K487-25  
Magnum Spool Gun.  
Arc Start Switch (K814) - A remote start switch used  
in conjunction with the K930-1 TIG Module to energize  
the output terminals via the TIG Module.  
K812 – Hand Amptrol.  
K870 – Foot Amptrol.  
NOTE: TIG welding requires a Magnum™ TIG Gun,  
appropriate Magnum Parts Kit and argon gas.  
RANGER 10-LX  
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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.  
3. Connect the K867 Universal Adapter to the 14 pin  
amphenol of the RANGER 10-LX as shown in  
Figure C.1. Make the proper connections for local  
or remote control according to Figure C.1 and the  
following NOTES, indicated on the figure:  
• Disconnect NEGATIVE (-) BATTERY  
LEAD before servicing.  
• Do not touch electrically live parts.  
A. These leads are not used for the RANGER  
10-LX. Insulate each unused lead individually.  
MOVING PARTS can injure.  
B. For wire feeders  
that return a signal  
for welding output,  
use an isolation relay to close leads 2 and 4.  
• Keep guards in place.  
• Keep away from moving parts.  
• Only qualified personnel should install,  
use or service this equipment.  
C. Refer to the Operation section of this manual  
for maximum auxiliary current draw.  
4. Set the welder “polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
CONNECTION OF THE RANGER 10-LX TO  
WIRE FEEDERS USING K867 UNIVERSAL  
ADAPTER (SEE FIGURE C.1)  
5. Set the “RANGE” switch to the “WIRE FEED” posi-  
tion.  
6. Place the “IDLER” switch in the “HIGH” position.  
NOTE: When you use the RANGER 10-LX with  
non-Lincoln Electric wire feeders or with  
certain earlier models of Lincoln wire feed-  
ers, you will require the K867 Univeral  
Adapter. The following discussion and  
connection diagram explain in general  
how to make the proper connections.  
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. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the wire feeder to  
the “ELECTRODE” terminal of the welder. Connect  
the work cable to the “TO WORK” terminal of the  
welder.  
FIGURE C.1 – RANGER 10-LX/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM  
14 PIN  
AMPHENOL  
A
B
C
RANGER 10-LX  
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C-5  
C-5  
ACCESSORIES  
7. Place the WIRE FEEDER switch in the “WITH CON-  
TROL CABLE” position.  
6. Place the “IDLER” switch in the “AUTO” position.  
7. Place the WIRE FEEDER switch in the “NO CON-  
TROL 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.  
8. Adjust wire feed speed at the LN-25 and adjust the  
welding voltage with the output “CONTROL” at the  
welder.  
NOTE: If optional remote control is used, place  
the output control switch in the “CON-  
TROL REMOTE” position.  
NOTE: If optional remote control is used, place  
the output control switch in the “CON-  
TROL REMOTE” position.  
CONNECTION OF THE LN-25 TO THE  
RANGER 10-LX “ACROSS THE ARC”  
(SEE FIGURE C.2.)  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-25 to the  
“ELECTRODE” terminal of the welder. Connect the  
work cable to the “TO WORK” terminal of the  
welder.  
NOTE: Welding cable must be sized for current  
and duty cycle of application.  
3. Set the welder “polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
4. Set the “RANGE” switch to the “WIRE FEED” posi-  
tion.  
5. Attach the single lead from the LN-25 control box  
to the work using the spring clip on the end of the  
lead. This is only a control lead — it carries no  
welding current.  
FIGURE C.2 – RANGER 10-LX/LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
K857  
RANGER 10-LX  
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C-6  
C-6  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
RANGER 10-LX USING K584 INPUT  
CABLE ASSEMBLY (SEE FIGURE C.3.)  
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. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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. Connect the electrode cable from the K584-XX  
Input Cable Assembly to the “ELECTRODE” termi-  
nal of the welder and to the LN-7 wire feeder.  
Connect the work cable to the “TO WORK” termi-  
nal of the welder.  
7. Place the WIRE FEEDER switch in the “WITH CON-  
TROL CABLE” position.  
8. Adjust wire feed speed at the LN-7 and set the  
welding voltage with the output “CONTROL” at a  
CV (constant voltage) position at the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
NOTE: If optional remote control is used, place the  
output control switch in the “CONTROL  
REMOTE” position.  
3. Connect the input cable from the K584-XX Input  
Cable Assembly to the 14 pin amphenol on the  
RANGER 10-LX and the input cable plug on the  
LN-7.  
4. Set the welder “polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
5. Set the “RANGE” switch to the “WIRE FEED” posi-  
tion.  
6. Place the “IDLER” switch in the “HIGH” position.  
FIGURE C.3  
RANGER 10-LX/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM  
RANGER 10-LX  
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C-7  
C-7  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
RANGER 10-LX USING K867 UNIVERSAL  
ADAPTER (SEE FIGURE C.4.)  
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. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
7. Place the WIRE FEEDER switch in the “WITH CON-  
TROL CABLE” position.  
3. Connect the K867 Universal Adapter to the LN-7  
wire feeder and the 14 pin amphenol of the  
RANGER 10-LX as indicated in Figure C.4. Make  
the proper connections for local or remote control  
according Figure C.4 and the following NOTES,  
indicated on the figure.  
8. Adjust wire feed speed at the LN-7 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.  
4. Set the welder “polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
5. Set the “RANGE” switch to the “WIRE FEED” posi-  
tion.  
6. Place the “IDLER” switch in the “HIGH” position.  
FIGURE C.4  
RANGER 10-LX/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM  
Insulate each unused lead  
individually.  
A
B Splice the leads and insulate.  
RANGER 10-LX  
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C-8  
C-8  
ACCESSORIES  
CONNECTION OF THE LN-8 TO THE  
RANGER 10-LX (SEE FIGURE C.5.)  
CAUTION  
1. Shut the welder off.  
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. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
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.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
3. Connect the K867 Universal adapter to the LN-8  
wire feeder and the 14 pin amphenol of the  
RANGER 10-LX as indicated in Figure C.5. Make  
the proper connections for local or remote control  
according to Figure C.5 and the following NOTES,  
indicated on the figure.  
7. Place the WIRE FEEDER switch in the “WITH CON-  
TROL CABLE” position.  
8. Adjust wire feed speed at the LN-8 and set the  
welding voltage with the output “CONTROL” to a  
CV (constant voltage) position at the welder.  
NOTE: If K595 control cable assembly is available,  
NOTE: If optional remote control is used, place the  
output control switch in the “CONTROL  
REMOTE” position.  
K867 universal adapter is not required.  
4. Set the welder “polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
5. Set the “RANGE” switch to the “WIRE FEED” posi-  
tion.  
6. Place the “IDLER” switch in the “˙HIGH” position.  
FIGURE C.5  
RANGER 10-LX/LN-8 CONNECTION DIAGRAM  
Insulate each unused lead  
individually.  
A
B Splice the leads and insulate.  
RANGER 10-LX  
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C-9  
C-9  
ACCESSORIES  
5. Set the welder “polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
CONNECTION OF THE K488 SG CON-  
TROL MODULE AND K487 MAGNUM  
SPOOL GUN TO THE RANGER 10-LX  
(SEE FIGURE C6.)  
6. Set the “RANGE” switch to the “WIRE FEED” posi-  
tion.  
7. Place the “IDLER” switch in the “HIGH” position.  
1. Shut the welder off.  
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.  
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. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory — do not adjust above  
RPM specifications listed in this manual.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
3. Connect the K691-10 Input Cable to the SG  
Control Module and the 14 pin amphenol of the  
RANGER 10-LX as indicated in Figure C.6.  
4. Set the slide switch on the SG Control Module to  
the “Lincoln” position.  
8. Place the WIRE FEEDER switch in the “WITH CON-  
TROL CABLE” position.  
CAUTION  
9. Adjust wire feed speed at the SG Control Module  
and set the welding voltage with the output “CON-  
TROL” to a CV (constant voltage) position at the  
welder.  
Be sure this switch is set to the “Lincoln” (contact clo-  
sure) position before attempting to operate the SG  
Control Module. Incorrect switch position could result  
in damage to the SG Control Module and/or the  
RANGER 10-LX.  
NOTE: If optional remote control is used, place the  
output control switch in the “CONTROL  
REMOTE” position.  
FIGURE C.6  
RANGER 10LX/K691-10/K488/K487 SPOOL GUN CONNECTION DIAGRAM  
115V RECEPTACLE  
K488 SG  
CONTROL MODULE  
K487-25  
SPOOL GUN  
14 PIN WIRE FEEDER  
RECEPTACLE  
K691-10  
INPUT CABLE  
6 PIN REMOTE  
RECEPTACLE  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO CONTROL MODULE  
TO WORK  
RANGER 10-LX  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Routine and Periodic Maintenance ............................................................................................D-2  
Engine Maintenance.............................................................................................................D-2  
Change the Oil ...............................................................................................................D-2  
Change the Oil Filter ......................................................................................................D-3  
Fuel.................................................................................................................................D-3  
Fuel Filter........................................................................................................................D-3  
Bleeding the Fuel System..............................................................................................D-4  
Air Cleaner......................................................................................................................D-5  
Tightening the Fan Belt..................................................................................................D-5  
Checking/Adding/Draining Radiator Coolant.................................................................D-6  
Clean Spark Arrester Screen .........................................................................................D-6  
Engine Maintenance Schedule ......................................................................................D-7  
Battery Maintenance............................................................................................................D-8  
Cleaning the Battery ......................................................................................................D-8  
Checking Electrolyte Level.............................................................................................D-8  
Charging the Battery......................................................................................................D-8  
Welder/Generator Maintenance ...........................................................................................D-8  
Storage...........................................................................................................................D-8  
Cleaning .........................................................................................................................D-8  
Brush Removal and Replacement .................................................................................D-8  
Receptacles ...................................................................................................................D-9  
Cable Connections.........................................................................................................D-9  
Major Component Locations .............................................................................................D-10  
RANGER 10-LX  
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D-2  
D-2  
MAINTENANCE  
OIL: Check the oil level before starting  
engine or daily. BE SURE TO MAIN-  
TAIN THE OIL LEVEL. Change the oil  
SAFETY PRECAUTIONS  
WARNING  
the first time after 50 hours of operation. Then, under  
normal operating conditions, change the oil as speci-  
fied in Table D.1. If the engine is operated under  
heavy load or in high ambient temperatures, change  
the oil more frequently.  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
• Turn the engine off before working inside the  
machine.  
• Remove covers or guards only when necessary to  
perform maintenance and replace them when the  
maintenance requiring their removal is complete.  
CHANGE THE OIL  
Change the oil, while the engine is still warm, as fol-  
lows:  
• If covers or guards are missing from the machine,  
get replacements from a Lincoln Distributor. See  
the Parts List at the back of this manual.  
1. Drain the oil from the drain plug located on the  
engine bottom, as shown in Figure D.1.  
2. Replace the plug and tighten it securely.  
3. Remove the oil fill cap and add oil until the level  
reaches the full mark on the dipstick. Use high  
quality detergent oil of API service class  
CC/CD/CE, oil viscosity grade 10W30. Always  
check the level with the dipstick before adding  
more oil.  
Read the Safety Precautions in the front of this manu-  
al and in the instruction manual for the Kubota diesel  
engine used with your machine before working on the  
RANGER 10-LX.  
Keep all equipment safety guards, covers, and devices  
in position and in good repair. Keep your hands, hair,  
clothing, and tools away from the fans, and all other  
moving parts when starting, operating, or repairing this  
machine.  
4. Reinstall the oil fill cap and the dipstick.  
ROUTINE AND PERIODIC  
MAINTENANCE  
ENGINE MAINTENANCE  
CAUTION  
To prevent the engine from accidentally starting, dis-  
connect the positive battery cable before servicing the  
engine.  
See Table D.1 for a summary of maintenance intervals  
for the items listed below. Follow either the hourly or  
the calendar intervals, whichever come first. More fre-  
quent service may be required, depending on your  
specific application and operating conditions.  
RANGER 10-LX  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 – OIL DRAIN AND REFILL LOCATION  
4
1
3
2
1. DIPSTICK  
3. OIL FILTER  
2. OIL DRAIN PLUG  
4. OIL FILL CAP  
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.  
If the engine is operated under heavy load or in high  
ambient temperatures, change the oil filter more fre-  
quently. See Table D.1 for recommended mainte-  
nance intervals.  
6. If there are no leaks, stop the engine and recheck  
the oil level. If necessary, add oil to bring the level  
up to the FULL mark, but do not overfill.  
FUEL: At the end of each day’s use, refill the  
fuel tank to minimize moisture condensation  
and dirt contamination in the fuel line. Do  
not overfill; leave room for the fuel to  
expand.  
Change the oil filter as follows:  
1. Drain the oil from the engine and allow the oil filter  
to drain.  
Use only fresh, No.2 grade DIESEL fuel oil. Do not use  
kerosene.  
2. Remove the old filter (spin it off) and discard it.  
Wipe off the filter mounting surface and adapter.  
FUEL FILTER: Clean the fuel filter every 100 hours of  
operation. Be sure to clean the fuel filter regularly.  
