Lincoln Electric Welder SVM168 B User Manual
RETURN TO MAIN MENU  
SVM168-B  
April, 2010  
®
RANGER 10,000 /10,000 PLUS  
For use with machine code numbers: Kohler 11041, 11151, 11394  
Honda 11095, 11398  
Robin/Subaru 11253. 11395  
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  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• 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  
ELECTRIC SHOCK can kill.  
ARC RAYS can burn.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
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.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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 within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical ven-  
tilation. In confined spaces or in some circumstances,  
outdoors, a respirator may be required. Additional pre-  
cautions 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. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of the  
equipment, maintenance of the equipment and the specific  
welding procedure and application involved. Worker expo-  
sure level should be checked upon installation and periodi-  
cally thereafter to be certain it is within applicable OSHA PEL  
and ACGIH TLV limits.  
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. 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 prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. 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.  
5.e. Read and understand the manufacturerʼs instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employerʼs safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
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iii  
iii  
SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can cause fire or  
explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
6.a. Remove fire hazards from the welding area.If  
this is not possible, cover them to prevent the welding sparks  
from starting a fire. Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjcent 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.  
• A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
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.  
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.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the 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.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturerʼs  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturerʼs recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available from  
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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iv  
iv  
SAFETY  
zones où lʼon pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque dʼincendie 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 dʼincendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. Sʼassurer que la masse est connectée le plus prés possible de  
la zone de travail quʼil est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des  
câbles jusquʼà ce quʼils se rompent.  
a. Les circuits à lʼélectrode 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 sʼisoler 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.  
d.Ne jamais plonger le porte-électrode dans lʼeau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode sʼapplicuent aussi au pistolet de  
soudage.  
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  
dʼopérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
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.  
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 nʼimporte quelle partie du  
corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
quʼun verre blanc afin de se protéger les yeux du rayon-  
nement de lʼarc et des projections quand on soude ou  
quand on regarde lʼarc.  
1. Relier à la terre le chassis du poste conformement au code de  
lʼélectricité 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 lʻarc.  
c. Protéger lʼautre personnel travaillant  
à
proximité au  
soudage à lʼaide dʼécrans appropriés et non-inflammables.  
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront  
effectués par un électricien qualifié.  
4. Des gouttes de laitier en fusion sont émises de lʼarc de  
soudage. Se protéger avec des vêtements de protection libres  
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-  
er à lʼinterrupteur à la boite de fusibles.  
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  
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v
RETURN TO MAIN MENU  
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
i-iv  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G  
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-481 Series  
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Section A-1  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation ..............................................................................................................Section A  
Technical Specifications............................................................................................A-2  
Safety Precautions ....................................................................................................A-4  
Machine Grounding...................................................................................................A-4  
Spark Arrestor ...........................................................................................................A-4  
Towing ............. .........................................................................................................A-4  
Pre-Operation Service...............................................................................................A-5  
Fuel ... ..................................................................................................................A-5  
Oil.........................................................................................................................A-5  
Battery Connections............................................................................................A-5  
Welding Output Cables .............................................................................................A-6  
Angle of Operation ....................................................................................................A-6  
High Altitude Operation.............................................................................................A-6  
Location/Ventilation...................................................................................................A-7  
Connection of Wire Feeders .....................................................................................A-7  
Additional Safety Precautions...................................................................................A-7  
Welder Operation ......................................................................................................A-7  
Auxiliary Power..........................................................................................................A-8  
120V Duplex Receptacles.........................................................................................A-8  
Motor Starting ...........................................................................................................A-8  
Electrical Devices used w/RANGER® 10,000 ..........................................................A-9  
Auxiliary Power While Welding................................................................................A-10  
Stand-by Power Connections.................................................................................A-10  
Connection of RANGER® 10,000 to Premises Wiring (Drawing) ...........................A-11  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - RANGER® 10,000 (K1419-4 ), (K2160-3 ) and (K2468-1)  
INPUT - GASOLINE ENGINE  
Description  
Operating  
Speed (RPM)  
Displacement  
cu. in.  
Capacities  
Make/Model  
Starting  
System  
Horsepower  
(cu.cm.)  
38(624)  
Kohler  
Fuel:  
(K1419-4)  
Kohler  
20 HP @  
3600 RPM  
Kohler  
9 Gal (34 L)  
Lubricating Oil:  
2.0 Qts. (1.9 L)  
2 cylinder  
4 Cycle  
CH20S  
12VDC  
Battery  
Air-Cooled  
Gasoline  
High Idle 3700  
Electric Start  
Group 58  
Battery  
Engine.  
(K2160-3)  
(K2160-4)  
Honda  
37.5 (614)  
Honda  
Fuel:  
Aluminum Alloy  
with Cast Iron  
Liners,  
20 HP@  
3600 RPM  
Honda  
Full Load 3500  
Low Idle 2200  
9 Gal (34 L)  
Lubricating Oil  
1.9 Qts. (1.8L)  
(435 cold  
Cranking  
Amps)  
GX620KI  
Electronic  
Ignition  
Fuel:  
20.5 HP@  
3600 RPM  
ROBIN/SUBARU  
(K2468-1)  
Subaru Robin  
EH64  
39.9 (653)  
ROBIN/SUBARU  
12 Gal (45.4 L)  
Lubricating Oil  
1.6 Qts. (1.6L)  
RATED OUTPUT @ 104°F (40°C)- WELDER  
Welding Output  
AC Constant Current 225A / 25V / 100%  
DC Constant Current 210A / 25V / 100%  
DC Constant Voltage 200A / 20V / 100%  
RATED OUTPUT @ 104°F (40°C)- GENERATOR  
1
Auxiliary Power  
9,000 Watts Continuous, 60 Hz AC  
10,000 Watts Peak, 60 Hz AC  
120/240 Volts  
PHYSICAL DIMENSIONS  
WIDTH  
HEIGHT  
DEPTH  
WEIGHT  
30.3 in.  
19.1 in.  
42.0 in.  
502 lbs. (228kg) K1419-4  
505 lbs. (229kg) K2160-3  
528 lbs. (240kg) K2468-1  
770 mm  
485 mm  
1067 mm  
1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.  
When welding available auxiliary power will be reduced.  
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A-3  
A-3  
INSTALLATION  
TECHNICAL SPECIFICATIONS - RANGER 10,000 PLUS (K1419-5 ), (K2468-2)  
INPUT - GASOLINE ENGINE  
Description  
Operating  
Speed (RPM)  
Displacement  
cu. in.  
Capacities  
Make/Model  
Starting  
System  
Horsepower  
(cu.cm.)  
41(674)  
Kohler  
Fuel:  
(K1419-5)  
Kohler  
12VDC  
Battery  
23 HP @  
3600 RPM  
Kohler  
2 cylinder  
4 Cycle  
High Idle 3700  
9 Gal (34 L)  
Lubricating Oil:  
2.0 Qts. (1.9 L)  
CH23S  
Electric Start  
Group 58  
Battery  
Air-Cooled  
Gasoline  
Full Load  
3500  
Engine.  
(435 cold  
Cranking  
Amps)  
Aluminum Alloy  
with Cast Iron  
Liners,  
Fuel:  
(K2468-2)  
Subaru Robin  
EH65  
22 HP@  
39.9 (653)  
SUBARU ROBIN  
9 Gal (34 L)  
Lubricating Oil  
1.6 Qts. (1.6L)  
3600 RPM  
Low Idle 2200  
Electronic  
Ignition  
SUBARU ROBIN  
RATED OUTPUT @ 104°F (40°C)- WELDER  
Welding Output  
AC Constant Current 225A / 25V / 100%  
DC Constant Current 210A / 25V / 100%  
DC Constant Voltage 200A / 20V / 100%  
RATED OUTPUT @ 104°F (40°C)- GENERATOR  
1
Auxiliary Power  
RANGER 10,000 PLUS  
RANGER 10,000  
9,000 Watts Continuous, 60 Hz AC  
10,500 Watts Peak, 60 Hz AC  
120/240 Volts  
9,000 Watts Continuous, 60 Hz AC  
10,000 Watts Peak, 60 Hz AC  
120/240 Volts  
PHYSICAL DIMENSIONS  
WIDTH  
HEIGHT  
DEPTH  
WEIGHT  
30.3 in.  
19.1 in.  
42.0 in.  
502 lbs. (228kg) K1419-5  
770 mm  
485 mm  
1067 mm  
528 lbs. (240kg) K2468-2  
505 lbs. (229kg) K2160-4  
1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.  
When welding available auxiliary power will be reduced.  
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A-4  
A-4  
INSTALLATION  
When this welder is mounted on a truck or trailer, itʼs  
frame must be electrically bonded to the metal frame of  
the vehicle. Use a #8 or larger copper wire connected  
between the machine grounding stud and the frame of  
the vehicle.  
SAFETY PRECAUTIONS  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturer’s  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
Where this engine driven welder is connected to  
premises wiring such as that in your home or shop, itʼs  
frame must be connected to the system earth ground.  
See further connection instructions in the section enti-  
tled “Standby Power Connections”, as well as the arti-  
cle on grounding in the latest National Electrical Code  
and the local code.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into the  
ground for at least ten feet and having no insulated  
joints, or to the metal framework of a building which  
has been effectively grounded. The National Electrical  
Code lists a number of alternate means of grounding  
electrical equipment. A machine grounding stud  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
marked with the symbol  
the welder.  
is provided on the front of  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
SPARK ARRESTER  
• Keep away from moving parts.  