Dust and dirt in the fuel system can cause the injection  
pump and injection nozzle to wear quickly. Clean the  
fuel filter as follows (See Figure D.2.):  
3. Apply a thin coat of new oil to the rubber gasket on  
the new oil filter.  
4. Spin the new filter onto the mounting adapter until  
the gasket just touches the mounting surface, then  
turn it down another 1/2 to 3/4 turn. Do not over-  
tighten the new filter.  
1. Close the fuel filter cock.  
2. Loosen the ring screw on the top of the filter pot,  
remove the pot and remove the element from inside  
the pot. Clean the inside of the pot with clean  
diesel fuel.  
5. Refill the engine with the proper amount and type of  
oil as described in the Change the Oil section,  
above. Start the engine and check for leaks around  
the filter element. Correct any leaks (usually by  
retightening the filter, but only enough to stop leaks)  
before placing the RANGER 10-LX back in service.  
3. Rinse the element with clean diesel fuel.  
RANGER 10-LX  
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D-4  
D-4  
MAINTENANCE  
FIGURE D.2 – FUEL FILTER  
5
1. COCK - CLOSED  
2. COCK - OPEN POSITION  
3. RING SCREW  
4. FILTER POT (ELEMENT INSIDE)  
5. VENT PLUGS  
1
3
2
4
4. Carefully place the element back into the fuel pot.  
Be careful not to allow any dirt to stick to the ele-  
ment.  
CAUTION  
To avoid personal injury, do not bleed a hot engine.  
This could cause fuel to spill onto a hot exhaust man-  
ifold, creating a danger of fire.  
5. Reassemble the filter pot and tighten the ring screw  
at the top.  
6. Open the fuel cock and loosen the two air vent  
plugs a few turns. When bubbles no longer appear  
around the plugs, screw them back in.  
1. Fill the fuel tank. Open the fuel cock.  
7. Bleed the fuel injection pump. (See the next sec-  
tion.)  
2. Loosen the fuel filter air vent plugs a few turns. See  
Figure D.2. When bubbles no longer appear, tight-  
en the plugs.  
3. Open the air vent cock on the top of the fuel injec-  
BLEEDING THE FUEL SYSTEM: You will need to  
bleed air from the fuel system any time the fuel filter or  
fuel lines have been detached and refitted; after the  
fuel tank has been run out of fuel; or before using the  
engine after long storage. Bleed the fuel system as  
follows:  
tion pump. See Figure D.3.  
4. Move the fuel feed pump lever by hand.  
5. When bubbles no longer appear around the air vent  
cock on the injection pump, close the cock.  
NOTE: Always keep the air vent cock on the fuel  
injection pump closed except when air is vented.  
Opening the air vent cock may cause the engine to  
stop.  
RANGER 10-LX  
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D-5  
D-5  
MAINTENANCE  
FIGURE D.3 – FUEL SYSTEM BLEEDING  
1. AIR VENT COCK  
2. FUEL FEED  
PUMP LEVER  
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:  
TIGHTENING THE FAN BELT: If the fan belt is loose,  
the engine can overheat and the battery lose its  
charge. Check tightness by pressing on the belt mid-  
way between the pulleys. It should deflect about 7 to  
9 mm (0.28 to 0.35 in.) under a load of 10 kgf (22.1  
lbs.).  
1. Remove the dust cup from the bottom of the air  
cleaner housing. Clean out any accumulated dust.  
2. If dust is sticking to the element, blow compressed  
air through the element from the inside out. Turn  
the element as you apply air. Air pressure should  
be under 686 kPa (7 kgf/cm2, 99 psi).  
Refer to the Kubota Operator’s Manual for the adjust-  
ment procedure.  
3. If carbon or oil sticks to the element, soak it in  
detergent for 15 minutes. Then wash the element  
in water, rinse it with clean water and let it air dry.  
Check the element for damage before reassem-  
bling the air cleaner.  
4. Replace the element at least every year or every six  
cleanings.  
RANGER 10-LX  
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D-6  
D-6  
MAINTENANCE  
FIGURE D.4 – COOLING SYSTEM  
RADIATOR CAP  
RESERVE TANK  
RADIATOR DRAIN COCK  
CHECKING/ADDING/DRAINING RADIATOR COOL-  
ANT: 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. Check the two drain cocks for tightness  
(one at the bottom side of the radiator, one on the side  
of the engine). See Figure D.4.  
CLEAN SPARK ARRESTER SCREEN: If the muffler  
has the optional spark arrester, remove it every 50  
hours or once a year, whichever comes first, and  
inspect it. Clean the arrester. Replace it if you find any  
damage.  
WARNING  
To avoid personal injury, never remove the radiator  
pressure cap nor the reserve tank cap while the engine  
is running under heavy load or immediately after it has  
stopped. Hot water may gush out, which can scald  
people nearby.  
To drain the cooling system, open both the radiator  
and the engine drain cocks (Figure D.4). Also open the  
radiator cap. Tighten both cocks and refill the radiator  
with fresh coolant. A 50/50 antifreeze/water solution  
should be used year round.  
RANGER 10-LX  
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D-7  
D-7  
MAINTENANCE  
TABLE D.1  
KUBOTA ENGINE MAINTENANCE SCHEDULE  
FREQUENCY  
MAINTENANCE REQUIRED  
Daily or Before  
Starting Engine  
• 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.  
Every 100 Hours • Clean air filter element.  
• Clean fuel filter.  
• Change engine oil.  
• Check battery electrolyte level.  
• Check fan belt tightness.  
Every 200 Hours • Check radiator hoses.  
• Replace oil filter cartridge.  
Every 400 Hours • Replace fuel filter element.  
Refer to your Kubota engine Owner’s Manual for periodic maintenance at 500 hours and beyond.  
RANGER 10-LX  
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D-8  
D-8  
MAINTENANCE  
CHECKING ELECTROLYTE LEVEL  
BATTERY MAINTENANCE  
WARNING  
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.  
The battery is a group 45, 495 amps cold cranking.  
GASES FROM BATTERY can explode.  
• Keep sparks, flame, and cigarettes  
away from battery.  
CHARGING THE BATTERY  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is  
correct. Improper polarity can damage the charging  
circuit. The RANGER 10-LX positive (+) battery termi-  
nal has a red terminal cover.  
To prevent EXPLOSION when:  
• INSTALLING A NEW BATTERY - Disconnect the  
negative cable from the old battery first and connect  
to the new battery last.  
• CONNECTING A BATTERY CHARGER -  
Remove the battery from the welder by  
disconnecting the negative cable first,  
then the positive cable and battery  
clamp. When reinstalling, connect the  
negative cable last. Keep the area well  
ventilated.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
After the battery is charged, reconnect the positive  
battery cable first and the negative cable last. Failure  
to do so can result in damage to the internal charger  
components.  
• USING A BOOSTER - Connect the positive lead to  
the battery first, then connect the negative lead to  
the engine foot.  
Follow the instructions of the battery charger manu-  
facturer for proper charger settings and charging time.  
BATTERY ACID CAN BURN EYES AND  
SKIN.  
WELDER/GENERATOR  
MAINTENANCE  
• Wear gloves and eye protection and be  
careful when working near a battery.  
Follow the instructions printed on the  
battery.  
STORAGE: Store the RANGER 10-LX in clean, dry,  
protected areas.  
CLEANING: Blow out the generator and controls peri-  
odically with low pressure air. Do this at least once a  
week in particularly dirty areas.  
CLEANING THE BATTERY  
Keep the battery clean by wiping it with a damp cloth  
when dirty. If the terminals appear corroded, discon-  
nect the battery cables and wash the terminals with an  
ammonia solution or a solution of 1/4 pound (0.113 kg)  
of baking soda and 1 quart (0.946 l) of water. Be sure  
the battery vent plugs (if equipped) are tight so that  
none of the solution enters the cells.  
BRUSH REMOVAL AND REPLACEMENT: It’s normal  
for the brushes and slip rings to wear and darken  
slightly. Inspect the brushes when a generator over-  
haul is necessary. Remove the brushes and clean the  
slip rings with fine emery paper. Refer to the “Brush  
Removal and Replacement” procedure in the Trouble-  
shooting and Repair section of this manual.  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petrole-  
um jelly or a non-conductive grease to retard corro-  
sion.  
CAUTION  
Do not attempt to polish slip rings while the engine is  
running.  
Keep the battery clean and dry. Moisture accumula-  
tion on the battery can lead to more rapid discharge  
and early battery failure.  
RANGER 10-LX  
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D-9  
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.  
CABLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always tight.  
FIGURE D.5 - BRUSH REMOVAL AND REPLACEMENT  
RANGER 10-LX  
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D-10  
D-10  
MAINTENANCE  
FIGURE D.6 - MAJOR COMPONENT LOCATIONS  
11. P.C. BOARD COVER  
12. CAPACITOR BANK  
1. OUTPUT TERMINALS (LOCATION)  
2. ENGINE CONTROLS (on Control Panel)  
3. AUXILIARY POWER RECEPTACLES  
4. OUTPUT CONTROL PANEL  
5. REACTOR ASSEMBLY  
13. RADIATOR ASSEMBLY  
14. CHOKE ASSEMBLY  
15. LIFT BAIL WELDED ASSEMBLY  
16. CASE BACK ASSEMBLY  
17. FIELD CAPACITOR  
6. FUEL TANK  
7. DIESEL ENGINE  
18. RECTIFIER BRIDGE (on fuel tank rail)  
19. CONTACTOR  
8. ROTOR/STATOR ASSEMBLY  
9. BATTERY (not shown)  
20. SHUTOFF & IDLER ASSEMBLY  
10. BASE WELDED ASSEMBLY  
20  
7
6
8
11  
19  
16  
15  
13  
5
14  
3
10  
17  
12  
4
1
RANGER 10-LX  
5/96  
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory 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-3  
Weld Winding, Reactor, and Range Switch...........................................................................E-4  
Output Bridge, Choke, Polarity Switch, CV Contactor, and Output Terminals.....................E-5  
RANGE  
SWITCH  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
SWITCH  
RECTIFIER  
BRIDGE  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
REGULATOR  
ALTERNATOR  
BATTERY  
IDLER  
SOLENOID  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
ENGINE  
PROTECTION  
RELAY  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
FIGURE E.1 – RANGER 10-LX BLOCK LOGIC DIAGRAM  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION,  
ROTOR, STATOR AND IDLER SOLENOID  
RANGE  
SWITCH  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
SWITCH  
RECTIFIER  
BRIDGE  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
REGULATOR  
ALTERNATOR  
BATTERY  
IDLER  
SOLENOID  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
ENGINE  
PROTECTION  
RELAY  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
wire feeders. The field feedback winding provides  
rotor current during machine operation. The output of  
the Ranger 10-LX is dependent on two criteria, the  
engine RPM and the amount of current in the rotor  
winding.  
BATTERY, STARTER, ENGINE,  
GLOW PLUGS, ENGINE  
PROTECTION, ROTOR, STATOR  
AND IDLER SOLENOID  
The engine alternator and regulator supply “charging”  
current for the battery circuit., The battery circuit pro-  
vides power for the printed circuit board and also for  
the idler solenoid. The idler solenoid is mechanically  
connected to the engine’s throttle linkage. If no weld-  
ing or auxiliary current is being drawn from the Ranger  
10-LX the printed circuit board activates the idler sole-  
noid, which then brings the engine to a low idle state.  
When output current is sensed, either weld or auxiliary,  
the printed circuit board deactivates the idler solenoid,  
and the engine returns to high RPM.  
The 12VDC battery powers the starter motor and glow  
plugs. The glow plugs are used to preheat the diesel  
engine to enhance starting., When the engine is  
started and running, the battery circuit voltage is fed  
through the printed circuit board to the rotating field  
coil in the rotor via a brush and slip ring configuration.  
This excitation (“flashing”) voltage magnetizes the  
rotor lamination. The rotor is mechanically coupled to  
the engine. This rotating magnet induces a voltage in  
the stationary windings of the main alternator (stator).,  
There are four separate and isolated windings incorpo-  
rated in the stator lamination assembly. Each set has  
a different number of turns producing different magni-  
tudes of AC output voltages. These four windings are  
the weld winding, the auxiliary power winding, the field  
feedback winding and the auxiliary power winding for  
The engine protection circuit shuts the engine off in the  
event of low oil pressure or over temperature of engine  
coolant.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 10-LX  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER  
RANGE  
SWITCH  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
SWITCH  
RECTIFIER  
BRIDGE  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
REGULATOR  
ALTERNATOR  
BATTERY  
IDLER  
SOLENOID  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
ENGINE  
PROTECTION  
RELAY  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
CONTROL CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
ROTOR FIELD FEEDBACK,  
AUXILIARY, AND WIRE FEEDER  
POWER  
When full field voltage is applied to the rotor and the  
engine is running at high speed (3700 RPM), a 230AC  
voltage is developed in the stator auxiliary winding.  
This winding is tapped to provide 115 VAC. The two  
voltages (115VAC and 230VAC), are connected to the  
appropriate receptacles and offer 10,000 watts (total)  
of AC power.  