------------------------------------------------------------------------  
Some federal, state, or local laws may require that  
gasoline engines be equipped with exhaust spark  
arresters when they are operated in certain locations  
where unarrested sparks may present a fire hazard.  
The standard muffler included with this welder does not  
qualify as a spark arrester. When required by local reg-  
ulations, the K894-1 spark arrester must be installed  
and properly maintained.  
See additional warning information at  
front of this operator’s manual.  
-----------------------------------------------------------  
MACHINE GROUNDING  
Because this portable engine driven welder or genera-  
tor creates itʼs own power, it is not necessary to con-  
nect itʼs frame to an earth ground, unless the machine  
is connected to premises wiring (your home, shop,  
etc.).  
CAUTION  
An incorrect arrester may lead to damage to the  
engine or adversely affect performance.  
------------------------------------------------------------------------  
TOWING  
WARNING  
The recommended trailer for use with this equipment  
(1)  
To prevent dangerous electric shock, other equip-  
ment to which this engine driven welder supplies  
power must:  
for road, in-plant and yard towing by a vehicle is  
Lincolnʼs K957-1. If the user adapts a non-Lincoln trail-  
er, he must assume responsibility that the method of  
attachment and usage does not result in a safety haz-  
ard nor damage the welding equipment. Some of the  
factors to be considered are as follows:  
• be grounded to the frame of the welder using a  
grounded type plug, or be double insulated.  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
------------------------------------------------------------------------  
1. Design capacity of trailer vs. weight of Lincoln equip-  
ment and likely additional attachments.  
2. Proper support of, and attachment to, the base of  
the welding equipment so there will be no undue  
stress to the framework.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-5  
A-5  
INSTALLATION  
FUEL  
3. Proper placement of the equipment on the trailer to  
insure stability side to side and front to back when  
being moved and when standing by itself while  
being operated or serviced.  
Fill the fuel tank with clean, fresh, lead-free gasoline.  
Observe fuel gauge while filling to prevent overfilling.  
4. Typical conditions of use, i.e., travel speed; rough-  
ness of surface on which the trailer will be operated;  
environmental conditions.  
WARNING  
•
Damage to the fuel tank may cause  
fire or explosion. Do not drill holes  
in or weld to the RANGER® 10,000  
or the RANGER® 10,000 PLUS  
base.  
(1)  
5. Conformance with federal, state and local laws  
(1) Consult applicable federal, state and local laws regarding specif-  
ic requirements for use on public highways.  
VEHICLE MOUNTING  
-----------------------------------------------------------------------  
WARNING  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
OIL  
LUBRICATION SYSTEM CAPACITY  
(INCLUDING FILTER)  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
• Follow vehicle manufacture’s instructions.  
------------------------------------------------------------------------  
Kohler CH20S / CH23S - 2.0 Quarts (1.9 Liters)  
Honda GX620KI - 1.9 Quarts (1.8 Liters)  
Robin Subaru EH64 /EH65 - 1.6 Quarts (1.6 Liters)  
The RANGER® 10,000 and the RANGER® 10,000  
PLUS are shipped with the engine crankcase filled  
with SAE 10W-30 oil. Check the oil level before start-  
ing the engine. If it is not up to the full mark on the dip  
stick, add oil as required. Make certain that the oil filler  
cap is tightened securely. Refer to the engine Ownerʼs  
Manual for specific oil recommendations.  
PRE-OPERATION SERVICE  
CAUTION  
CAUTION  
BATTERY CONNECTIONS  
READ the engine operating and maintenance  
instructions supplied with this machine.  
Use caution as the electrolyte is a strong  
acid that can burn skin and damage eyes.  
-----------------------------------------------------------------------  
WARNING  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away  
from tank.  
• Do not leave unattended while  
fueling.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
engine.  
This welder is shipped with the negative battery cable  
disconnected. Make sure that the Engine Switch is in  
the “STOP” position and attach the disconnected  
cable securely to the negative battery terminal before  
attempting to operate the machine. If the battery is dis-  
charged and does not have enough power to start the  
engine, see the battery charging instructions in the  
Battery section.  
GASOLINE  
can cause fire  
or explosion.  
NOTE: This machine is furnished with a wet charged  
battery; if unused for several months, the battery may  
require a booster charge. Be careful to charge the bat-  
tery with the correct polarity.  
• Do not overfill tank, fuel expan-  
sion may cause overflow.  
GASOLINE FUEL ONLY  
------------------------------------------------------------------------  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-6  
A-6  
INSTALLATION  
WELDING OUTPUT CABLES  
WARNING  
• Lift only with equipment of ade-  
quate lifting capacity.  
With the engine off, connect the electrode and work  
cables to the studs provided. These connections  
should be checked periodically and tightened if neces-  
sary. Loose connections will result in overheating of the  
output studs.  
• Be sure machine is stable when  
lifting.  
• Do not lift this machine using  
lift bale if it is equipped with a  
heavy accessory such as trailer  
or gas cylinder.  
When welding at a considerable distance from the  
welder, be sure you use ample size welding cables.  
Listed below are copper cable sizes recommended for  
the rated current and duty cycle. Lengths stipulated are  
the distance from the welder to work and back to the  
welder again. Cable sizes are increased for greater  
lengths primarily for the purpose of minimizing cable  
voltage drop.  
FALLING  
• Do not lift machine if lift bale is  
damaged.  
EQUIPMENT can  
cause injury.  
• Do not operate machine while  
suspended from lift bale.  
------------------------------------------------------------------------  
HIGH ALTITUDE OPERATION  
At higher altitudes, Welder output de-rating may be neces-  
sary.  
TOTAL COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
Kohler and Subaru Robin Models:  
225 Amps  
100% Duty Cycle  
For maximum rating, de-rate the welder output 3.5% for  
every 1000ft. (305m) above 3000ft. (914m).  
0-100 Ft.  
1 AWG  
1 AWG  
Honda Model:  
For maximum rating, de-rate the welder output 3.5% for  
every 1000ft. (305m) above sea level.  
100-200 Ft.  
200-250 Ft.  
1/0 AWG  
If operation will consistently be at altitudes above 5,000 ft.  
(1525m), a carburetor jet designed for high altitudes should  
be installed. This will result in better fuel economy, cleaner  
exhaust and longer spark plug life. It will not give increased  
power. Contact your local authorized engine service shop for  
high altitude jet kits that are available from the engine manu-  
facturer.  
ANGLE OF OPERATION  
Internal combustion engines are designed to run in a  
level condition which is where the optimum perfor-  
mance is achieved. The maximum angle of operation  
for the engine is 15 degrees from horizontal in any  
direction. If the engine is to be operated at an angle,  
provisions must be made for checking and maintaining  
the oil at the normal (FULL) oil capacity in the  
crankcase in a level condition.  
CAUTION  
Do not operate with a high altitude jet installed at alti-  
tudes below 5000 ft. This will result in the engine running  
too lean and result in higher engine operating tempera-  
tures which can shorten engine life.  
--------------------------------------------------------------------------------  
Muffler Relocation  
When operating at an angle, the effective fuel capacity  
will be slightly less than the specified 9 gallons.  
LIFTING  
WARNING  
The RANGER® 10,000 and the RANGRER 10,000  
PLUS weigh approximately 575 lbs. with a full tank of  
gasoline. A lift bail is mounted to the machine and  
should always be used when lifting the machine.  
•
Shut off welder and allow muffler to cool before touch-  
ing muffler.  
--------------------------------------------------------------------------------  
The RANGER® 10,000 PLUS AND RANGER® 10,000 are  
shipped with the exhaust coming out on the left side. The  
exhaust can be changed to the opposite side by removing  
the two screws that hold the exhaust port cover in place and  
installing the cover on the opposite side. (Operating the  
RANGER® 10,000 PLUS AND RANGER® 10,000 without  
the cover in place will result in a higher noise level and no  
increase in machine output.)  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-7  
A-7  
INSTALLATION  
d. Position the “RANGE” switch to the “WIRE FEED”  
position.  
LOCATION / VENTILATION  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid heated air coming out of the welder recirculating  
back to the cooling air inlet. Also, locate the welder so  
that engine exhaust fumes are properly vented to an  
outside area.  
e. Attach the single lead from the LN-25 control box  
to the work using the spring clip on the end of the  
lead - it carries no welding current.  
f. Place the engine switch in the “AUTO” position.  
g. Adjust wire feed speed at the LN-25 and adjust the  
welding voltage with the output “CONTROL” at the  
welder.  
STACKING  
NOTE: The welding electrode is energized at all times,  
unless an LN-25 with built-in contactor is used.  
If the output “CONTROL” is set below “3”, the  
LN-25 contactor may not pull in.  
RANGER® 10,000 machines cannot be stacked.  
CONNECTION OF LINCOLN ELECTRIC  
WIRE FEEDERS  
CONNECTION OF K930-2 TIG MODULE TO THE  
RANGER® 10,000 OR RANGER® 10,000 PLUS.  
WARNING  
The TIG Module is an accessory that provides high  
frequency and shielding gas control for AC and DC  
GTAW (TIG) welding. See IM528 supplied with the  
TIG Module for installation instructions.  
Shut off welder before making any electrical  
connections.  
------------------------------------------------------------------------  
WIRE FEED (CONSTANT VOLTAGE)  
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE  
FEEDER  
NOTE: The TIG Module does not require the use of a  
high frequency bypass capacitor. However, if  
any other high frequency equipment is used, a  
Bypass Capacitor Kit (T12246) must be  
installed in the RANGER® 10,000.  