The AC voltage developed in the field winding is fed to  
the full wave field bridge. The DC output of the field  
bridge is filtered by the field capacitor and controlled  
by the printed circuit board according to the output or  
remote control setting. This filtered and controlled  
voltage is fed to the rotor winding via the brush and  
slip ring configuration. As the feedback voltage is  
increased or decreased, the outputs of the weld and  
auxiliary windings are increased or decreased.  
The auxiliary wire feeder winding offers 115VAC and is  
tapped to also provide 42VAC. The current draw from  
this winding should be limited to 8 amps. These volt-  
ages and remote control signals are fed through the  
bypass (filter) board to the amphenol receptacles.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 10-LX  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH  
RANGE  
SWITCH  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
SWITCH  
RECTIFIER  
BRIDGE  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
REGULATOR  
ALTERNATOR  
BATTERY  
IDLER  
SOLENOID  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
ENGINE  
PROTECTION  
RELAY  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
WELD WINDING, REACTOR, AND  
RANGE SWITCH  
The stator weld winding is connected to the reactor  
and range switch. The inductance in the reactor offers  
an impedance to current flow. The reactor coil is  
tapped at various points. As the range switch is ro-  
tated, different amounts of reactor coil are brought into  
the current path. As more turns of reactor are brought  
into the circuit, the more impedance there is to current  
flow. Simply stated, the more reactor in the circuit, the  
lower the welding current.  
If a constant voltage is desired for wire feeding, then  
the reactor is bypassed and the range switch is con-  
nected to one of four taps on the stator weld winding  
to provide a lower but “stiffer” output voltage.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 10-LX  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – OUTPUT BRIDGE, CAPACITOR, CHOKE, POLARITY SWITCH, CV CONTACTOR AND  
OUTPUT TERMINALS  
RANGE  
SWITCH  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
SWITCH  
RECTIFIER  
BRIDGE  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
REGULATOR  
ALTERNATOR  
BATTERY  
IDLER  
SOLENOID  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
ENGINE  
PROTECTION  
RELAY  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
OUTPUT BRIDGE, CHOKE,  
POLARITY SWITCH, CV  
CONTACTOR AND OUTPUT  
TERMINALS  
The AC voltage developed in the stator weld winding  
is delivered, through the reactor and range switch, to  
the output bridge and polarity switch. Depending  
upon the setting of the polarity switch, either AC volt-  
age or DC voltage is delivered to the output terminals.  
If AC output is selected, then the current path is from  
the stator weld winding through the reactor, range  
switch, and polarity switch to the output terminals. If  
a DC output is called for, then the current path is  
through the output rectifier bridge, where the AC volt-  
age is rectified to a DC voltage, and then to the choke,  
where the DC output is filtered. The filtered DC current  
path is through the polarity switch to the output termi-  
nals.  
When a CV (constant voltage) is desired, the reactor is  
passed by. The range switch applies a lower AC volt-  
age to the rectifier bridge. The DC output of the bridge  
is filtered and “stiffened” by the capacitors. This lower  
but “stiffer” DC output is passed through the choke,  
polarity switch, and CV output contactor to the output  
terminals. The CV output contactor provides for an  
electrically “cold” electrode when in the constant volt-  
age mode.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 10-LX  
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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.................................................................................F-3  
Troubleshooting Guide.................................................................................................F4 - F-20  
Test Procedures  
Rotor Voltage Test .........................................................................................................F-21  
Rotor Resistance Test ...................................................................................................F-23  
Auxiliary and Field Winding Test ...................................................................................F-25  
Output Rectifier Bridge Test..........................................................................................F-29  
Charging Circuit Test.....................................................................................................F-31  
Protection Relay (CR1) Test ..........................................................................................F-33  
Engine Throttle Adjustment Test ...................................................................................F-35  
Oscilloscope Waveforms.....................................................................................................F-39  
Normal Open Circuit Voltage Waveform (115 VAC Supply)..........................................F-39  
Typical DC Weld Output Waveform (CV Mode) – Machine Loaded..............................F-40  
Typical DC Weld Output Waveform – Machine Loaded................................................F-41  
Typical AC Weld Output Waveform – Machine Loaded................................................F-42  
Abnormal Open Circuit Weld Voltage Waveform (one diode open)..............................F-43  
Abnormal Open Circuit DC Weld Voltage Waveform  
(High CV Mode) – Output Capacitor Bank not Functioning ...................................F-44  
Normal Open Circuit Weld Voltage Waveform (High CV Mode) ...................................F-45  
Normal Open Circuit DC Weld Voltage Waveform........................................................F-46  
Normal Open Circuit AC Weld Voltage Waveform ........................................................F-47  
Replacement Procedures ....................................................................................................F-48  
Brush Removal and Replacement ................................................................................F-48  
Field Capacitor and Rectifier Bridge Removal and Replacement ................................F-51  
Control Board Removal and Replacement ...................................................................F-54  
Output Rectifier Bridge Removal and Replacement.....................................................F-57  
Output Capacitor Removal and Replacement..............................................................F-60  
Output Contactor Removal and Replacement..............................................................F-62  
Stator and/or Rotor Removal and Replacement (Kit S20788)......................................F-65  
Retest After Repair ..............................................................................................................F-70  
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F-2  
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. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure  
listed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the sub-  
ject component is either good or bad. If there are  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into three main categories: Output Problems,  
Engine Problems, and Welding Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this chapter. Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case wrap-around  
cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
• Remove the PC Board from the static-shielding bag  
and place it directly into the equipment. Don’t set  
the PC Board on or near paper, plastic or cloth which  
could have a static charge. If the PC Board can’t be  
installed immediately, put it back in the static-  
shielding bag.  
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.  
• If the PC Board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
• If you return a PC Board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow  
proper failure analysis.  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure symp-  
tom has been corrected by the replacement PC  
board.  
1. Determine to the best of your technical ability that  
the PC board is the most likely component caus-  
ing the failure symptom.  
NOTE: Allow the machine to heat up so that all elec-  
trical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and substitute  
it with the original PC board to recreate the original  
problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static  
electrical damage and electrical shock. Read the  
warning inside the static resistant bag and perform  
the following procedures:  
a. If the original problem does not reappear  
by substituting the original board, then the  
PC board was not the problem. Continue  
to look for bad connections in the control  
wiring harness, junction blocks, and termi-  
nal strips.  
PC Board can be damaged by  
static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the  
machine.  
• Remove your body’s static charge  
before opening the static-shield-  
ing bag. Wear an anti-static wrist  
strap. For safety, use a 1 Meg  
ohm resistive cord connected to a  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
grounded part of the equipment  
frame.  
6. Always indicate that this procedure was followed  
when warranty reports are to be submitted.  
• If you don’t have a wrist strap,  
touch an unpainted, grounded,  
part of the equipment frame.  
Keep touching the frame to pre-  
vent static build-up. Be sure not  
to touch any electrically live parts  
at the same time.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED  
PC BOARDS TO VERIFY PROBLEM,” will help  
avoid denial of legitimate PC board warranty  
claims.  
Workstations  
Reusable  
Container  
Do Not Destroy  
• Tools which come in contact with the PC Board must  
be either conductive, anti-static or static-dissipative.  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical dam- 1. Contact your local Lincoln 1. Contact The Lincoln Electric  
age is evident.  
Authorized  
Facility.  
Field  
Service  
Service Dept. (216) 383-2531 or  
1-800-833-9353 (WELD).  
No weld output and no auxiliary 1. Make sure the REMOTE switch 1. Perform the Rotor Voltage  
power. Engine operates normally.  
(S7) is in the proper position –  
“MACHINE CONTROL” if a  
remote control unit is NOT con-  
nected to the machine.  
Test.  
2. If the Rotor Voltage Test is nor-  
mal, then perform the Rotor  
Resistance Test.  
2. Check the brushes for wear and  
proper contact to the rotor slip  
rings.  
3. If the Rotor Voltage Test is NOT  
normal, perform the Auxiliary  
and Field Winding Voltage  
Test. Then check the field  
diode bridge (D2), the field  
capacitor (C2), and the Output  
Control (R1). Replace if neces-  
sary.  
4. The control board may be  
faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No weld output, the auxiliary 1. If the Polarity mode switch (S1) 1. If OCV is present in the CC  
power (230-115VAC) is operating  
normally. Engine operates normal-  
ly.  
is in a constant voltage (CV)  
position, make sure the CV out-  
put contactor is activating.  
mode but NOT in the CV mode,  
check the CV output contactor  
and also the Polarity mode  
switch (S1).  
2. With the Polarity mode switch  
(S1) is in a constant current 2. If OCV is absent in both modes  
(CC) position, check the open  
circuit voltage at the welder  
output terminals. Normal AC is  
70 to 76VAC. Normal DC is 61  
to 68VDC. If the OCV is OK,  
proceed to Step #2., If the OCV  
is NOT present at the welder  
output terminals, contact your  
local Lincoln Authorized Field  
Service Facility.  
(CV and CC), disconnect lead  
W1 from the output bridge (D1).  
With the engine at high idle and  
the output control at maximum,  
check for 70 to 76VAC from  
lead W1 to lead W2 on the main  
transformer.  
See Wiring  
Diagram. If the AC voltage is  
NOT present, the winding may  
be faulty. Check the winding for  
continuity and test to be sure it  
is NOT grounded to the stator  
iron. Replace if necessary. If  
the correct voltage is present,  
proceed to step #3.  
3. Check the welding cables,  
clamps, and electrode holder  
for loose or broken connec-  
tions.  
3. Check the reactor, Range  
switch (S2), and associated  
wires for loose or faulty connec-  
tions. Check the reactor wind-  
ing for continuity and test to be  
sure it is NOT grounded to the  
reactor iron.  
4. Check the choke (L1), Polarity  
mode switch (S1), and associ-  
ated wires for loose or faulty  
connections. Check the choke  
winding for continuity and test  
to be sure it is NOT grounded to  
the choke iron.  
5. Check the weld output termi-  
nals and associated wires for  
loose or faulty connections.  
6. Perform the Output Rectifier  
Bridge Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No auxiliary power at receptacles – 1. If the machine is equipped with 1. Check the auxiliary power  
welding output is normal – engine  
runs normally.  
circuit breakers, check circuit  
breakers. Reset if tripped.  
receptacles and associated  
wires for loose or faulty con-  
nections.  
2. Make sure the output control  
(R1) is set at the maximum 2. Perform the Auxiliary and  
position.  
Field Winding Voltage Test.  
3. Check for loose or faulty plug(s)  
at the power receptacles.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Machine has low welding output 1. If a remote control unit is NOT 1. If the engine high idle RPM is  
and low auxiliary output.  
connected to the machine,  
make sure the REMOTE switch  
is in the proper position –  
“MACHINE CONTROL.”  
low, perform the Throttle  
Adjustment Test.  
2. Perform the Rotor Voltage  
Test.  
2. The brushes may be worn.  
Contact your local Lincoln  
3. If the rotor voltage is low, the  
field capacitor (C1) or the field  
bridge (D2) may be faulty. Test  
and replace if necessary.  
Authorized  
Facility.  
Field  
Service  
3. The Engine RPM may be low.  
4. Check the output control  
potentiometer (R1). Normal  
resistance is 10,000 ohms.  
Also check associated wiring  
for loose or faulty connections.  
5. The rotor may be faulty.  
Perform the Rotor Resistance  
Test.  
6. The control board may be  
faulty. Replace.  
7. If the engine high idle RPM is  
OK, then the engine may have  
lost horsepower and be in need  
of major repair.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No DC welding output. AC welding 1. Make sure the Polarity mode 1. Perform the Output Rectifier  
output and auxiliary power are nor-  
switch (S1) is in the proper posi-  
Bridge Test.  
mal.  
tion and is “seated” correctly.  
2. Check the choke (L1), the  
Polarity switch (S1), and associ-  
ated wires for loose or faulty  
connections. Check the choke  
winding for continuity and test  
to be sure it is NOT grounded to  
the choke iron.  
2. Make sure the electrode and  
polarity are correct for the  
process being used.  
No AC welding output. DC weld- 1. Make sure the Polarity mode 1. Check the operation of the  
ing output and auxiliary power are  
normal.  
switch (S1) is in the proper  
position and is “seated” cor-  
rectly.  
Polarity mode switch (S1). Also  
check the associated wires for  
loose or faulty connections.  
See Wiring Diagram.  
2. Make sure the electrode is cor-  
rect for the process being used. 2. Check for continuity from lead  
“S2” to lead “E” located in the  
3. Make sure the welding cables  
main stator. See Wiring Dia-  
are not coiled or too long.  
gram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No constant voltage (CV) welding 1. Make sure the Range switch 1. Check the operation of the CV  
output. Constant current (CC) and  
the auxiliary power are operating  
normally.  
(S2) is in the proper position  
and “seated” correctly.  
output contactor. Make certain  
it is “closing” and the contacts  
have continuity when contactor  
2. Put the control cable switch  
(S8) in the “No control cable”  
is activated.  
Diagram.  
See Wiring  
position.  
If CV output is  
restored, the output contactor 2. Check the operation of the  
is functioning correctly. Place a  
jumper wire from pin “D” to Pin  
“C” in the 14 pin amphenol. If  
CV output is restored, the prob-  
lem is in the control cable or  
wire feeder. If CV output is NOT  
restored, check the continuity  
of leads #2 and #4 within the  
wiring harness. See Wiring  
Diagram.  