The LN-15 has an internal contactor and the electrode  
is not energized until the gun trigger is closed. When  
the gun trigger is closed the wire will begin to feed and  
the welding process is started.  
.
INSTRUCTIONS  
a. Shut the welder off.  
ADDITIONAL SAFETY PRECAUTIONS  
b. Connect the electrode cable from the LN-15 to  
the“ELECTRODE” terminal of the welder. Connect  
the work cable to the “TO WORK” terminal of the  
welder.  
Always operate the welder with the roof and case sides  
in place as this provides maximum protection from  
moving parts and assures proper cooling air flow.  
c. Set the Polarity switch to the desired polarity, either  
DC (-) or DC (+).  
Read and understand all Safety Precautions before  
operating this machine. Always follow these and any  
other safety procedures included in this manual and in  
the Engine Ownerʼs Manual.  
d. Attach the single lead from the front of the LN-15  
to work using the spring clip at the end of the lead.  
This is a control lead to supply current to the wire  
feeder motor; it does not carry welding current.  
e. Set the “RANGE” switch to the “WIRE FEED-CV”  
position  
WELDER OPERATION  
f. Place the Engine switch in the “High Idle” position.  
g. Adjust the wire feed speed at the LN-15 and adjust  
the welding voltage with the output “CONTROL” at  
the welder. Output “CONTROL” must be set above 3.  
Note: LN-15 Control Cable model will not work with  
the RANGER® 10,000.  
WELDER OUTPUT  
• Maximum Open Circuit Voltage at 3700 RPM is  
80 Volts RMS.  
• Duty Cycle is the percentage of time the load is  
being applied in a 10 minute period. For example, a  
60% duty cycle represents 6 minutes of load and 4  
minutes of no load in a 10 minute period. Duty Cycle  
for the RANGER® 10,000 is 100%.  
CONNECTION OF THE LN-25  
a. Shut the welder off.  
b. 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.  
RANGER® 10,000 and RANGER® 10,000 PLUS  
Constant Current  
225 Amps AC @ 25 Volts  
210 Amps DC @ 25 Volts  
c. Position the welder “Polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
Constant Voltage  
200 Amps DC @ 20 Volts  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-8  
A-8  
INSTALLATION  
GND  
AUXILIARY POWER  
The RANGER® 10,000 can provide up to 9,000 watts  
of 120/240 volts AC, single phase 60Hz power for con-  
tinuous use, and up to 10,000 watts of 120/240 volts  
AC, single phase 60Hz power peak use.  
The RANGER® 10,000 PLUS can provide up to 9,000  
watts of 120/240 volts AC, single phase 60Hz power  
for continuous use, and up to 10,500 watts of 120/240  
volts AC, single phase 60Hz power peak use.  
120 V  
240 V  
120 V*  
The front of the machine includes three receptacles for  
connecting the AC power plugs; one 50 amp 120/240  
volt NEMA 14-50R receptacle and two 20 amp 120 volt  
NEMA 5-20R receptacles. Output voltage is within +/-  
10% at all loads up to rated capacity.  
*Current Sensing for Automatic Idle.  
(Receptacle viewed from front of Machine)  
120 V DUPLEX RECEPTACLES  
The 120V auxiliary power receptacles should only be  
used with three wire grounded type plugs or approved  
double insulated tools with two wire plugs.  
CAUTION  
Do not connect any plugs that connect to the  
power receptacles in parallel.  
------------------------------------------------------------------------  
The current rating of any plug used with the system  
must be at least equal to the current load through the  
associated receptacle.  
Start the engine and set the “IDLER” control switch to  
the desired operating mode. Set the “CONTROL” to  
10. Voltage is now correct at the receptacles for auxil-  
iary power.  
MOTOR STARTING  
Most 1.5 hp AC single phase motors can be started if  
there is no load on the motor or other load connected  
to the machine, since the full load current rating of a  
1.5 hp motor is approximately 20 amperes (10  
amperes for 240 volt motors). The motor may be run at  
full load when plugged into only one side of the duplex  
receptacle. Larger motors through 2 hp can be run pro-  
vided the receptacle rating as previously stated is not  
exceeded. This may necessitate 240V operation only.  
120/240 VOLT DUAL VOLTAGE RECEPTACLE  
The 120/240 volt receptacle can supply up to 38 amps  
of 240 volt power to a two wire circuit, up to 38 amps  
of 120 volts power from each side of a three wire cir-  
cuit (up to 76 amps total). Do not connect the 120 volt  
circuits in parallel. Current sensing for the automatic  
idle feature is only in one leg of the three wire circuit as  
shown in the following column.  
RANGER® 10,000 Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Voltage  
Volts  
120  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
Current  
(Amps)  
15  
Load  
(Watts)  
1800  
2400  
3600  
4800  
9000  
14 AWG  
12 AWG  
10 AWG  
8 AWG  
6 AWG  
4 AWG  
30  
60  
(9)  
40  
(12)  
(9)  
75  
(23)  
(15)  
(46)  
(30)  
(15)  
125  
(38)  
(27)  
(69)  
(53)  
(27)  
175  
(53)  
(42)  
(107)  
(84)  
(46)  
300  
(91)  
(69)  
120  
20  
30  
75  
60  
50  
150  
100  
50  
88  
225  
175  
90  
138  
350  
275  
150  
225  
600  
450  
225  
240  
15  
(18)  
(23)  
(18)  
(183)  
(137)  
(69)  
240  
20  
240  
38  
Conductor size is based on maximum 2.0% voltage drop.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-9  
A-9  
INSTALLATION  
TABLE lll  
ELECTRICAL DEVICE USE WITH THE RANGER® 10,000 or RANGER® 10,000 PLUS.  
Type  
Common Electrical Devices  
Possible Concerns  
Resistive  
Heaters, toasters, incandescent  
light bulbs, electric range, hot  
pan, skillet, coffee maker.  
NONE  
Capacitive  
TV sets, radios, microwaves,  
appliances with electrical control.  
Voltage spikes or high voltage  
regulation can cause the capac-  
itative elements to fail. Surge  
protection, transient protection,  
and additional loading is recom-  
mended for 100% fail-safe  
operation. DO NOT RUN  
THESE DEVICES WITHOUT  
ADDITIONAL RESISTIVE  
TYPE LOADS.  
Inductive  
Single-phase induction motors,  
drills, well pumps, grinders, small  
refrigerators, weed and hedge  
trimmers  
These devices require large  
current inrush for starting.  
Some synchronous motors may  
be frequency sensitive to attain  
maximum output torque, but  
they SHOULD BE SAFE from  
any frequency induced failures.  
Capacitive/Inductive  
Computers, high resolution TV sets,  
complicated electrical equipment.  
An inductive type line condition-  
er along with transient and  
surge protection is required,  
and liabilities still exist. DO  
NOT USE THESE DEVICES  
WITH A RANGER® 10,000  
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-  
ed to the RANGER® 10,000 or RANGER® 10,000 PLUS.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-10  
A-10  
INSTALLATION  
1. Install a double pole, double throw switch between  
the power company meter and the premises  
disconnect.  
AUXILIARY POWER WHILE WELDING  
Simultaneous welding and power loads are permitted  
by following Table I. The permissible currents shown  
assume that current is being drawn from either the  
120V or 240V supply (not both at the same time). Also,  
the “Output Control” is set at “10” for maximum auxil-  
iary power.  
Switch rating must be the same or greater than  
the customerʼs premises disconnect and service  
overcurrent protection.  
2. Take necessary steps to assure load is limited to  
the capacity of the RANGER® 10,000 by installing  
a 40 Amp 240V double pole circuit breaker.  
TABLE I  
SIMULTANEOUS WELDING AND POWER  
Maximum rated load for the 240V auxiliary is 38  
amperes. Loading above 38 amperes will reduce  
output voltage below the allowable -10% of rated  
voltage which may damage appliances or other  
motor-driven equipment.  
Output Selector  
Setting  
Permissible Power  
Watts (Unity Power  
Factor)  
Permissible Auxiliary  
Current in Amperes  
@ 120V *-or- @ 240V  
Max. Stick or Wire  
Feed Setting  
None  
3450  
0
0
3. Install a 50 amp 120/240V plug (NEMA type 14-50)  
to the Double Pole Circuit Breaker using a 4 con  
ductor cable that is properly sized for the ampacity  
and length to be used.  
145 Stick Setting  
90 Stick Setting  
NO WELDING  
32  
16  
6000  
9000  
50**  
76**  
25  
38  
(The 50amp 120/240V plug is available in the  
optional plug kit.)  
* Each duplex receptacle is limited to 20 amps.  
4. Plug this cable into the 50 amp 120/240V  
receptacle on the RANGER® 10,000 case front.  
** Not to exceed 40A per 120VAC branch circuit  
when splitting the 240 VAC output.  
STANDBY POWER CONNECTIONS  
The RANGER® 10,000 or RANGER® 10,000 PLUS is  
suitable for temporary, standby, or emergency power  
using the engine manufacturerʼs recommended mainte-  
nance schedule.  
The RANGER® 10,000 or RANGER® 10,000 PLUS  
can be permanently installed as a standby power unit  
for 240V-3 wire, single phase 38 ampere service.  
WARNING  
Connections must be made by a licensed electri-  
cian who can determine how the 120/240V power  
can be adapted to the particular installation and  
comply with all applicable electrical codes. The fol-  
lowing information can be used as a guide by the  
electrician for most applications. (Refer to the con-  
nection diagram shown in Figure A.1.)  
-------------------------------------------------------------------------  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-11  
A-11  
INSTALLATION  
Figure A.1  
CONNECTION OF RANGER® 10,000 OR RANGER® 10,000 PLUS TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
240 Volt  
60 Hz.  
3-Wire  
Service  
120 VOLT  
COMPANY  
METER  
120 VOLT  
NEUTRAL  
BUS  
N
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  
GROUND  
40 AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
4 CONDUCTOR COPPER CABLE  
SEE NATIONAL ELECTRICAL CODE  
FOR WIRE RECOMMENDATIONS.  
WARNING  
Connection of RANGER® 10,000 to premises  
wiring must be done by a licensed electrician and  
must comply with the National Electrical Code and  
all other applicable electrical codes.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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A-12  
A-12  
NOTES  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation ................................................................................................................Section B  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Engine Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3  
Controls Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3  
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3  
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Welding Process (Stick/Tig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5  
Summary of Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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B-2  
OPERATION  
B-2  
SAFETY PRECAUTIONS  
WELDER CONTROLS - FUNCTION AND  
OPERATION  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturer’s  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
ENGINE SWITCH  
The engine switch is used to Start the Engine, Select  
High Idle or Auto Idle while the engine is running, and  
stop the Engine.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
When placed in the “OFF”  
position, the ignition  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
circuit is de-energized to shut down the engine.  
When held in the “START”  
starter motor is energized.  
position, the engine  
) position, the engine will  
• Always wear dry insulating gloves.  
When in “HIGH IDLE” (  
• Always operate the welder with the hinged door  
closed and the side panels in place.  
run continuously at high speed.  
When in “AUTO IDLE” (  
/
) position, the  
• Read carefully the Safety Precautions page  
before operating this machine. Always follow  
these and any other safety procedures included  
in this manual and in the Engine Instruction  
Manual.  
engine will run continuously and the idler operates as  
follows:  
•
Welding  
------------------------------------------------------------------------  
When the electrode touches the work, the welding  
arc is initiated and the engine accelerates to full  
speed.  
GENERAL DESCRIPTION  
The RANGER®™10,000 and RANGER® 10,000 PLUS  
are twin-cylinder, gasoline driven, multi-process arc  
welders and AC power generators. They are built with  
a heavy gauge steel case for durability on the job site.  
After welding ceases (and no auxiliary power is  
being drawn), the engine will return to low idle  
after approximately 10 to 14 seconds.  
•
Auxiliary Power  
With the engine running at low idle and auxiliary  
power for lights or tools is drawn (approximately  
100-150 watts or greater) from the receptacles,  
the engine will accelerate to high speed. If no  
power is being drawn from the receptacles (and  
not welding) for 10-14 seconds, the idler reduces  
the engine speed to low idle.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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B-3  
B-3  
OPERATION  
“
RANGE” SWITCH  
The “Range” switch is used to select one of three  
amperage ranges with generous overlap for Stick/TIG  
welding, or one Wire Feed welding range.  
Process  
Range Setting  
Current Range  
STICK/TIG  
90 Max.  
145 Max.  
40 to 90 Amps  
70 to 145 Amps  
(constant current)  
(3 range settings)  
210DC/225AC Max.  
120 to 210 (DC) 225(AC)  
WIRE FEED  
(constant voltage)  
(one range setting)  
15 to 25V  
Up to 200 Amps  
CAUTION  
Never change the “RANGE” Switch setting while  
welding. This will damage the switch.  
------------------------------------------------------------------------  
“
CONTROL” DIAL  
Provides a fine welding current adjustment within the  
Range Switch settings in the STICK mode and welding  
voltage control with the Range switch set in the wire  
feed mode.  
POLARITY SWITCH  
Provides three selectable welding polarities: AC, DC+ & DC- .  
CAUTION  
Never change the Polarity switch setting while welding.  
This will damage the switch.  
-------------------------------------------------------------------------------------------------------------------  
RANGER® 10,000 AND RANGER® 10,000 PLUS APPROXIMATE FUEL CONSUMPTION  
KOHLER  
20 H.P. COMMAND  
23 HP CH23S  
HONDA  
20 H.P. GX620KI  
ROBIN / SUBARU  
20.5 H.P. P220  
22.5 HP EH665  
Low Idle - No Load  
2200 RPM  
.4 Gallons/Hour  
(1.5 Liters/Hour)  
.7 Gallons/Hour  
(2.8 Liters/Hour)  
1.2 Gallons/Hour  
(4.6 Liters/Hour)  
1.3 Gallons/Hour  
(4.9 Liters/Hour)  
1.2 Gallons/Hour  
(4.5 Liters/Hour)  
1.4 Gallons/Hour)  
(5.3 Liters/Hour)  
.3 Gallons/Hour  
(1.3 Liters/Hour)  
.7 Gallons/Hour  
(2.8 Liters/Hour)  
1.3 Gallons/Hour  
(5 Liters/Hour)  
.6 Gallons/Hour  
(2.3 Liters/Hour)  
.8 Gallons/Hour  
(3.0 Liters/Hour)  
1.5 Gallons/Hour  
(5.8 Liters/Hour)  
1.6 Gallons/Hour  
(6.1 Liters/Hour)  
1.2 Gallons/Hour  
(4.5 Liters/Hour)  
1.6 Gallons/Hour)  
(6.1 Liters/Hour)  
High Idle - No Load  
3700 RPM  
AC CC Weld Output  
225 Amps @ 25 Volts  
DC CC Weld Output  
210 Amps @ 25 Volts  
DC CV Weld Output  
200 Amps @ 20 Volts  
Auxiliary Power  
1.5 Gallons/Hour  
(5.9 Liters/Hour)  
1.2 Gallons/Hour  
(4.5 Liters/Hour)  
1.7 Gallons/Hour)  
(6.5 Liters/Hour)  
9000 Watts  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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B-4  
B-4  
OPERATION  
STOPPING THE ENGINE  
STARTING/SHUTDOWN INSTRUCTIONS  
STARTING THE ENGINE  
Remove all welding and auxiliary power loads and  
allow engine to run at low idle speed for a few minutes  
to cool the engine.  
WARNING  
• Do not touch electrically live parts  
of electrode with skin or wet  
clothing.  
Stop the engine by placing the Engine switch in the  
“OFF”  
position.  
A fuel shut off valve is not required on the RANGER®  
10,000 because the fuel tank is mounted below the  
engine.  
• Keep flammable material away.  
BREAK-IN PERIOD  
• Insulate yourself from work and  
ground. Wear eye, ear, and body  
protection.  
It is normal for any engine to use a greater amount of  
oil until the break-in is accomplished. Check the oil  
level twice a day during the break-in period (approxi-  
mately 50 running hours).  
• Keep your head out of the fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
IMPORTANT: IN ORDER TO ACCOMPLISH THIS  
BREAK-IN, THE UNIT SHOULD BE  
SUBJECTED TO MODERATE  
Be sure all Pre-Operation Maintenance has been per-  
formed. Also, read the Engine Ownerʼs Manual before  
starting for the first time.  
LOADS, WITHIN THE RATING OF  
THE MACHINE. AVOID LONG IDLE  
RUNNING PERIODS. REMOVE  
LOADS AND ALLOW ENGINE TO  
COOL BEFORE SHUTDOWN.  
Remove all loads connected to the AC power recepta-  
cles. Use the choke control as follows:  
The engine manufacturerʼs recommendation for the  
running time until the first oil change is as follows:  
KOHLER ENGINE - Always pull the choke control out  
when starting the engine; cold, warm or hot.  
HONDA ENGINE - If the engine is cold, pull the choke  
control out. Do Not use the choke if the engine is warm  
or hot.  
KOHLER  
HONDA  
ROBIN/SUBARU  
5 HRS.  
First Month  
or 20 HRS.  
25 HRS.  
Turn the engine switch to the “start”  
position and  
crank the engine until it starts. Release the switch as  
soon as the engine starts, slowly return the choke  
The oil filter is to be changed at every second oil  
change. Refer to the Engine Ownerʼs Manual for more  
information.  
control to the full “in” position (choke open),  
and turn  
the switch to the Auto Idle position.  
/
Do not turn the switch to the “start” position while the  
engine is running because this will cause damage to  
the ring gear and/or starter motor.  
After running at high engine speed for 10-14 seconds,  
the engine will go to low idle.  
Allow the engine to warm up by letting it run at low idle  
for a few minutes.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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B-5  
B-5  
OPERATION  
SETTINGS FOR 1% THORIATED TUNGSTEN  
WELDING PROCESS  
For any electrodes the procedures should be kept with-  
in the rating of the machine. For electrode information  
see the appropriate Lincoln publication.  
TUNGSTEN  
DIAMETER (in.)  
RANGE SWITCH  
SETTINGS  
APPROXIMATE  
CURRENT RANGE  
1/8  
3/32  
1/16  
90, 145, or 210  
90 or 145  
90 or 145  
80 - 225 Amps  
50 - 180 Amps  
45 - 120 Amps  
STICK (CONSTANT CURRENT) WELDING  
The K930-[ ] TIG Module should be used with the  
RANGER® 10,000 on high idle to maintain satisfactory  
operation. It can be used in the AUTO position but the  
delay going to low idle after welding is ceased will be  
increased if the AFTER FLOW CONTROL is set above 10  
seconds.  