Range swtich (S2), and check  
the associated wires for loose  
or faulty connections. See  
Wiring Diagram.  
3. Check the continuity from leads  
C1, C2, C3, and C4 to lead W1  
located in the main stator. See  
Wiring Diagram.  
3. Make sure the wire feeder and  
welding cables are connected  
correctly.  
The constant voltage (CV) welding 1. Make sure the Range switch 1. Check the operation of the CV  
output is low or unstable.  
Constant current (CC) and auxiliary  
power are operating normally.  
(S2) is in the proper position  
(CV) and “seated” correctly.  
output contactor. Make sure it  
is “closing” and the contacts  
have continuity when the con-  
tactor is activated. See Wiring  
Diagram.  
2. Make sure the wire feeder and  
welding cables are connected  
correctly.  
2. Check the operation of the  
Range switch (S2), and check  
the associated wires for loose  
or faulty connections. See  
Wiring Diagram.  
3. The capacitor bank (C6, C7, C8,  
and C9) may be faulty. Check  
or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not idle down to low  
speed. Machine has normal weld  
output and auxiliary power.  
1. Make sure the Idler switch (S5) 1. With the Idler switch (S5) in the  
is in the “Auto” position.  
“AUTO” position and the engine  
running, check for the presence  
of 12VDC at leads #222F to  
#214, located at the Idler sole-  
noid. If 12VDC is present and  
the idler solenoid is not activat-  
ing, then the solenoid may be  
faulty or there is a mechanical  
restriction preventing it from  
functioning.  
2. Make sure there is NOT an  
external load on the weld termi-  
nals nor the auxiliary power  
receptacles.  
3. Check circuit breaker CB1.  
Reset breaker if “tripped.”  
2. If there is NOT 12VDC at leads  
#222F to #214, check the CB1  
circuit breaker. Also check for  
12VDC from lead #222F to lead  
#5 (ground). If 12VDC is pre-  
sent, then check lead #214 for  
continuity (zero Ohms) from the  
idler solenoid to the printed cir-  
cuit board plug 5J1. Also check  
the Idler switch (S5) and associ-  
ated leads.  
See Wiring  
Diagram. If the above are OK,  
then the control board may be  
faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-11  
F-11  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not go to high idle when 1. Make sure the welding cables 1. Check for broken or faulty con-  
attempting to weld. Welding out-  
put is normal when Idler switch is  
in “HIGH” position. Automatic idle  
function works properly when the  
auxiliary power is loaded.  
and connections are tight.  
nections in the sensing leads  
(#254 and #254A, #241 for CV  
mode). Make sure their con-  
nections are tight at the work  
output terminal, Polarity mode  
switch, and CV output contac-  
tor. See Wiring Diagram.  
2. Make sure leads #254 and  
#254A are looped three times  
through the current sensor on  
the control board. For CV oper-  
ation, make sure leads #240,  
#241, and #242 have continuity  
(zero ohms) from their connec-  
tion points to the control board  
plug J2. See Wiring Diagram.  
3. If the automatic idle function  
works correctly in the constant  
current (CC) mode but NOT in  
the constant voltage (CV)  
mode, the control board may  
be faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-12  
F-12  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not go to high idle 1. Make sure the welding cables 1. Check for broken or faulty con-  
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.  
and auxiliary power lead con-  
nections are tight.  
nections in the sensing leads  
(#254, 254A and lead #3).  
Make sure lead #3 is looped  
through the current sensor on  
the control board.  
2. Automatic idler may not func-  
tion if the auxiliary power is  
loaded to less than 150 watts.  
2. The control board may be  
faulty. Replace.  
3. If using the 115/230 volt recep-  
tacle for 115 volts, try using the  
“other side” of the receptacle.  
The internal load sensing is only  
on one side of the receptacle.  
The engine will not crank or cranks 1. Check for loose or faulty battery 1. If the battery is replaced or tests  
very slowly.  
cable connections.  
good, then the charging circuit  
may be faulty. Perform the  
Charging Circuit Test.  
2. The battery may be faulty.  
2. The starter motor or starter  
solenoid may be faulty.  
3. The engine may be hard to  
crank due to a mechanical fail-  
ure in the engine.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-13  
F-13  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine cranks but will not 1. The engine may be low on or 1. The fuel solenoid may be faulty.  
start. out of fuel. Check or replace.  
2. The oil level or pressure may be 2. The engine protection relay  
low, causing the engine protec-  
tion system to shut off fuel flow  
to the engine. Check the oil  
pressure light.  
(CR1) may be faulty. Perform  
the Protection Relay (CR1)  
Test.  
3. The engine may be faulty.  
3. The engine coolant may be  
overheated, causing the engine  
protection system to shut off  
fuel flow to the engine. Check  
the water temperature light.  
4. The engine “glow” plugs may  
not be operating correctly.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-14  
F-14  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine goes to low idle but 1. Make sure there is NOT an 1. The idler solenoid linkage may  
does not stay in low idle.  
external load (auxiliary or weld)  
connected to the RANGER 10-  
LX.  
be misadjusted or damaged.  
2. The idler solenoid (L2) hold-in  
circuitry may be faulty. Check  
lead #214 for continuity (zero  
ohms) from the solenoid to the  
control board plug 5J1. See  
Wiring Diagram.  
With the  
Ranger 10-LX in the low idle  
mode, check for 10 to 12VDC  
from lead #222F to lead #214.  
If the correct DC voltage is pre-  
sent, the idler solenoid (L2) may  
be faulty. If the correct DC volt-  
age is NOT present, the control  
board may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-15  
F-15  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
Output control on welder not func- 1. Make sure the Remote switch 1. Check the Output Control (R1).  
tioning.  
(S7) is in the “MACHINE CON-  
TROL” position.  
Normal resistance is 10,000  
ohms. Replace if defective.  
2. The Output Control (R1) may be 2. Check the Remote switch (S7)  
defective.  
and associated wiring. See  
Wiring Diagram (leads #75, #76,  
and #77).  
3. The control board may be  
faulty. Replace.  
Remote output control not func- 1. Make sure the Remote switch 1. Check the Remote switch (S7)  
tioning.  
(S7) is in the “REMOTE” posi-  
tion.  
and associated wiring. See  
Wiring Diagram (leads #75, #76,  
and #77).  
2. The remote control unit may be  
faulty. Repair or replace.  
2. The RF bypass board may be  
defective. Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-16  
F-16  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The wire feeder does not work 1. Check circuit breaker CB2. 1. Check for the presence of  
when connected to the welder  
amphenol.  
Reset if tripped.  
115VAC at leads #31A and #32.  
See Wiring Diagram.  
2. The wire feeder control cable  
may be faulty.  
replace.  
Check or 2. Check for the presence of  
42VAC at leads #31B to #42.  
See Wiring Diagram.  
3. The wire feeder may be faulty.  
Check or replace.  
3. If any of the above voltages are  
missing or low, then check the  
circuit breaker CB2 for proper  
operation.  
4. The RF bypass board may be  
faulty. Check or replace.  
5. Perform the Auxiliary and Field  
Winding Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-17  
F-17  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The CV output contactor does not 1. Make sure the Wire Feeder 1. With the jumper installed in pins  
pull in when using a wire feeder  
with a control cable connected to  
the RANGER 10-LX amphenol.  
switch (S8) is in the “WITH  
CONTROL CABLE” position.  
“D” and “C” in the 14 pin  
amphenol, check for 12VDC  
from leads #224F(+) to #2C(-) at  
the CV output contactor. If  
12VDC is present and the con-  
tactor does NOT activate, then  
the contactor may be defective.  
2. Install a jumper wire from pins  
“D” to “C” on the 14 pin amphe-  
nol. If the output contactor acti-  
vates, the problem is external to  
the RANGER 10-LX. The wire  
feeder or control cable may be 2. If the correct voltage is NOT  
faulty.  
present in Step #1, check from  
lead #224F to ground (lead #5)  
for the presence of 12VDC. If  
12VDC is present, then check  
the continuity of lead 2C  
through the RF bypass board to  
the 14 pin amphenol. See  
Wiring Diagram.  
3. If 12VDC is NOT present from  
lead #224F to ground (lead #5),  
then check the #224F lead for  
an open circuit. See Wiring  
Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-18  
F-18  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The CV output contactor does not 1. Make sure the wire feeder is 1. Check the Wire Feeder switch  
pull in when the wire feeder switch  
(S8) is in the NO CONTROL CABLE  
position.  
connected correctly to the  
RANGER 10-LX.  
(S8) and associated leads. See  
Wiring Diagram.  
2. Check for loose or faulty con-  
nections on leads #224F, #2C,  
#2D, #244, and #243. Also  
check the sensing leads #240  
and #242.  
3. Check the Idler switch (S5) and  
associated leads. See Wiring  
Diagram.  
4. The control board may be  
faulty.  
The CV output contactor does not 1. Make certain the Wire Feeder 1. Check to make sure that lead  
deactivate (drop out) when a wire  
feeder with a control cable is con-  
nected to the RANGER 10-LX.  
switch (S8) is in the “WITH  
CONTROL CABLE” position.  
#2C is not grounded. See  
Wiring Diagram.  
2. The Wire Feeder control cable 2. Remove lead #224F from the  
may be faulty.  
replace.  
Check or  
CV output contactor. If the con-  
tactor does not deactivate, the  
contactor may be faulty. Repair  
or replace.  
3. The wire feeder may be faulty.  
Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-19  
F-19  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The CV output contactor does not 1. Make sure the wire feeder is 1. Remove lead #224F from the  
deactivate (drop out) when a wire  
feeder without a control cable is  
connected to the RANGER 10-LX.  
connected properly to the  
RANGER 10-LX.  
CV output contactor. If the con-  
tactor does not deactivate, the  
contactor may be faulty. Repair  
or replace.  
2. Make sure the Wire Feeder  
switch (S8) is in the “NO CON-  
TROL CABLE” position.  
2. The control board may be  
faulty.  
3. The CV output contactor will  
normally be activated (closed) if  
the Idler switch (S5) is in the  
“HIGH” position.  
The battery does not stay charged. 1. Check for loose or faulty con- 1. Perform the Charging Circuit  
nections at the battery and  
Test.  
engine charging system.  
2. The battery may be faulty.  
Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
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.” The 1. Check for loose or faulty con- 1. Check for the correct open cir-  
engine runs normally (3700 RPM  
no load). The auxiliary power is  
functioning normally.  
nections at the weld output ter-  
minals and welding cable con-  
nections.  
cuit voltage (OCV) at the weld-  
ing output terminals. If the cor-  
rect voltage is present at the  
output terminals, then check for  
loose connections on the heavy  
current carrying leads inside the  
RANGER 10-LX. See Wiring  
Diagram.  
2. The welding cables may be too  
long or coiled, causing an  
excessive voltage drop.  
2. If the OCV is low at the welder  
output terminals, perform the  
Engine Throttle Adjustment  
Test.  
3. Perform the Output Rectifier  
Bridge Test.  
4. Check for shorted or grounded  
windings in the reactor and also  
in the main stator. See Wiring  
Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
RANGER 10-LX  
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F-21  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the rotor at maximum  
engine speed (3700 RPM). This information will aid the technician in determining if the gen-  
erator field is operating properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
RANGER 10-LX  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
ROTOR VOLTAGE TEST (continued)  
FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST  
TEST PROCEDURE  
1. With the 5/16” and 3/8” nut driver, remove  
the sheet metal screws from the right hand  
case side.  
8. If the voltage reading is low or not present,  
the generator field is not functioning prop-  
erly. Perform the Rotor Resistance Test.  
The field diode bridge (D2), the field capac-  
itor (C2), and/or the control board may be  
faulty.  
2. Carefully remove the right case side.  
3. Set the volt/ohmmeter to the DC volts  
position.  
9. If the voltage reading is normal, the field  
circuit is functioning properly. Install the  
right case side with the sheet metal screws  
and the 5/16” and 3/8” nut drivers.  
4. Connect the positive meter probe to the  
brush nearest the rotor lamination (lead  
#200A). See Figure F.1 for location.  
5. Connect the negative meter probe to the  
other brush (lead #219).  
6. Start the engine and run it at high idle (3700  
RPM). Set the output control to the MAXI-  
MUM position (position 10).  
7. Check the voltage reading on the voltmeter.  
It should read between 37 and 47 VDC.  
RANGER 10-LX  
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F-23  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
RANGER 10-LX  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.2 – LEADS 200A AND 219 REMOVED  
TEST PROCEDURE  
1. With the 5/16” and 3/8” nut drivers, remove  
the sheet metal screws from the right hand  
case side.  
8. Measure the resistance to ground.  
A. Set the ohmmeter on the high scale  
(X100,000).  
2. Carefully remove the right case side.  
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.  
3. Conduct the test with the engine OFF.  
4. Isolate the rotor electrically by removing  
the generator brush leads. Refer to Figure  
F.2 as you perform the remaining steps.  
C. Check the resistance. It should read  
very high, at least 0.5 megohm  
(500,000 ohms).  
5. Remove lead #219 from the negative brush.  
6. Remove lead #200A from the positive  
brush.  