Connect welding cables to the "TO WORK” and  
"ELECTRODE” studs. Start the engine. Set the  
"Polarity” switch to the desired polarity. The “RANGE”  
switch markings indicate the maximum current for that  
range as well as the typical electrode size for that  
range. The “OUTPUT” Control provides fine adjust-  
ment of the welding current within the select range. For  
maximum output within a selected range set the “OUT-  
PUT” Control at 10. For minimum output within a  
selected range set the “OUTPUT” Control at 5. (“OUT-  
PUT” Control settings below 5 may reduce arc stabili-  
ty) For best overall welding performance set the  
“RANGE” Switch to the lowest setting and the OUT-  
PUT” Control near the maximum to achieve the  
desired welding current.  
NOTE: For AC TIG Welding, the maximum TIG welding  
output currents on each range setting will be approxi-  
mately 50% higher than those marked on the nameplate.  
This is due to the special nature of the AC TIG welding  
arc. Do not AC TIG weld on the 225AC range setting. The  
output current may exceed the rating of the RANGER®  
10,000.  
WIRE FEED WELDING PROCESSES  
(CONSTANT VOLTAGE)  
TYPICAL  
ELECTRODE SIZE  
The Innershield® electrode recommended for use with  
the RANGER® 10,000 is NR®-211-MP. The electrode  
sizes and welding ranges that can be used with the  
RANGER® 10,000 are shown in the following table:  
RANGE SETTING  
90 MAX.  
CURRENT RANGE  
40 TO 90 AMPS  
70 TO 145 AMPS  
3/32  
1/8  
145 MAX.  
Diameter  
(in.)  
Wire Speed  
Range In./Min. Current Range  
Approximate  
5/32  
210(DC)/225(AC)  
MAX.  
120 TO 210(DC),  
225(AC) AMPS  
.035  
.045  
.068  
80 - 110  
70 - 130  
40 - 90  
75A to 120A  
120A to 170A  
125A to 210A  
The RANGER® 10,000 can be used with a broad  
range of AC and DC stick electrodes. See “Welding  
Tips 1” included with the RANGER® 10,000 for elec-  
trodes within the rating of this unit and recommended  
welding currents of each.  
The RANGER® 10,000 is recommended for limited “MIG”  
welding (GMAW - gas metal arc welding). The recom-  
mended electrodes are .030” and .035” L-50 and L-56.  
They must be used with a blended shielding gas such as  
C25 (75% Argon - 25% CO2). The welding ranges that  
TIG (CONSTANT CURRENT) WELDING  
The K930-[ ] TIG Module installed on a RANGER®  
10,000 provides high frequency and shielding gas con-  
trol for AC and DC GTAW (TIG) welding processes.  
Output control is from the RANGER® 10,000. The out-  
put control on the TIG Module is not functional. After  
flow time is adjustable from 0 to 55 seconds.  
can be used with the RANGER® 10,000 are shown in the  
following table:  
Diameter  
(in.)  
Wire Speed  
Range In./Min.  
Approximate  
Current Range  
When using the RANGER® 10,000 for AC TIG welding  
of aluminum, the following settings and electrodes are  
recommended:  
.030  
.035  
75 - 300  
50A to 130A  
90A to 175A  
100 - 250  
ARC GOUGING  
SETTINGS FOR PURE TUNGSTEN  
The RANGER® 10,000 can be used for limited arc goug-  
ing. Set the Range switch to adjust output current to the  
desired level for the gouging electrode being used  
according to the ratings in the following table:  
TUNGSTEN  
DIAMETER (in.)  
RANGE SWITCH  
SETTINGS  
APPROXIMATE  
\CURRENT RANGE  
1/8  
3/32  
1/16  
90 or 145  
90 or 145  
90  
80 - 150 Amps  
45 - 130 Amps  
40 - 80 Amps  
ELECTRODE SETTING  
CURRENT RANGE (DC, electrode positive)  
1/8  
5/32  
3/16  
30  
90  
150  
-
-
-
60 Amps  
150 Amps  
250 Amps  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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B-6  
B-6  
OPERATION  
Summary of Welding Processes  
CONTROL  
ELECTRODE  
PROCESS  
CABLE  
USED  
IDLE  
MODE  
WHEN NOT  
WELDING  
TO START  
WELDING  
STICK  
No  
No  
AUTO  
AUTO  
Hot  
Touch electrode to work.  
Welding starts immediately  
and engine goes to high  
idle.  
WIRE FEED, LN-25 WITH  
INTERNAL CONTACTOR  
Cold  
Press gun trigger, LN-25  
contactor closes. Welding  
starts immediately and  
engine goes to high idle.  
NOTE: Output Control  
must be set above “3”  
TIG, TIG MODULE WITH  
WITH CONTACTOR KIT  
CONTROL CABLE, & ARC  
START SWITCH  
Yes  
No  
High  
High  
Cold  
Cold  
Press Arc Start Switch  
contactor closes,  
welding starts immediately.  
WIRE FEED, LN-15  
ACROSS the ARC  
Press gun trigger.  
LN-15 contactor closes,  
Welding starts immediately  
Note: Output Control must  
be set above “3”.  
(has internal contactor)  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES SECTION -  
Accessories............................................................................................................Section C  
Optional Equipment ..................................................................................................C-2  
Recommended Equipment.......................................................................................C-3  
Stick...................................................................................................................C-3  
Wirefeed.............................................................................................................C-3  
TIG .....................................................................................................................C-3  
Plasma Cutting ..................................................................................................C-3  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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C-2  
C-2  
ACCESSORIES  
K802-R Power Plug Kit- provides four 120V plugs  
rated at 15 amps each and one dual voltage, Full KVA  
plug rated at 120/240V, 50 amps.  
OPTIONAL EQUIPMENT (Field Installed)  
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR  
SMALL WELDERS - For road, off-road and in-plant  
and yard towing. (For highway use, consult applicable  
federal, state and local laws regarding requirements for  
brakes, lights, fenders, etc.)  
K802-N Power Plug Kit - Provides four 120V plugs  
rated at 20 amps each and one dual voltage, full KVA  
plug rated at 120/240V, 50 amps.  
Order K957-1 Trailer  
K894-1 Spark Arrester Kit - Includes a heavy gauge  
steel, approved spark arrester and clamp for easy  
mounting to muffler exhaust pipe.  
K958-1 Ball Hitch  
K958-2 Lunette Eye Hitch  
K959-2 Fender & Light Kit  
K965-1 Cable Storage Rack  
K1690-1 GFCI RECEPTACLE KIT - Includes one UL  
approved120V ground fault circuit interrupter duplex type  
receptacle with cover and installation instructions.  
Replaces the factory installed 120V duplex receptacle.  
Each receptacle of the GFCI Duplex is rated at 20 Amps,  
the maximum total current from the GFCI Duplex is limit-  
ed to the 20 Amps. Two kits are required.  
K889-2 & -3 Two-Wheel Undercarriage - For moving  
by hand. Overall Width 29 in (.74m) Both have pneu-  
matic tires. Puncture proof tires included with K889-3.  
K1631-1 Puncture Proof Wheel Kit - For converting  
K889-2 or K933-1 to puncture proof pneumatic tires.  
K1816-1 FULL KVA ADAPTER KIT - Plugs into the  
120/240V NEMA 14-50R receptacle on the case front  
(which accepts 4-prong plugs) and converts it to a  
NEMA 6-50R receptacle, (which accepts 3-prong  
plugs.)  
K893-1 Caster for Undercarriage - Mounts to the  
front of the K889-2 or 3 to allow easy movement on  
smooth surfaces. Includes 6” diameter hard rubber  
wheel and convenient toe-on, toe-off locking brake.  
K933-1 Four Wheel Undercarriage - For Hand  
T12153-9 Full-KVA Power Plug - One dual voltage plug  
Moving. Rear pneumatic tires, front molded wheels.  
rated at 120/240V, 50 amps.  
K934-1 Cylinder Brackets - For use with K933-1. For  
K930-2 TIG Module - Provides high frequency and  
shielding gas control.for AC and DC GTAW (TIG) weld-  
ing applications. Its compact case is designed foe easy  
carrying, complete with a handle. High frequency  
bypass is built in  
transporting one welding gas cylinder.  
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR-  
RIAGE - For moving by hand at construction sites.  
Heavy duty puncture resistant pneumatic tires.  
Requires K938-1 Contactor Kit, K936-4 Control Cable,  
and K814 Arc Start Switch.  
K1770-1 UNDERCARRIAGE (FACTORY) - For mov-  
ing by hand on a smooth surface. One or two gas cylin-  
ders can be mounted on the rear of the undercarriage  
with the installation of K1745-1 Cylinder Holder(s).  
Heavy duty puncture resistant pneumatic tires and  
front caster.  
K938-1 Contactor Kit - For use with TIG Module,  
Provides a “cold” electrode until the triggering device  
(Arc Start Switch) is pressed.  
K936-4 Control Cable - Connects TIG Module to  
RANGER® 10,000.  
K1745-1 GAS CYLINDER HOLDER  
Holds Welding Gas Cylinder for use on K1770-1  
Undercarriage. One or two may be installed on an  
undercarriage.  
K814 Arc Start Switch - Attaches to the TIG torch for  
convenient finger control.  
K937-45 Control Cable Extension - Allows TIG Module  
to be operated at distances up to 200ft. from the power  
source. Available in 45ft. (13.7m).  
K1788-1 ROLL CAGE - Gives added damage protec-  
tion. Attaches to K1737-1, K1770-1, and K957-1.  
K886-1 Canvas Cover -To protect the RANGER®  
10,000 when not in use. Made from attractive red can-  
vas material which is flame retardant, mildew resistant,  
and water repellent.  
K844-1 Water Valve Kit - For use with water cooled  
TIG torch, Installs inside of TIG Module.  
K939-1 Docking Kit - For Mounting the K930-2 TIG  
Module on top of the RANGER® 10,000.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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C-3  
C-3  
ACCESSORIES  
PLASMA CUTTING:  
RECOMMENDED EQUIPMENT  
K1580-1- Pro-Cut 55 (Requires full KVA Adapter  
STICK  
K1816-1).  
K704 Accessory Kit - For Stick Welding. Includes 35 ft (10.7m).  
• 2/0 AWG electrode cable, 30 ft. (9.1m)  
• 2/0 AWG work cable with lugs, headshield, filter plate, work  
clamp, and electrode holder. 400 amp capacity.  
K875 Accessory Kit - For stick welding. Includes 20 Ft. (6.1m).  
#6 electrode cable with lug, 15 Ft. (4.6m) #6 work cable with  
lugs, headshield, filter plate, work clamp, and electrode holder  
and sample pack of mild steel electrode. 150 amp capacity.  
WIRE FEED  
K449 LN-25 - Includes internal contactor for across the  
arc operation (no control cable). Provides “cold” elec-  
trode until gun trigger is pressed. Includes gas sole-  
noid.  
K1870-1 LN-15 Across the Arc  
Magnum Gun and Magnum Gun Connector Kit are  
required for gas-shielded welding. Innershield Gun is  
required for gasless welding.  
K126-2 Magnum 350 Innershield Gun (for LN-25, LN-  
15).  
K1802-1 Magnum 300 MIG Gun (for LN-25, includes  
Connector Kit).  
K470-2 Magnum 300 MIG Gun (for LN-15, requires  
K466-10 Magnum Gun Connector Kit).  
K1500-1 Gun Receiver Bushing (for LN-15, K126-2)  
Note: See Wire Feeder IM Manual for appropriate  
Drive Roll & Guide Tube Kits.  
TIG WELDING  
K1783-9- PTA-26V TIG Torch.  
KP509- Magnum Parts Kit and Argon gas.  
K930-2- TIG Module.  
Required TIG Equipment:  
K938-1 Connector Kit  
K936-4 Control Cable  
K814 Arc Start Switch  
Optional TIG Equipment:  
K939-1 Docking Kit  
K937-45 Control Cable Extension  
K844-1 Water Valve Kit  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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C-4  
C-4  
NOTES  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
- MAINTENANCE SECTION -  
Maintenance ...........................................................................................................Section D  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Engine Oil Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Change the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3  
Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
Hardware & Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
Engine Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5  
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
CAUTION  
WARNING  
Make certain that the oil filler cap is securely tight-  
ened after checking or adding oil. If the cap is not  
tight, oil consumption can increase significantly  
which may be evidenced by white smoke coming  
from the exhaust.  
Have qualified personnel do the maintenance  
work. Turn the engine off before working inside  
the machine. In some cases, it may be necessary  
to remove safety guards to perform required  
maintenance. Remove guards only when  
necessary and replace them when the mainte-  
nance requiring their removal is complete.  
Always use the greatest care when working near  
moving parts.  
• OIL - Maintenance schedule for changing the oil and  
oil filter after break-in :  
KOHLER  
HONDA  
ROBIN / SUBARU  
Do not put your hands near the engine cooling  
blower fan. If a problem cannot be corrected by  
following the instructions, take the machine to  
the nearest Lincoln Field Service Shop.  
-----------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
6 Months  
Oil  
100 HRS. 100 HRS.  
1 Year or  
100 HRS.  
200 HRS.  
Oil Filter 200 HRS. 200 HRS.  
• Do not touch electrically live parts  
or electrode with skin or wet  
clothing.  
• Insulate yourself from work and  
ground  
The above schedule is for normal operating conditions.  
More frequent oil changes are required with dusty, high  
temperature and other severe operating conditions.  
Refer to the maintenance section of the Engine  
Owner's Manual for more information.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
NOTE: Engine life will be reduced if the oil and oil fil-  
ter are not changed according to the manufac-  
turerʼs recommendation.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas  
or vent exhaust outside.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
ENGINE OIL CHANGE  
Drain the oil while the engine is warm to assure rapid  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
and complete draining.  
• Remove the oil filler cap and dipstick. Remove the  
yellow cap from the oil drain valve and attach the flex-  
ible drain tube supplied with the machine. Push in  
and twist the drain valve counterclockwise. Pull the  
valve out and drain the oil into a suitable container.  
• Close the drain valve by pushing in and twisting  
clockwise. Replace the yellow cap.  
------------------------------------------------------------------------  
See additional warning information  
throughout this operator’s manual and  
the Engine manual as well.  
------------------------------------------------------------  
Read the Safety Precautions in the front of this manual  
and the engine instruction manual before working on  
this machine.  
• Refill to the upper limit mark on the dipstick with the  
recommended oil. Tighten the oil filler cap securely.  
Keep all equipment safety guards, covers, and devices  
in position and in good repair. Keep hands, hair, cloth-  
ing, and tools away from gears, fans, and all other mov-  
ing parts when starting, operating, or repairing the  
equipment.  
ENGINE OIL REFILL CAPACITIES  
Without oil filter replacement:  
• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler  
•1.6 US qt. (1.3 IMP qt., 1.5 liter)-Honda GX620KI  
•1.5 US qt. (1.2 IMP qt., 1.4 liter)-Robin / Subaru  
ROUTINE MAINTENANCE  
•
At the end of each dayʼs use, refill the fuel tank to  
minimize moisture condensation in the tank.  
Running out of fuel tends to draw dirt into the fuel  
system. Also, check the crankcase oil level and  
add oil if indicated.  
With oil filter replacement:  
• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler  
•1.9 US qt. (1.6 Imp qt. , 1.8 liter)-Honda GX620KI  
•1.6 US qt. (1.4 IMP qt., 1.6 liter)-Robin / Subaru  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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D-3  
D-3  
MAINTENANCE  
Use 4-stroke motor oil that meets or exceeds the  
requirements for API service classification SG or SH.  
Always check the API SERVICE label on the oil con-  
tainer to be sure it includes the letters SG or SH.  
AIR CLEANER AND OTHER MAINTENANCE  
•
Air Cleaner - With normal operating conditions, the  
maintenance schedule for cleaning and re-oiling  
the foam pre-filter is every 25 hours and replace-  
ment of the air cleaner filter every 100 hours. More  
frequent servicing is required with dusty operating  
conditions. Refer to the maintenance section of the  
Engine Ownerʼs Manual for more information.  
SAE 10W-30 is recommended for general, all-tempera-  
ture use, -5 F to 104 F (-20 C to 40 C).  
See Engine Ownerʼs Manual for more specific informa-  
tion on oil viscosity recommendations.  
•
Refer to the maintenance section of the Engine  
Ownerʼs Manual for the maintenance schedule,  
spark plug servicing, cooling system servicing, and  
fuel filter replacement.  
Wash your hands with soap and water after handling  
used oil.  
Please dispose of used motor oil in a manner that is  
compatible with the environment. We suggest you take  
it in a sealed container to your local service station or  
recycling center for reclamation.  
•
•
Blow out the machine with low pressure air peri-  
odically. In particularly dirty locations, this may be  
required once a week.  
Do not throw it in the trash, pour it on the ground or  
down a drain.  
Output RANGER® Selector and Polarity Switches:  
Switch contacts should not be greased. To keep  
contacts clean, rotate the switch through its entire  
range frequently. Good practice is to turn the handle  
from maximum to minimum setting twice each  
morning before starting to weld.  
OIL FILTER CHANGE  
1. Drain the engine oil.  
2. Remove the oil filter, and drain the oil into a suitable  
container. Discard the used oil filter.  
3. Clean the filter mounting base, and coat the gasket of  
the new oil filter with clean engine oil.  
4. Screw on the new oil filter by hand, until the gasket  
contacts the filter mounting base, then use an oil fil-  
ter socket tool to tighten the filter an additional 1/2 to  
7/8 turn.  
5. Refill the crankcase with the specified amount of the  
recommended oil. Reinstall the oil filler cap.  
6. Start the engine and check for oil filter leaks.  
7. Stop the engine, and check the oil level. If necessary,  
add oil to the upper limit mark on the dipstick.  
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D-4  
D-4  
MAINTENANCE  
ENGINE ADJUSTMENTS  
WARNING  
GASES FROM BATTERY can explode.  
OVERSPEED IS HAZARDOUS  
• Keep sparks, flame and cigarettes away from battery.  
To prevent EXPLOSION when:  
• INSTALLING A NEW BATTERY - disconnect negative  
cable from old battery first and connect to new battery  
last.  
WARNING  
The maximum allowable high idle speed for this  
machine is 3750 RPM, no load. Do NOT tamper  
with governor components or setting or make any  
other adjustments to increase the maximum  
speed. Severe personal injury and damage to the  
machine can result if operated at speeds above  
maximum.  
------------------------------------------------------------------------  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
• CONNECTING A BATTERY CHARGER - Remove bat-  
tery from welder by disconnecting negative cable first,  
then positive cable and battery clamp. When rein-  
stalling, connect negative cable last. Keep well venti-  
lated.  
• USING A BOOSTER - connect positive lead to battery  
first then connect negative lead to engine foot.  