If the test does not meet the resistance  
specifications, then the rotor may be  
faulty. Replace the rotor.  
7. Measure the resistance across the rotor  
slip rings.  
If the test does meet the resistance speci-  
fications, then the rotor is okay.  
a. Set the ohmmeter on the low scale  
(X1).  
9. Connect lead #200A to the positive brush,  
which is the one nearest the rotor lamina-  
tion. Connect lead #219 to the negative  
brush.  
b. Place one meter probe on one of the  
rotor slip rings. Place the other probe  
on the other slip ring.  
c. Check the resistance across the slip  
rings. It should read approximately 5  
or 6 ohms.  
10. Reinstall the right case side using the  
sheet metal screws and the 5/16” and  
3/8” nut drivers.  
RANGER 10-LX  
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F-25  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct AC voltages are being generated from the stator  
windings.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
4/8” Nut driver  
Wiring Diagram  
RANGER 10-LX  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.3 – LOCATION OF LEADS #3 AND #5  
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. 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.  
2. Carefully remove the left case side.  
3. Set the voltmeter to the AC volts position.  
3. Set the voltmeter to the AC volts position.  
4. Connect the voltmeter probes to leads #3  
and #5 where they connect to the 115VAC  
receptacle. See Figure F.3.  
4. Connect the voltmeter probes to leads #6  
and #3 where they connect to the 230 VAC  
receptacle.  
5. Start the engine and run it at high idle (3700  
RPM).  
NOTE: It is easier to insert the probes directly  
into the receptacle to perform this test.  
However, the probes may not reach in far  
enough to make or keep a good connection.  
In this case, before you start the engine, insert  
two test probes into the receptacle. Hold the  
test probes firmly in place to measure voltage  
(step 7).  
6. Set the output control to the maximum  
position (position 10).  
7. Check the AC voltage reading. It should be  
approximately 125VAC.  
5. Start the engine and run it at high idle (3700  
RPM)  
6. Set the output control to the maximum  
position (position 10)  
7. Check the AC voltage reading. It should be  
approximately 240 VAC.  
RANGER 10-LX  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.4 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER  
Field Bridge Rectifier  
(see inset)  
Capacitor  
To test the field winding:  
If any one or more of the readings are missing  
or not within specifications, then check for  
loose or broken wires between the test points  
and the stator windings. See the Wiring  
Diagram. Make sure the windings are NOT  
grounded internally to the stator iron. If the  
leads are intact, then the stator may be faulty.  
Replace the stator. If the voltage readings are  
within specifications, then the windings are  
good and functioning properly.  
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. Set the voltmeter to the AC volts position.  
4. Connect the voltmeter probes to leads #7  
and #9 where they connect to the field  
bridge rectifier. See Figure F.4.  
7. Reinstall the right case side using the 5/16”  
and 1/8” nut drivers and sheet metal  
screws.  
5. Start the engine and run it at high idle (3700  
RPM).  
6. Set the output control to the maximum  
position (position 10).  
7. Check the AC voltage reading. It should be  
between 40 and 47 VAC.  
RANGER 10-LX  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.4A – 14 PIN AMPHENOL PIN ASSIGNMENTS  
To test the feeder winding:  
9. Connect the voltmeter probes to leads #31  
and #42 where they connect to the circuit  
breaker CB2 and the 14 pin amphenol. See  
the Wiring Diagram.  
1. Using the 5/16” and 1/8” nut drivers,  
remove the sheet metal screws from the  
right case side.  
NOTE: It is possible to check this voltage  
reading at the amphenol by inserting the test  
probes at pin K (for lead #42) and I (for lead  
#31B). See Figure 4A. However, if you use this  
method and get no voltage reading, it could  
mean there is a break or loose connection in  
the leads between the circuit breaker and the  
amphenol. Check the reading again with one  
probe at the circuit breaker connection for lead  
#31 and the other probe at amphenol pin K.  
2. Carefully remove the right case side.  
3. Set the voltmeter to the AC volts position.  
4. Connect the voltmeter probes to leads #31  
and #32 where they connect to the circuit  
breaker CB2 and the 14 pin amphenol. See  
the Wiring Diagram.  
NOTE: It is possible to check this voltage  
reading at the amphenol by inserting the test  
probes at pin A (for lead #32) and pin J (for lead  
#31A). See Figure F.4A. However, if you use  
this method and get no voltage reading, it  
could mean there is a break or loose connec-  
tion in the leads between the circuit breaker  
and the amphenol. Check the reading again  
and with one probe at the circuit breaker con-  
nection for lead #31 and the other probe at  
amphenol pin A.  
10. Set the output control to the maximum  
position. (position 10).  
11. Check the AC voltage reading. It should  
be between 43 and 50 VAC.  
If the voltage readings are within specifica-  
tions, then the windings are good and func-  
tioning correctly.  
If any one or more of the readings are missing  
or not within specifications, then check for  
loose or broken wires between the test points  
and the stator windings. See the wiring dia-  
gram. Make sure that the windings are NOT  
grounded internally to the stator iron. If the  
leads are intact, then the stator may be faulty.  
Replace the stator.  
5. Start the engine and run it at high idle (3700  
RPM).  
6. Set the output control to the maximum  
position (position 10).  
8. Check the AC voltage reading. It should be  
between 115 and 126 VAC.  
12. Reinstall the right case side using the  
5/16” and 3/8” nut drivers and sheet metal  
screws.  
RANGER 10-LX  
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F-29  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there are faulty diodes in the output rectifier bridge.  
MATERIALS NEEDED  
Volt/Ohmmeter (Diode Tester)  
5/16” Nut driver  
3/8” Nut driver  
1/2” Wrench  
Wiring Diagram  
RANGER 10-LX  
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F-30  
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. Carefully remove the right and left case  
sides.  
8. Reverse the tester leads and check the  
diodes again. Diodes should have a low  
resistance in one polarity and a very high  
resistance in the opposite polarity.  
3. Conduct this test with the engine OFF.  
4. Locate the two halves of the output rectifier.  
The negative plate is located on the lower  
left side of the machine behind the case  
front. The positive plate is located on the  
lower right side of the machine behind the  
case front. See Figure F.5.  
9. Replace any “shorted” or “open” diode as  
the tests indicate.  
10. Reconnect the diode pigtails and heavy  
leads to their respective studs.  
11. Reinstall the left and right case sides using  
the 5/16” and 3/8” nut drivers and sheet  
metal screws.  
5. With the 1/2” wrench, remove the nuts and  
washers holding the diode pigtails and the  
heavy current-carrying leads to the studs  
located at the tops and bottoms of the rec-  
tifier plates. Note their locations and the  
order of fasteners for reassembly.  
6. Electrically isolate the diode pigtails by  
carefully bending them out into “free air.”  
RANGER 10-LX  
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F-31  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the engine alternator, regulator, and associated circuitry are func-  
tioning properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
RANGER 10-LX  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
CHARGING CIRCUIT TEST (continued)  
FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR  
5J  
234  
233  
236  
224A 222D  
TEST PROCEDURE  
1. With the 5/16” and 3/8” nut drivers,  
remove the sheet metal screws from the  
left case side.  
8. If the correct AC volts are present at leads  
#233 to #234 but the DC volts are incorrect  
at leads #222D to lead #5J (case ground),  
the regulator may be faulty. Before replac-  
ing the regulator, check the wiring from the  
regulator to the alternator and the charging  
circuit. See the Wiring Diagram.  
2. Carefully remove the left case side.  
3. Locate the engine alternator and regulator.  
See Figure F.6.  
4. Start the engine and run it at high idle  
(3700 RPM).  
NOTE: If you test with probes at the plug by  
the regulator and you get no reading, check  
the wires back to the alternator. The problem  
may be in the wiring, not the alternator.  
5. Set the voltmeter for AC volts and measure  
the AC volts at leads #233 and #234.  
Normal is between 22 and 26 VAC.  
6. Set the voltmeter for DC volts and measure  
the DC volts at leads #222D to lead #5J  
(case ground). Normal is 13.5 to 15 VDC.  
7. If the correct AC volts are present at leads  
#233 to #234, the engine alternator is  
operating correctly. If the voltage is low or  
missing, the engine alternator may be  
faulty. Replace.  
RANGER 10-LX  
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F-33  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the coil of the relay and  
also if the relay contacts are functioning properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
12VDC power supply (battery)  
RANGER 10-LX  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
PROTECTION RELAY (CR1) TEST (continued)  
FIGURE F.7 – CR1 LEAD CONNECTIONS  
TEST PROCEDURE  
1. Using the 5/16” and 3/8” nut drivers,  
7. With 12VDC applied to the relay coil, use  
the ohmmeter to check for continuity (zero  
ohms) from terminals #4 to #7. If zero or a  
very low resistance is measured, the con-  
tacts are okay. If a high or infinite resis-  
tance is measured, the contacts are faulty.  
If NO voltage is applied to the coil termi-  
nals, the resistance from #4 to #7 should  
be infinite.  
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. Remove leads #252, #253, #224 and #235  
from relay CR1. See Figure F.7.  
5. Using the 12VDC power supply, apply  
12VDC to the coil terminals “A” and “B” of  
the relay.  
8. Install the left case side using the 5/16”  
and 3/8” nut drivers and sheet metal  
screws.  
6. Check visually to see if the relay is operat-  
ing when voltage is applied to the coil ter-  
minals. If the relay IS operating, proceed  
to step #7. If the relay is NOT operating  
when coil voltage is applied, then check  
the resistance of the coil. Normal coil  
resistance is 100 to 150 ohms. If the relay  
coil is “shorted” or “open,” the relay will  
NOT operate. Replace the relay.  
RANGER 10-LX  
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F-35  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
If the machine output is low, this test will determine whether the engine is operating at the  
correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjusting the  
throttle to the correct RPM are given.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
1/2” wrench  
10mm wrench  
7/16” wrench  
Strobe-tach, frequency counter, or oscilloscope  
Chalk  
RANGER 10-LX  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.8 – MARK LOCATION, STROBE/TACH METHOD  
Flywheel  
Chalk mark  
TEST PROCEDURE  
This test can be conducted by any one of three  
methods.  
7. With the machine at HIGH IDLE, the tach  
should read between 3650 and 3700 RPM.  
WIth the machine at LOW IDLE, the tach  
should read between 2150 and 2220 RPM.  
Strobe-tach Method:  
1. With the 5/16” nut drivers, remove the sheet  
metal screws from the right case side.  
8. If any of the readings is incorrect, adjust the  
throttle as follows.  
2. Carefully remove the right case side.  
3. Carefully lift the double door assembly to  
gain access to the engine compartment.  
4. With the chalk, mark one of the flywheel  
bolts. See Figure F.8 for location. Conduct  
this procedure with the engine OFF.  
5. Connect the strobe-tach according to the  
manufacturer’s instructions.  
6. Start the engine and direct the strobe-tach  
light on the flywheel and synchronize it to  
the rotating mark.  
RANGER 10-LX  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.9 – HIGH IDLE ADJUSTMENT NUT  
Lock Nut  
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.  
With the 10mm wrench turn the adjustment  
screw counterclockwise to increase the high  
idle RPM. Note: It is usually NOT necessary to  
cut or remove the wire and seal. Adjust the  
speed until the tach reads between 3650 and  
3700 RPM.  
2. Start the engine and check the frequency  
counter. At HIGH IDLE (3700 RPM), the  
counter should read 63 Hz. At LOW IDLE  
(2200 RPM), the counter should read 37 Hz.  
Note that these are median measurements:  
Hertz readings may vary slightly above or  
below.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
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.  
With the10mm wrench, turn the adjustment  
screw counterclockwise to increase the high  
idle RPM. Note: It is usually NOT necessary to  
cut or remove the wire and seal. Adjust the  
speed until the frequency is 63 Hz.  
Adjust LOW IDLE: First make sure there is  
NOT a load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 7/16”  
wrench to loosen the lock nut. See Figure F.10  
for location. Use the 1/2” wrench to adjust the  
solenoid, which changes the amount of throw  
in the throttle lever arm. Adjust the nut until the  
tach reads between 2150 and 2220 RPM.  
Adjust LOW IDLE: First make sure there is NOT  
a load on the machine. Set the IDLE switch to  
AUTO and wait for the engine to change to low  
idle speed. Use the 7/16” wrench to loosen the  
lock nut. See Figure F.10. for location. Use  
the 1/2” wrench to adjust the solenoid, which  
changes the amount of throw in the throttle  
lever arm. Adjust the nut until the frequency is  
37 Hz.  
Frequency Counter Method  
1. Plug the frequency counter into one of the  
115 VAC receptacles.  
RANGER 10-LX  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.10 – LOW IDLE ADJUSTMENT NUT  
7/16” Lock Nut  
1/2” Adjustment Nut  
Oscilloscope Method:  
1. Connect the oscilloscope to the 115 VAC  
receptacle, according to the manufactur-  
er’s instructions. At 3700 RPM, the wave-  
form should exhibit a period of 15.8 mil-  
liseconds. At 2200 RPM, the waveform  
should exhibit a period of 27.02 millisec-  
onds. Refer to NORMAL OPEN CIRCUIT  
VOLTAGE WAVEFORM (115 VAC SUPPLY)  
HIGH IDLE – NO LOAD in this section of  
the manual.  