BATTERY ACID CAN BURN EYES AND SKIN.  
• Wear gloves and eye protection and be careful when  
working near battery. Follow instructions printed on  
battery.  
BATTERY  
SLIP RINGS  
1. When replacing, jumping, or otherwise connecting  
the battery to the battery cables, the proper  
polarity must be observed. Failure to observe  
the proper polarity could result in damage to the  
charging circuit. The positive (+) battery cable  
has a red terminal cover.  
A slight amount of darkening and wear of the slip rings  
and brushes is normal. Brushes should be inspected  
when a general overhaul is necessary.If brushes are to  
be replaced, clean slip rings with a fine emery paper.  
2. If the battery requires charging from an external  
charger, disconnect the negative battery cable  
first and then the positive battery cable before  
attaching the charger leads. Failure to do so  
can result in damage to the internal charger  
components. When reconnecting the cables,  
connect the positive cable first and the negative  
cable last.  
CAUTION  
Do not attempt to polish slip rings while engine is  
running.  
------------------------------------------------------------------------  
HARDWARE  
Both English and Metric fasteners are used in this  
welder.  
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D-5  
D-5  
MAINTENANCE  
ENGINE MAINTENANCE PARTS  
KOHLER C20S  
HONDA GX620KI  
ROBIN / SUBARU EH64  
KOHLER 1205001  
HONDA  
ROBIN / SUBARU  
Oil Filter  
FRAM PH3614*  
15410-ZJ4-999A  
248-65801-00, FRAM PH4967  
Air Filter  
Element  
KOHLER 4708303  
FRAM CA79  
HONDA  
ROBIN / SUBARU  
263-32610-A1  
17210-ZJ1-841  
Air Filter  
Pre-Cleaner  
KOHLER 2408302  
HONDA  
N/A  
17218-ZJ1-840  
Fuel Filter  
KOHLER 2505002  
FRAM G1  
HONDA  
ROBIN / SUBARU  
011-00600-20  
16910-ZE8-015  
Spark Plugs  
(Resistor  
Type)  
CHAMPION RC12YC  
(.030” GAP)  
CHAMPION -J16CR-U  
NGK-ZGR5A  
ROBIN / SUBARU  
X65-01407-30  
030in, (76 mm) Gap  
NGK-BPR4EY  
*
Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.  
ENGINE MAINTENANCE PARTS  
KOHLER C23S  
SUBARU ROBIN EH65  
HONDA GX620KI  
KOHLER 1205001  
SUBARU ROBIN  
HONDA  
Oil Filter  
FRAM PH8172*  
248-65801-00, FRAM PH4967  
15410-ZJ4-999A  
Air Filter  
Element  
KOHLER 4708303  
FRAM CA79  
SUBARU ROBIN  
263-32610-A1  
HONDA  
17210-ZJ1-841  
Air Filter  
Pre-Cleaner  
KOHLER 2408302  
N/A  
HONDA  
17218-ZJ1-840  
Fuel Filter  
KOHLER 2405010  
SUBARU ROBIN  
011-00600-20  
HONDA  
16910-ZE8-015  
Spark Plugs  
(Resistor  
Type)  
CHAMPION RC12YC  
(.030” GAP)  
SUBARU ROBIN  
X65-01407-30  
NGK-BPR4EY  
CHAMPION -J16CR-U  
NGK-ZGR5A  
030in, (76 mm) Gap  
*
Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.  
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D-6  
D-6  
MAINTENANCE  
FIGURE D.1 - MAJOR COMPONENT LOCATION  
1. CASEFRONT  
2. OUTPUT RECTIFIER ASSEMBLY  
3. BASE/UNDERCARRIAGE ASSEMBLY  
4. ENGINE/ROTOR/STATOR ASSEMBLY  
5. CASE TOP & SIDES  
5
4
1
3
2
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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, Excitation, Rotor,  
Stator, and Idler Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2  
Rotor Field Feedback and Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3  
Weld Winding, Reactor, and Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4  
Output Bridge, Choke, Polarity Switch, and Output Terminals . . . . . . . . . . . . . . . . .E-5  
FIGURE E.1 – RANGER® 10,000 BLOCK LOGIC DIAGRAM  
RANGE  
SWITCH  
AC  
ELECTRODE  
TERMINAL  
POLARITY  
SWITCH  
CHOKE  
OUTPUT  
BRIDGE  
AC  
REACTOR  
CV  
TAP  
WORK  
TERMINAL  
STATOR  
MECHANICAL  
ROTATION  
ROTOR  
SLIP  
STARTER  
ENGINE  
ROTOR  
STATOR  
RINGS  
FLYWHEEL  
ALTERNATOR  
IDLER  
SOLENOID  
BATTERY  
FIELD  
CAPACITOR  
115 & 230VAC  
RECEPTACLES  
OUTPUT  
CONTROL  
PRINTED CIRCUIT  
BOARD  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID  
RANGE  
SWITCH  
AC  
ELECTROD  
TERMINAL  
POLARITY  
SWITCH  
CHOKE  
OUTPUT  
BRIDGE  
AC  
REACTOR  
CV  
TAP  
WORK  
TERMINAL  
STATOR  
MECHANICAL  
ROTATION  
ROTOR  
SLIP  
STARTER  
ENGINE  
ROTOR  
STATOR  
RINGS  
FLYWHEEL  
ALTERNATOR  
IDLER  
SOLENOID  
BATTERY  
FIELD  
CAPACITOR  
115 & 230VAC  
RECEPTACLES  
OUTPUT  
CONTROL  
PRINTED CIRCUIT  
BOARD  
winding and the field feedback winding. The field  
feedback winding provides rotor current during  
machine operation. The output of the RANGER®  
10,000 is dependent on two criteria: the engine RPM  
and the amount of current in the rotor winding.  
BATTERY, STARTER, ENGINE,  
ROTOR, STATOR, AND IDLER  
SOLENOID  
The 12VDC battery powers the starter motor. 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 mag-  
netizes the rotor lamination. The rotor is mechanically  
coupled to the engine. This rotating magnet induces a  
voltage in the stationary windings of the main alterna-  
tor (stator). Three separate and isolated windings are  
incorporated in the stator lamination assembly. Each  
winding set has a different number of turns producing  
different magnitudes of AC output voltages. The three  
windings are the weld winding, the auxiliary power  
The flywheel alternator, located on the engine, supplies  
“charging” current for the battery circuit. The battery  
circuit provides power for the printed circuit board and  
also for the idler solenoid. The idler solenoid is  
mechanically connected to the engine throttle linkage.  
If no current is being drawn from the RANGER®  
10,000, the printed circuit board activates the idler  
solenoid, 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.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER  
RANGE  
SWITCH  
AC  
ELECTRODE  
TERMINAL  
POLARITY  
SWITCH  
CHOKE  
OUTPUT  
BRIDGE  
AC  
REACTOR  
CV  
TAP  
WORK  
TERMINAL  
STAT O R  
MECHANICAL  
ROTATION  
ROTOR  
SLIP  
STARTER  
ENGINE  
ROTOR  
STATOR  
RINGS  
FLYWHEEL  
ALTERNATOR  
IDLER  
SOLENOID  
BATTERY  
FIELD  
CAPACITOR  
115 & 230VAC  
RECEPTACLES  
OUTPUT  
CONTROL  
PRINTED CIRCUIT  
BOARD  
When full field voltage is applied to the rotor and the  
engine is running at high speed (3700 RPM), a 230 AC  
voltage is developed in the stator auxiliary winding.  
This winding is tapped to provide 115 VAC. The two  
voltages, (115 VAC and 230 VAC), are connected to  
the appropriate receptacles and offer 9000 watts (total)  
of continuous AC power.  
ROTOR FIELD FEEDBACK AND  
AUXILIARY POWER  
The AC voltage developed in the field winding is fed to  
the full wave field bridge. The DC output of the bridge  
is filtered by the field capacitor and controlled by the  
printed circuit board according to the output control  
setting. This filtered and controlled voltage is fed to  
the rotor winding via the brush and slip ring configura-  
tion. As the feedback voltage is increased or de-  
creased, the outputs of the weld and auxiliary windings  
are increased or decreased.  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH  
RANGE  
SWITCH  
AC  
ELECTRODE  
TERMINAL  
POLARITY  
SWITCH  
CHOKE  
OUTPUT  
BRIDGE  
AC  
REACTOR  
CV  
TAP  
WORK  
TERMINAL  
STATOR  
MECHANICAL  
ROTAT ION  
ROTOR  
SLIP  
STARTER  
ENGINE  
ROTOR  
STATOR  
RINGS  
FLYWHEEL  
ALTERNATOR  
IDLER  
SOLENOID  
BATTERY  
FIELD  
CAPACITOR  
115 & 230VAC  
RECEPTACLES  
OUTPUT  
CONTROL  
PRINTED CIRCUIT  
BOARD  
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 a tap on the stator weld winding to provide  
a lower but “stiffer” output voltage.  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS  
RANGE  
SWITCH  
AC  
ELECTRODE  
TERMINAL  
POLARITY  
SWITCH  
CHOKE  
OUTPUT  
BRIDGE  
AC  
REACTOR  
CV  
TAP  
WORK  
TERMINAL  
STATOR  
MECHANICAL  
ROTATION  
ROTOR  
SLIP  
STARTER  
ENGINE  
ROTOR  
STATOR  
RINGS  
FLYWHEEL  
ALTERNATOR  
IDLER  
SOLENOID  
BATTERY  
FIELD  
CAPACITOR  
115 & 230VAC  
RECEPTACLES  
OUTPUT  
CONTROL  
PRINTED CIRCUIT  
BOARD  
OUTPUT BRIDGE, CHOKE,  
POLARITY SWITCH, 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 Bridge, where the AC voltage 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 and on to the Output  
Terminals.  