Adjust LOW IDLE: First make sure there is  
NOT a load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 7/16”  
wrench to loosen the lock nut. See Figure  
F.10 for location. Use the 1/2” wrench to  
adjust the solenoid, which changes the  
amount of throw in the throttle lever arm.  
Adjust the nut until the period is 27.02 mil-  
liseconds.  
2. If either waveform periods is incorrect,  
adjust the throttle as follows:  
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 the adjustment  
screw and lock nut. With the 10mm  
wrench, turn the adjustment screw coun-  
terclockwise to increase the high idle RPM.  
Note: It is usually NOT necessary to cut or  
remove the wire and seal. Adjust the  
speed until the period is 15.8 milliseconds.  
RANGER 10-LX  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
15.8 ms  
CH1  
0 volts  
5 ms  
50 volts  
This is the typical auxiliary output  
voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
Note: Scope probes connected at  
machine 115VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP)  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 250 AMPS AT 30VDC  
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. The machine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-41  
F-41  
TROUBLESHOOTING & REPAIR  
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
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. The machine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-42  
F-42  
TROUBLESHOOTING & REPAIR  
TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
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. The machine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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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  
CH1  
0 volts  
5 ms  
50 volts  
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  
non-functioning output diode. Each  
vertical division represents 50 volts  
and each horizontal division repre-  
sents 5 milliseconds in time.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-44  
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  
5 ms  
50 volts  
This is NOT the typical CV output  
voltage waveform. The capacitor  
bank is not functioning. Note the  
“ripple” in the waveform. The capac-  
itor bank was disconnected to simu-  
late an open or non-functioning  
capacitor bank. Each vertical divi-  
sion represents 50 volts and each  
horizontal division represents 5 mil-  
liseconds in time.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
CH1  
0 volts  
5 ms  
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.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
CH1  
0 volts  
5 ms  
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.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
CH1  
0 volts  
5 ms  
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.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 10-LX  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained person-  
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-  
nician 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353  
(WELD).  
DESCRIPTION  
The following procedure will aid the technician in accessing the generator brushes for  
maintenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
7/16” Wrench  
5/16” Wrench  
Slot head screwdriver  
Needle nose pliers  
RANGER 10-LX  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
11. Slide the brush holder assembly back into  
the bracket and, with the 5/16” wrench,  
install the two screws that hold it in place.  
PROCEDURE  
1. Perform this procedure with the engine  
OFF.  
12. With the 7/16” wrench, install the brush  
holder assembly bracket to the stator  
frame.,  
2. With the 5/16” and 3/8” nut drivers,  
remove the sheet metal screws from the  
right case side.  
13. Slowly remove the non-metallic retainer  
from the brush holder and let the brushes  
snap back against the slip rings.  
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.  
14. With the needle nose pliers, connect the  
red and white wires to the appropriate ter-  
minals on the brushes. The red wire is  
nearest to the rotor lamination.  
5. With the 7/16” wrench, remove the brush  
holder assembly bracket from the stator  
frame.  
15. Check the wire connections for clearance  
and tightness.  
6. With the 5/16” wrench, remove the two  
screws that secure the brush holder  
assembly to the bracket. Slide the brush  
holder assembly out of the bracket.  
16. Install the right case side using the sheet  
metal screws and 5/16” and 3/8” nut  
drivers.  
7. To change the brushes, use the slot head  
screw driver to pop off the plastic retainer  
on the back of the brush holder assembly.  
8. Remove the old brushes and insert the  
new ones. One corner of the terminal clip  
is beveled so that the brush can go in only  
one way.  
9. Snap the plastic retainer back onto the  
brush holder. The brushes may need  
some repositioning; wiggle them slightly to  
help them seat properly on the slip rings.  
10. To reinstall the brushes, depress the  
spring-loaded brushes into the holder and  
slip a suitable non-metallic, fairly stiff  
retainer through the slots at the top and  
bottom of the holder.  
RANGER 10-LX  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
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  
CAUTION  
replaced, clean slip rings with a fine emery  
paper.  
Do not attempt to polish slip rings while engine  
is running.  
FIGURE F.11 - BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE  
219  
200A  
1. BRUSHES  
2. CABLE TIE  
3. RETAINER CLIP  
1. BRACKET MOUNTING HOLES  
RANGER 10-LX  
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F-51  
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. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in accessing and removing the field capacitor  
and rectifier bridge for maintenance or replacement of either component.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
Jumper wire with alligator clips on each end for discharging the field capacitor  
Slot head screw driver  
Needle nose pliers  
Wiring Diagram  
RANGER 10-LX  
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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)  
Jumper  
PROCEDURE  
1. Perform this procedure with the engine  
OFF.  
7. To install the capacitor, reattach the leads  
to their respective terminals [#200 to pos-  
itive (+); #201A to negative (-)] and tighten  
the screws.  
2. With the 5/16” and 3/8” nut drivers, remove  
the sheet metal screws from the right case  
side.  
8. Using the 5/16” nut driver, assemble the  
capacitor and mounting bracket to the  
fuel tank support bracket.  
3. Carefully remove the right case side.  
4. Discharge the field capacitor by connecting  
the jumper wire clips on the white and red  
wire terminals on the top of the capacitor.  
See Figure F.12. Leave the clips on for at  
least 5 seconds, then remove.  
9. Check that the leads are not grounded  
and also for clearance and tightness.  
10. Install the right case side using the sheet  
metal screws and 5/16” and 1/8” nut dri-  
vers.  
5. Loosen the two screws on the top of the  
capacitor. Lead #200 attaches to the posi-  
tive (+) terminal. Lead #201A attaches to  
the negative (-) terminal.  
6. With the 5/16” nut driver, remove the sheet  
metal screw that holds the capacitor  
mounting bracket to the fuel tank support  
bracket. Remove the field capacitor.  
RANGER 10-LX  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT (continued)  
PROCEDURE - RECTIFIER BRIDGE  
REMOVAL AND REPLACEMENT  
8. Replace the wires to their appropriate loca-  
tions on the new rectifier bridge. (See the  
Wiring Diagram.)  
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.  
Leads #200, #200A and #200B are piggy-  
backed on the positive (+) terminal.  
Depending on the bridge used, this corner  
may be beveled and/or marked with a +  
sign.  
3. Carefully remove the right case side.  
4. Discharge the field capacitor by connecting  
the jumper wire clips on the white and red  
wire terminals on the top of the capacitor.  
See Figure F.12. Leave the clips on for at  
least 5 seconds, then remove.  
Lead #201 is located on the negative (-) ter-  
minal, which will always be located diago-  
nally across from the positive (+) terminal.  
5. With the needle nose pliers, gently remove  
the six wires from the field rectifier bridge.  
The two leads #7 and #9 are the AC side of  
the bridge and attach to the other two cor-  
ners of the rectifier. Either lead can go on  
either terminal.  
6. WIth the slot head screw driver remove the  
rectifier mounting screw, nut, and washers  
that hold the rectifier to either the vertical  
baffle or the fuel tank support bracket.  
Remove the field rectifier bridge.  
9. Check that the leads are not grounded and  
also for clearance and tightness.  
10. Install the right case side using the sheet  
metal screws and 5/16” and 1/8” nut dri-  
vers.  
7. Install the new rectifier using the mounting  
screw and associated hardware. Place the  
flat washer under the screw head and the  
lock washer under the nut.  
RANGER 10-LX  
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F-54  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this man-  
ual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the control board for maintenance  
or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
1/4” Nut driver  
Diagonal cutters  
1/2” wrench  
Wiring Diagram  
RANGER 10-LX  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT  
(continued)  
FIGURE F.13 - CONTROL BOARD LOCATION  
J1  
#5C  
#222  
#213  
CONTROL  
BOARD  
COVER  
CONTROL  
J2  
10. Remove the two molex plugs from the  
control board. Also remove the three indi-  
vidual leads #213, #222 and #5C. (Note  
lead placement.)  
PROCEDURE  
Before starting the following procedure, refer to  
the topic “PC Board Troubleshooting  
Procedures” at the beginning of this section.  
11. Detach the two in-line connectors from the  
current sensing leads (#254 and #254A).  
See the Wiring Diagram. These leads  
attach to the current sensor located on the  
control board.  
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 top and  
right case side.  
12. Remove lead #3 from the 115VAC recepta-  
cle. Thread the lead through the hole in  
the current sensor in order to separate it  
from the control board. It will probably be  
necessary to cut any cable ties restraining  
the wiring. Use the diagonal cutters.  
3. If necessary, use the 1/2” wrench to remove  
the exhaust pipe from the muffler.  
4. Carefully remove the right case side.  
5. Remove the rubber gasket (cover seal) from  
the lift bail.  
13. With the 1/4” nut driver, remove the screws  
holding the control board.  
6. Remove the fuel cap and the rubber gasket  
from the fill tube.  
14. Replace the old control board with a new  
one.  
7. Unlatch the double door assembly and use  
the slot head screwdriver and 3/8” wrench  
to remove the door support rod from the  
door assembly.  
15. Thread lead #3 back through the current  
sensor on the control board and reattach  
the lead to the 115VAC receptacle.  
8. Remove the case top, then reinstall the  
fuel cap.  
9. With the 5/16” nut driver, remove the control  
board cover. See Figure F.13.  
RANGER 10-LX  
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F-56  
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.  
18. Connect the three individual leads #213,  
#222 and #5C.  
19. Replace any cable ties that were cut dur-  
ing the removal procedure.  
20. With the 5/16” nut driver, install the control  
board cover.  
21. Install the right case side, top, gaskets and  
double door support rod.  
RANGER 10-LX  
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F-57  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output rectifier bridge for  
maintenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
1/2” Wrench  
7/16” Wrench  
7/16” Nut driver  
Dow Corning 340  
Wiring Diagram  
RANGER 10-LX  
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F-58  
F-58  
TROUBLESHOOTING & REPAIR  
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.  
5. With the 1/2” wrench, remove the two heavy  
leads and one small lead from the rectifier  
heat sink plate. (Note that the small lead is  
always on top for reassembly.)  
2. With the 5/16” and 3/8” nut drivers, remove  
the sheet metal screws from the left and right  
case sides.  
6. With the 7/16” wrench, remove the nut and  
washers holding the top stud assembly to the  
rectifier mounting bolts.  
3. Carefully remove the left and right case  
sides. Note that the output rectifier is di-  
vided into two parts. The positive portion is  
located on the lower right side and the neg-  
ative portion on the lower left side of the  
machine.  
7. With the 7/16” wrench, remove the nuts, lock  
washers, and flat washers from the two top  
mounting bolts. (Note insulator place-  
ment.)  
For the remaining steps refer to FIgure F.14.  
8. With the 3/8” nut driver, remove the two bot-  
tom mounting sheet metal screws. (Note  
insulator placement - upon reassembly the  
heat sink must be electrically insulated from  
the frame of the Ranger 10-LX.)  
4. With the 1/2” wrench, remove the diode pig-  
tails and heavy leads from the terminal studs.  
Note lead and washer placement: nut, split  
washer, flat washer, leads. Label leads for  
reassembly. See wiring diagram.  
RANGER 10-LX  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT (continued)  
9. Clear the leads and carefully remove the  
heat sink assembly.  
3. With the 7/16” wrench, fit the flat washers,  
lock washers, and nuts to the two top  
mounting bolts.  
10. Repeat the above procedure to remove  
the other half of the output rectifier.  
4. With the 7/16” wrench, fit the washers and  
nut to hold the top stud assembly to the  
rectifier mounting bolts.  
REASSEMBLY:  
When reassembling, use Dow Corning 340 on  
all aluminum electrical connection surfaces.  
5. WIth the 1/2” wrench, reattach the diode  
pigtails and heavy leads to the terminal  
studs. Placement is: leads, flat washer, split  
washer, nut.  
1. With the 3/8” nut driver, mount the heat sink  
assemblies at the bottom using the sheet  
metal mounting screws. Be sure to place  
the insulators properly so that the heat  
sinks are electrically insulated from the  
machine frame.  
6. With the 5/16” and 3/8” nut drivers, replace  
the machine case sides and top.  
2. With the 1/2” wrench, reattach the two  
heavy leads and one small lead to the heat  
sink plate. (Small lead goes on top.)  
RANGER 10-LX  
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F-60  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output capacitor bank of four  
capacitors for maintenance or replacement.  
MATERIALS NEEDED  
Volt/Ohmmeter  
25-watt resistor  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
RANGER 10-LX  
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F-61  
F-61  
TROUBLESHOOTING & REPAIR  
OUTPUT CAPACITOR BANK EMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.15 - OUTPUT CAPACITOR BANK/PRINTED CIRCUIT BOARD LOCATION  
1. PC BOARD COVER  
2. VERTICAL BAFFLE  
3. CAPACITOR (4)  
4. BUSS BAR (2)  
1
4
2
3
PROCEDURE  
1. Perform this procedure with the engine OFF.  
7. Carefully remove the capacitor bank  
assembly.  
2. WIth the 5/16” and 3/8” nut drivers, remove  
the sheet metal screws from the right case  
side.  
8. To replace the capacitor bank assembly,  
mount the assembly to the base of the  
machine using the four screws and the 3/8”  
nut driver.  
3. Carefully remove the right case side.  
4. With the voltmeter, check the voltage across  
each of the four output capacitors. If a volt-  
age is present, use a 25-watt resistor to dis-  
charge each capacitor. See Figure F.15.  
9. With the 1/2” wrench, attach the two heavy  
leads, the two small leads, and associated  
fasteners to the positive and negative  
capacitor buss bars. Observe capacitor  
polarity.  
5. With the 1/2” wrench, remove the two nuts,  
bolts, and associated washers holding the  
two heavy leads and two small leads (#242B  
negative and #240A positive) to the capacitor  
bank buss bars. Note lead placement.  
10. Install the right case side using the 5/16”  
and 3/8” nut drivers.  
6. With the 3/8” nut driver, remove the four  
mounting screws holding the capacitor bank  
assembly to the base of the RANGER 10-LX.  
RANGER 10-LX  
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F-62  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output contactor for mainte-  
nance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
1/2” Wrench  
Slot head screw driver  
Needle nose pliers  
Wiring Diagram  
RANGER 10-LX  
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F-63  
F-63  
TROUBLESHOOTING & REPAIR  
OUTPUT CAPACITOR REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.16 – OUTPUT CONTACTOR LOCATION  
1. CONTACTOR  
2. COIL LEAD CONNECTIONS  
3. HEAVY LEAD CONNECTIONS  
4. MOUNTING HARDWARE  
5. VERTICAL BAFFLE  
1
2
4
4
3
5
PROCEDURE  
1. Perform this procedure with the engine OFF.  
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.  
2. With the 5/16” and 3/8” nut drivers, remove  
the sheet metal screws from the left case  
side.  
3. Carefully remove the left case side.  
8. WIth the 1/2” wrench and the two nuts,  
bolts and associated washers, attach the  
heavy lead and two small leads to the out-  
put contactor. Also attach the copper strap  
to the contactor.  
4. With the needle nose pliers, remove the five  
small leads connected to the output contac-  
tor coil (leads #224F, #224K, #14B, #2C and  
#2D). Note lead placement. See Figure  
F.17.  
9. With the needle nose pliers, carefully attach  
the five small leads to the contactor coil.  
See Wiring Diagram and Figure F.17.  
5. With the 1/2” wrench, remove the nut, bolt,  
and associated washers holding the heavy  
lead and two small leads (#241 and #241A) to  
the output contactor. Also remove the heavy  
copper strap connected to the contactor.  
10. Install the left case side using the sheet  
metal screws and 5/16” and 3/8” nut dri-  
vers.  
6. With the slot head screw driver and 3/8” nut  
driver, remove the three mounting screws,  
nuts, and associated washers from the con-  
tactor. The contactor can now be removed.  
RANGER 10-LX  
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F-64  
F-64  
TROUBLESHOOTING & REPAIRs  
OUTPUT CAPACITOR REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.17 – CONTACTOR COIL LEAD PLACEMENT  
224C  
224F  
2C  
14B  
2D  
Copper Strap  
241  
241A  
RANGER 10-LX  
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F-65  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the stator and/or rotor for main-  
tenance or replacement. The key to successful stator removal is to free all stator connec-  
tions in order to be able to pivot the machine case front to the side. This allows the stator to  
be pulled straight out from the engine.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
Feeler gauges  
Needle nose pliers  
Diagonal cutters  
Slot head screw driver  
7/16” Wrench  
1/2” Wrench  
Gear puller  
Socket wrench extension (8”)  
RANGER 10-LX  
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F-66  
F-66  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR REMOVAL AND  
REPLACEMENT (continued)  
FIGURE F.18 – COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL  
11  
10  
9
7
Support engine  
when removing  
stator  
5
13  
12  
4
Support rotor  
when removing  
8
1. STATOR MOUNTING BRACKET  
2. MOUINTING BRACKET BOLT (2)  
3. ROTOR BEARING SCREWS (2)  
4. BLOWER  
6
5. TOLERANCE RING  
6. BRUSH ASSEMBLY BRACKET  
7. STATOR MOUNTING BOLT (8)  
8. ROTOR BEARING  
9. ROTOR  
1
2
3
10. FLEX PLATE  
11. ENGINE  
12. ROTOR BOLT (6)  
13. SPACER (3)  
RANGER 10-LX  
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F-67  
F-67  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR ROTOR REMOVAL  
AND REPLACEMENT (continued)  
PROCEDURE (Stator Removal)  
1. Perform this procedure with the engine  
OFF.  
Remove the PC board cover.  
Disconnect lead #3 from the 115VAC  
receptacle and remove it from the current  
sensor located on the control board. It  
may be necessary to remove the recepta-  
cles.  
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.  
3. If necessary, use the 1/2” wrench to  
remove the exhaust pipe from the muffler.  
Disconnect lead #5 from the 115 VAC  
receptacle.  
4. Carefully remove the left and right case  
sides, then remove the positive (+) lead  
from the battery.  
Disconnect lead #5D from the common  
ground screw.  
5. Remove the rubber gasket (cover seal)  
from the lift bail.  
Disconnect lead #6 from the 115/230 VAC  
receptacle.  
6. Remove the fuel cap and the rubber gasket  
from the fill tube.  
Disconnect leads #7 and #9 from the field  
rectifier bridge (D2). You may have already  
done this step when you removed the fuel  
tank. Cut any necessary cable ties to free  
leads #7 and #9 from the cable bundle.  
7. Unlatch the double door assembly and use  
the slot head screw driver and 3/8” wrench  
to remove the door support rod from the  
door assembly.  
Remove lead W1 (heavy stator lead) from  
the left side output rectifier assembly.  
8. Remove the case top, then reinstall the fuel  
cap.  
Remove lead S2 (heavy stator lead) from  
the left side output rectifier assembly.  
9. With the 1/2” socket wrench, remove the  
fuel tank. (Four bolts hold the fuel tank.)  
With the 3/8” nut driver, remove lead #226  
from the fuel gauge.  
Untape and disconnect W2 from S1 to  
separate the stator from the reactor.  
16. Using the 3/8” wrench, remove the four  
screws (2 on each side) holding the output  
rectifier assemblies to the base of the  
machine.  
10. With the slot head screw driver, remove the  
field bridge rectifier. Leave the leads  
attached. Cut any necessary cable ties.  
11. Perform the Output Capacitor Bank  
17. Using the 1/2” wrench, remove the four  
choke mounting bolts from the base of the  
machine. Push the choke forward, toward  
the front of the machine.  
Removal procedure.  
12. Perform the Brush Removal procedure.  
13. Cut the cable ties from the reactor to the  
range switch.  
18. Perform the Output Contactor Removal  
procedure.  
14. Remove the four stator leads connected to  
the range switch. Use care. Excessive  
torgue will break the terminals away from  
the rivets.  
19. Remove the heavy lead from the choke to  
the bottom of the positive output rectifier.  
20. Slide the choke assembly out.  
15. Remove all stator leads from connection  
points on the front panel:  
21. Using the 1/2” wrench, remove the three  
reactor mounting bolts from the base of  
the machine.  
Remove lead #31 from circuit breaker CB2.  
22. Using the 5/16” wrench, remove the three  
sheet metal screws holding the front verti-  
cal baffle.  
Disconnect the in-line connector on leads  
#42 and #32 located between the stator  
and the 14-pin amphenol.  
RANGER 10-LX  
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F-68  
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.  
29. Remove the eight 9/16” bolts that mount  
the stator to the engine.  
30. Using a gear puller, carefully remove the  
stator.  
24. Clear all stator leads and cut any necessary  
cable ties.  
25. Carefully lift and pivot the front panel  
assembly, along with the reactor, around to  
the right side of the machine. Support the  
unit with a box or large pan. See Figure  
F.19.  
ROTOR REMOVAL PROCEDURE  
1. Support the rotor. See Figure F.18.  
2. Remove the six 1/2” rotor bolts and spacers.  
Caution: The rotor will be free to fall when the  
bolts are removed.  
26. Remove the two 3/8” nuts and bolts that  
hold the stator mounting bracket to the  
base of the machine. See Figure F.18.  
3. Rotor bearing must be removed before sta-  
tor is reinstalled. (Install bearing after stator  
is reinstalled).  
27. Remove the 1/2” blower (fan) bolt the blow-  
er, and the two 3/8” screws that hold the  
rotor bearing in place. You will need to use  
a gear puller to remove the blower.  
4. Install bearing tolerance ring.  
5. Carefully install stator and check air gap  
.015” (minimum).  
28. Support the engine. See Figure F.18.  
RANGER 10-LX  
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F-69  
F-69  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR ROTOR REMOVAL  
AND REPLACEMENT (continued)  
REASSEMBLY NOTES  
Front Panel/PC Board  
■ 4 stator leads to Range switch  
■ Lead #31 from CB2  
1. Be sure to remove the rotor bearing from  
the stator frame before reinstalling the  
rotor/stator Also remove the tolerance  
ring.  
■ Leads #42 and #32 between stator and 14-  
pin amphenol  
2. Install the rotor to the flex plate and install  
the flex plate to the engine.  
■ Lead #3 to 115 VAC receptacle  
3. Carefully install the stator. Tighten the  
eight bolts finger-tight only.  
■ Lead #5 to 115 VAC receptacle  
■ Lead #5D to common ground screw  
■ Lead #6 to 115/230 VAC receptacle  
■ Leads #7 and #9 to field bridge rectifier  
4. Install a new tolerance ring and press in a  
new rotor bearing.  
5. Tighten stator bolts.  
■ Lead W1 (heavy lead) to left side output  
6. Check the air gap for .015” (minimum).  
rectifier assembly  
■ Lead S2 (heavy lead) to left side output rec-  
LEAD RECONNECTION  
CHECKLIST  
tifier assembly  
■ Lead W2 to S1  
Engine  
■ Lead #226 to fuel gauge  
RANGER 10-LX  
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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.  
ENGINE OUTPUT  
Mode  
Low Idle  
High Idle  
No Load RPM  
2150-2250  
3650-3700  
Load RPM  
NA  
3400-3650  
WELDER DC OUTPUT1  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
61 - 68  
25 - 35  
250 - 285  
WELDER AC OUTPUT1  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
70 - 76  
25 - 35  
250 - 305  
WELDER CV OUTPUT1  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
Maximum  
Maximum  
Wire Feed CV High  
Wire Feed CV Med HI  
Wire Feed CV Med LO  
Wire Feed CV Low  
59 - 62  
42 - 45  
33.5 - 36  
25 - 27  
30 - 34  
23 - 26  
19 - 21  
14.5 - 16  
250 - 280  
220 - 240  
155 - 170  
135 - 155  
AUXILIARY POWER OUTPUT  
230 Volt Receptacle  
115 Volt Receptacle2  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
245 - 253  
210 - 240  
43 - 48  
120 - 127  
106 - 121  
78 - 83  
AMPHENOL AUXILIARY OUTPUT  
42 Volt Auxiliary  
Load Volts  
115 Volt Receptacle2  
Open Circuit  
Voltage  
Open Circuit  
Load Volts  
Voltage  
43 - 50  
40 - 48  
115 - 126  
110 - 126  
FIELD AMPS AND VOLTS  
Slip Ring Volts  
37 - 47 VDC  
Field Amps  
6 - 6.8 Amps DC  
1 OUTPUT CONTROL switch set at MAXIMUM (position 10).  
2 Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.  
RANGER 10-LX  
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G-1  
G-1  
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5  
RF Bypass Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6  
Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7  
RANGER 10LX  
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NOTES  
RANGER 10LX  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
Wiring Diagram Ranger 10LX Code 9816  
3
TURNS  
254A  
CURRENT  
SENSOR  
254  
CB1  
10A  
242A  
#10 WIRE  
L1 (CHOKE)  
210  
(-)  
3
3
222E  
3
6
5
241  
222F  
BLACK  
VM  
(+)  
L2  
210  
240  
75  
COM.  
240  
242  
211  
76  
IDLER  
10  
CONTROL PC  
BOARD  
SOLENOID  
254  
(+)  
11  
PULL  
COIL  
HOLD  
COIL  
241A  
-
1
240A  
9
1
CV OUTPUT  
CONTACTOR  
CV-  
J2  
3
4
CV+  
12  
77  
D1  
R5  
+
B2  
+
+
+
+
DC+  
224B  
2
S1  
MODE  
100  
213  
214  
}
RED  
WHITE  
-
4
8
7
232  
2
25W  
DC-  
AC  
SWITCH  
224F  
224K  
C6  
C8  
C7  
C9  
P7  
J7  
S2  
OUTPUT  
(-)  
+
220  
242B  
235B  
RECTIFIER  
D8  
CR2  
241  
14B  
31,000 MFD CAPACITOR  
W1  
211  
252  
FLASHING  
CURRENT  
242A  
4
8
6
1
2
7
A
ENGINE  
PROTECTION  
RELAY  
200B  
201A  
6
9
4
2C  
2D  
250  
CR1  
J1  
219  
243  
}
7
3
5
253  
B
214  
235  
224  
S2  
E
253  
OUTPUT  
REACTOR  
224B  
CONTROL  
B1  
B3  
S1  
5C  
10K POT  
MAX  
254A  
R1  
75  
5G  
5L  
CLOSED WITH S2, IN  
C1, C2, C3 OR C4  
POSITION.  
CW  
R4  
C1  
R5  
R3  
76D  
-
C2  
21  
77D  
R6  
R2  
R1  
75A  
R7  
C3  
WORK  
ELECTRODE  
C4  
+
GND  
76A  
76  
SELECTOR  
SWITCH  
S2  
S8  
W2  
222  
77  
NO CONTROL  
CABLE SWITCH  
S7  
(SHOWN IN  
ENGINE  
HOUR METER  
224D  
5L  
REMOTE  
SWITCH  
W1  
HIGH IDLE  
SHOWN IN  
NO CABLE  
POSITION  
POSITION)  
BATTERY  
CHARGER  
224E  
244  
76D  
77A  
IDLER  
SWITCH  
S5  
C4  
R
(SHOWN IN  
REMOTE  
POSITION)  
C3  
C2  
"SIG" TERMINAL  
5C  
HIGH  
C1  
224  
3
250  
224F  
226  
CB2  
15A  
FUEL  
SENDER  
243  
FUEL  
3
AUTO  
STATOR  
GAUGE  
6
9
3
7
31  
32  
5
42  
5D  
S
+
236  
235A  
235B  
235  
31A  
31B  
5W  
244  
COMMON GROUND  
SCREW  
5G  
5A  
5B  
5B  
5E  
5E  
5D  
GLOW PLUG  
SWITCH  
GND-E  
GREEN  
S3  
5H  
S6  
224A  
2C  
RUN  
224C  
223  
222A  
224F  
235A  
SWITCH  
222  
224F  
244  
224E  
S4  
GLOW PLUG  
INDICATOR  
IN LINE CONNECTORS  
232  
START  
222C  
OIL  
SWITCH  
WATER  
TEMP.  
PRESSURE  
3
R
J
3D  
(+2)00B  
31A  
32  
R
220  
115AC  
200  
RF BYPASS  
PC BOARD  
A
225  
GND-E  
200A  
230  
9
222B  
115  
V
7
D
C
H
E
4A  
2A  
21  
201A  
220A  
232A  
1
GLOW PLUGS  
75A  
76A  
77A  
2C  
CONTACTOR  
WORK  
J6  
D2  
2
3
4
200  
J3  
OIL PRESSURE  
SWITCH  
WATER  
TEMP.  
SWITCH  
(-)  
C2  
}
5
(+)  
WHITE  
77C  
76C  
6
5U  
GND-D TERM.  
3D  
201  
4A  
5
4
3
2
1
6
7
8
REMOTE  
CONTROL  
3C  
F
FIELD RECTIFIER  
800 MFD  
CAPACITOR  
2A  
222D  
222E  
77C  
219  
75C  
31B  
G
I
222B  
115  
V
76C  
(-)  
J5  
222A  
225  
75C  
POSITIVE  
SLIP RING  
IS NEAREST  
TO THE  
(+)  
42VAC  
J7  
236  
222D  
42  
K
B
}
224A  
"RED" ON  
BRUSH HOLDER  
4C  
STARTER  
GND-A  
224C  
5U  
5N  
GROUND  
SOLENOID  
5J  
WHITE  
TERM.  
LAMINATION  
COIL  
STARTER  
(+)  
(-)  
AMPHENOL  
1
5
2
6
1
3
4
CONTACTOR  
ROTOR FIELD  
234  
GND-C  
77B  
76B  
5H  
A
B
C
GREEN  
B
G
Y
R
U
U
RED  
77B  
NOTE: COMPONENTS SHOWN  
VIEWED FROM REAR  
75B  
1
3
115/230V  
REMOTE  
CONTROL  
J4  
WHITE  
76B  
75B  
2B  
J8  
237  
2B  
4B  
12 VOLT  
REGULATOR  
233  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
ELECTRICAL SYMBOLS PER E1537  
}
BATTERY  
3C  
PULL  
COIL  
HOLD  
COIL  
D
E
F
CONTACTOR  
GROUND  
2
4
CRANK  
MOTOR  
4B  
6
4C  
5N  
L3  
GREEN  
GREEN  
J4  
J1, J5  
J2  
J3  
5K  
5J  
GND-B  
FUEL  
FRAME  
GROUND  
WHITE TERM.  
SHUTDOWN  
SOLENOID  
BLACK  
AMPHENOL  
2
5K  
5E  
ALTERNATOR  
J6  
P6  
GND SCREW AT  
OUTPUT STUDS  
ENGINE  
GROUND  
5H  
N.A. SINCE COMPONENTS OR CIRCUITRY OF  
A
PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
COMMON CODE NUMBER.  
A
COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING  
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.  
RANGER 10LX  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
Wiring Diagram Ranger 10LX CSA Code 9821  
3
TURNS  
254A  
CURRENT  
SENSOR  
254  
CB1  
10A  
242A  
#10 WIRE  
L1 (CHOKE)  
210  
(-)  
3
3
222E  
3
6
5
241  
222F  
BLACK  
VM  
(+)  
L2  
210  
240  
75  
COM.  
240  
242  
211  
76  
IDLER  
10  
CONTROL PC  
BOARD  
SOLENOID  
254  
(+)  
11  
PULL  
COIL  
HOLD  
COIL  
241A  
-
1
240A  
9
1
CV OUTPUT  
CONTACTOR  
CV-  
J2  
3
4
CV+  
77  
12  
D1  
R5  
+
B2  
+
+
+
+
224B  
DC+  
2
S1  
MODE  
100  
213  
214  
}
RED  
WHITE  
-
4
8
7
232  
2
25W  
DC-  
AC  
SWITCH  
224F  
C6  
C8  
C7  
C9  
P7  
J7  
224K  
S2  
OUTPUT  
(-)  
+
220  
242B  
235B  
RECTIFIER  
D8  
CR2  
241  
14B  
31,000 MFD CAPACITOR  
W1  
211  
252  
FLASHING  
CURRENT  
242A  
4
8
6
1
2
A
ENGINE  
PROTECTION  
RELAY  
200B  
201A  
6
9
4
2C  
2D  
250  
CR1  
J1  
219  
243  
7
}
7
3
5
253  
B
214  
235  
224  
S2  
E
253  
OUTPUT  
REACTOR  
224B  
CONTROL  
B1  
B3  
S1  
5C  
10K POT  
MAX  
CW  
254A  
CLOSED WITH S2, IN  
C1, C2, C3 OR C4  
R1  
75  
5G  
5L  
R4  
C1  
R5  
76D  
-
C2  
C3  
R3  
POSITION.  
21  
77D  
R6  
R2  
R1  
75A  
R7  
WORK  
ELECTRODE  
C4  
+
GND  
76A  
SELECTOR  
SWITCH  
S2  
S8  
NO CONTROL  
W2  
222  
77  
76  
S7  
(SHOWN IN  
HIGH IDLE  
POSITION)  
ENGINE  
CABLE SWITCH  
224D  
5L  
REMOTE  
W1  
HOUR METER  
SHOWN IN  
NO CABLE  
POSITION  
SWITCH  
BATTERY  
CHARGER  
224E  
244  
76D  
77A  
IDLER  
SWITCH  
S5  
C4  
R
(SHOWN IN  
REMOTE  
C3  
C2  
"SIG" TERMINAL  
5C  
HIGH  
POSITION)  
3
C1  
224  
250  
224F  
226  
CB2  
15A  
FUEL  
243  
FUEL  
GAUGE  
3
AUTO  
STATOR  
SENDER  
9
6
3
7
31  
32  
5
42  
5D  
S
+
236  
235A  
235B  
235  
31A  
31B  
5W  
244  
COMMON GROUND  
SCREW  
5G  
5A  
5B  
5B  
5E  
5E  
5D  
GLOW PLUG  
SWITCH  
GND-E  
GREEN  
S3  
5H  
S6  
224A  
2C  
RUN  
SWITCH  
224C  
223  
222A  
224F  
224E  
235A  
222  
224F  
244  
S4  
GLOW PLUG  
INDICATOR  
IN LINE CONNECTORS  
232  
START  
15  
222C  
OIL  
PRESSURE  
SWITCH  
8
WATER  
TEMP.  
R
J
(+2)00B  
D2  
31A  
32  
R
220  
115AC  
GND-E  
GND-D  
200  
200A  
RF BYPASS  
PC BOARD  
A
115 V  
225  
230  
9
222B  
7
D
C
H
E
4A  
2A  
21  
201A  
220A  
J6  
232A  
1
GLOW PLUGS  
75A  
76A  
77A  
2C  
8
CONTACTOR  
WORK  
2
3
4
200  
J3  
15  
OIL PRESSURE  
SWITCH  
WATER  
TEMP.  
SWITCH  
5
(-)  
C2  
}
WHITE  
TERM.  
5U  
(+)  
10  
77C  
76C  
201  
13  
6
4A  
5
4
3
2
1
6
7
8
REMOTE  
CONTROL  
F
FIELD RECTIFIER  
800 MFD  
CAPACITOR  
2A  
222D  
222E  
77C  
219  
115  
V
75C  
31B  
G
I
222B  
76C  
(-)  
J5  
3
222A  
225  
75C  
13  
J7  
POSITIVE  
(+)  
42VAC  
236  
222D  
SLIP RING  
IS NEAREST  
TO THE  
42  
K
B
}
224A  
5U  
"RED" ON  
BRUSH HOLDER  
4C  
STARTER  
224C  
GND-A  
GROUND  
SOLENOID  
5J  
WHITE  
TERM.  
LAMINATION  
COIL  
STARTER  
CONTACTOR  
(+)  
(-)  
5N  
AMPHENOL  
1
15A  
15A  
CB3  
10  
5
2
ROTOR FIELD  
234  
CB4  
CB6  
CB8  
GND-C  
77B  
76B  
5H  
A
B
C
B
G
Y
R
U
U
RED  
J8  
77B  
NOTE: COMPONENTS SHOWN  
VIEWED FROM REAR  
75B  
6
1
3
4
1
3
REMOTE  
CONTROL  
115/230V  
J4  
WHITE  
76B  
75B  
2B  
237  
15A  
15A  
2B  
4B  
12 VOLT  
REGULATOR  
233  
CB5  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
ELECTRICAL SYMBOLS PER E1537  
3B  
3B  
}
BATTERY  
PULL  
COIL  
HOLD  
COIL  
D
E
F
11  
12  
CONTACTOR  
GROUND  
2
4
CRANK  
MOTOR  
4B  
50A  
50A  
4C  
L3  
GREEN  
J4  
J1, J5  
J2  
CB7  
3B  
J3  
5K  
5J  
5N  
3B  
GND-B  
FUEL  
GREEN  
FRAME  
GROUND  
SHUTDOWN  
SOLENOID  
BLACK  
WHITE  
TERM.  
AMPHENOL  
2
5K  
5E  
ALTERNATOR  
J6  
P6  
GND SCREW AT  
OUTPUT STUDS  
11  
ENGINE  
GROUND  
5H  
12  
N.A. SINCE COMPONENTS OR CIRCUITRY OF  
A
PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF  
COMMON CODE NUMBER.  
A
COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING  
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.  
RANGER 10LX  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
Control PC Board (G2318) Schematic  
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. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result  
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
RANGER 10LX  
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G-5  
G-5  
ELECTRICAL DIAGRAMS  
Control PC Board (G2318) Layout  
2 3 1 G 8 - 3  
ITEM  
REQ'D.  
PART No.  
IDENTIFICATION  
X
X
X
X
X
X
TP-J  
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
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
TP-A  
5
X
X
X
X
X
X
X
X
RANGER 10 LX  
CONTROL  
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
222  
TP-F  
TP-B  
X
X
X
X
X
X
X
X
X
X
G2318  
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
X
X
X
X
X
X
X
X
X
X
X
X
X
X
TP-C  
1-27-95A  
THIS SHEET CONTAINS PROPRIETARY INFORMATION  
EQUIP.  
ENGINE WELDER  
TYPE  
OWNED BY  
AND IS  
THE LINCOLN ELECTRIC CO.  
NOT TO BE REPRODUCED, DISCLOSED OR USED  
WITHOUT THE EXPRESS PERMISSION OF  
CONTROL P.C. BOARD ASSEMBLY  
SUBJECT  
SCALE  
FULL  
SHT.  
NO.  
THE LINCOLN ELECTRIC CO.  
R.T.  
2-7-94  
JJ  
CHK  
REF.  
2318  
DR  
DATE  
SUP'S'D'G  
G
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. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result  
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
RANGER 10LX  
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G-6  
G-6  
DIAGRAMS  
RF BYPASS BOARD SCHEMATIC  
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. This information is provided for reference only. Lincoln Electric dis-  
courages board level troubleshooting and repair since it may compromise the quality of the design and  
may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in  
damage to the machine.  
RANGER 10LX  
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G-7  
G-7  
DIAGRAMS  
DIMENSION PRINT  
RANGER 10LX  
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SVM ERROR REPORTING FORM  
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 col-  
umn 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.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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