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E-6  
E-6  
NOTES  
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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-13  
Test Procedures  
Rotor Voltage Test ................................................................................................F-15  
Rotor Resistance Test ..........................................................................................F-17  
Auxiliary and Field Winding Test...........................................................................F-21  
Output Rectifier Bridge Test .................................................................................F-25  
Charging Circuit Test ............................................................................................F-27  
Engine Throttle Adjustment Test ..........................................................................F-29  
Oscilloscope Waveforms ............................................................................................F-33  
Normal Open Circuit Voltage Waveform (115 VAC Supply) .................................F-33  
Typical DC Weld Output Waveform (CV Mode) – Machine Loaded.....................F-34  
Typical DC Weld Output Waveform (CC Mode) – Machine Loaded ....................F-35  
Typical AC Weld Output Waveform – Machine Loaded .......................................F-36  
Abnormal Open Circuit Weld Voltage Waveform (CV Mode, one diode open)....F-37  
Abnormal Open Circuit DC Weld Voltage Waveform ...........................................F-38  
Normal Open Circuit Weld Voltage Waveform (CV Mode) ...................................F-39  
Normal Open Circuit DC Weld Voltage Waveform ...............................................F-40  
Normal Open Circuit AC Weld Voltage Waveform ...............................................F-41  
Replacement Procedures............................................................................................F-43  
Brush Removal and Replacement........................................................................F-43  
Printed Circuit Board Removal and Replacement ...............................................F-47  
Output Rectifier Bridge Removal and Replacement............................................F-51  
Engine Rotor Removal and Replacement (Kit S20788) .......................................F-55  
Retest After Repair......................................................................................................F-60  
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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 1-888-935-3877.  
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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. Donʼt set the  
PC board on or near paper, plastic or cloth which  
could have a static charge. If the PC board canʼt be  
installed immediately, put it back in the static-shield-  
ing bag.  
WARNING  
ELECTRIC SHOCK  
can kill.  
•
Have an electrician install and  
service this equipment. Turn the  
input power OFF at the fuse box  
before working on equipment. Do  
not touch electrically hot parts.  
- If the PC board uses protective shorting jumpers,  
donʼt 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 prop-  
er failure analysis.  
CAUTION  
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  
symptom has been corrected by the  
replacement PC board.  
NOTE: It is desirable to have a spare (known good)  
PC board available for PC board troubleshooting.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
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 terminal 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 bodyʼs static  
charge before opening the static-  
shielding bag. Wear an anti-static  
wrist strap. For safety, use a 1  
Meg ohm resistive cord connected  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
to  
a
grounded part of the  
equipment frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
- If you donʼt have a wrist strap,  
touch an un-painted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent  
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  
- 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  
TROUBLESHOOTING GUIDE  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major Physical or Electrical 1. Contact your local Lincoln 1. Contact The Lincoln Electric  
Damage is Evident.  
Authorized  
Facility.  
Field  
Service  
Service Dept. 1-888-935-3877.  
No weld output and no auxiliary 1. Check the brushes for wear and  
1. Perform the Rotor Voltage  
power. Engine runs normally.  
proper contact to the rotor slip  
rings.  
Test.  
2. Check for the presence of  
12VDC (at the pc board) from  
lead #216 to frame ground.  
This is the “flashing” voltage  
and is present only when the  
Start, Run, Stop switch S3 is in  
the “Start” position. If the 12  
VDC is missing check the leads,  
switches and connections  
associated with the lead #216.  
See Wiring Diagram.  
Check for the presence of 12  
VDC (at the pc board) from lead  
#224 to frame ground. This is  
the supply voltage to the board  
and is present when the engine  
is running and the S3 switch is  
in the “Run” position. If the  
12VDC is missing check the  
leads, switches and connec-  
tions associated with the lead  
#224. See Wiring Diagram.  
3. If Rotor Voltage Test is normal,  
then preform the Rotor  
Resistance Test.  
4. If the Rotor Voltage Test is NOT  
normal, perform the Auxiliary  
and Field Winding Voltage  
Test. Then check the Field  
Diode Bridge (D2) and the Field  
Capacitor (C1). Replace if nec-  
essary. If the Field Bridge and  
Field Capacitor are good, then  
the Printed Circuit 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  
1-888-935-3877.  
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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. Check the open circuit voltage 1. Disconnect lead W1 from the  
power (230-115VAC) is operating  
normally. Engine runs normally.  
(OCV) at the welder output ter-  
minals, engine at high idle (3650  
RPM). Normal maximum is 73  
to 80VAC. Normal DC maxi-  
mum is 67 to 72VDC. If the  
OCV is OK then proceed to  
Step #2. If the OCV is not pre-  
sent at the welder output termi-  
nals, contact your local Lincoln  
Output Bridge (D1) and check  
for the presence of 80VAC from  
lead W1 to lead W2 on the main  
stator winding. See wiring dia-  
gram. If the AC voltage is NOT  
present, the winding in the sta-  
tor may be faulty. Check the  
winding for continuity and test  
to be sure it is NOT grounded to  
the stator iron. Replace if nec-  
essary. If the correct AC volt-  
age is present, proceed to step  
#2.  
Authorized  
Facility.  
Field  
Service  
2. Check the welding cables,  
clamps and electrode holder for  
loose or broken connections.  
2. Check the Reactor, Range  
Switch (S1) 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.  
3. Check the Choke (L1), Polarity  
Switch (S2) and associated  
wires for loose or faulty connec-  
tions. Check the choke winding  
for continuity and test to be  
sure it is NOT grounded to the  
choke iron.  
4. Check the weld output termi-  
nals and associated wires for  
loose or faulty connections.  
5. Perform the Output 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  
1-888-935-3877.  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
TROUBLESHOOTING GUIDE  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No auxiliary power, welding output 1. If machine is equipped with cir- 1. Check the auxiliary power  
is normal. Engine runs normally.  
cuit breakers, check circuit  
breakers CB1 thru CB5. Reset  
if tripped.  
receptacles and associated  
wires for loose or faulty connec-  
tions.  
2. Make sure the Output Control  
(R1) is set at the maximum  
position.  
2. Perform the Auxiliary and  
Field Winding Voltage Test.  
3. If machine is equipped with cir-  
cuit breakers, check for faulty  
breakers and loose or faulty  
connections on associated  
wiring.  
3. Check for loose or faulty plug(s)  
at the power receptacle(s).  
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  
1-888-935-3877.  
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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. The brushes may be worn. 1. If the engine HIGH IDLE RPM is  
and low auxiliary output.  
Contact your local Lincoln  
Authorized Service Facility.  
low, then perform The Throttle  
Adjustment Test.  
2. The engine RPM may be low.  
2. Perform the Rotor Voltage  
Test.  
3. If the rotor voltage is low the  
Field Capacitor (C1) or the Field  
Bridge (D2) may be faulty. Test  
and replace if necessary.  
4. Check the Output Control  
Potentiometer. Normal resis-  
tance 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 Printed Circuit 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  
1-888-935-3877.  
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F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
TROUBLESHOOTING GUIDE  
detailed in the beginning of this manual.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No DC welding output. AC welding 1. Make sure the Polarity Switch is  
1. Perform the Output Bridge Test.  
output and auxiliary power is nor-  
mal.  
in the proper position and is  
“seated” correctly.  
2. Check the Choke (L1), the  
Polarity Switch (S2) and associ-  
ated wires for loose or faulty  
connections. Check the choke  
winding for continuity and test  
to be sure it is NOT grounded  
the choke iron.  
2. Make sure the electrode and  
polarity are correct for the  
process being used.  
No AC welding output. DC welding 1. Make sure the Polarity Switch is 1. Check the operation of the  
output and auxiliary power is nor-  
mal.  
in the proper position and is  
“seated” correctly.  
Polarity Switch (S2). Also check  
the associated wires for loose  
or faulty connections.  
Wiring Diagram.  
See  
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  
main stator. See Wiring Dia-  
3. Make sure the welding cables  
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  
1-888-935-3877.  
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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  
output. Constant current (CC) and  
the auxiliary power are operating  
normally.  
(S1) is in the proper position  
(CV) and “seated” correctly.  
Range Switch (S1) and check  
the associated wires for loose  
or faulty connections. See  
Wiring Diagram.  
2. Make sure the wire feeder is  
connected correctly.  
2. Check for continuity from lead  
C1 to lead W1 located in the  
main stator. See Wiring Dia-  
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  
1-888-935-3877.  
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F-10  
F-10  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
TROUBLESHOOTING GUIDE  
detailed in the beginning of this manual.  
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 (S4) 1. With the Idler Switch (S4) in the  
is in the “Auto” position.  
“Auto” position, check for the  
presence of 12VDC at leads  
#213 to #215 located at the  
Idler Solenoid. If 12VDC is pre-  
sent and the Idler Solenoid is  
not activating, then the solenoid  
may be faulty or there is a  
mechanical restriction prevent-  
ing it from functioning.  
2. Make sure there is NOT an  
external load on the weld termi-  
nals nor the auxiliary power  
receptacles.  
2. If there is NOT 12VDC at leads  
#213 to #215, then test for  
12VDC from lead #213 to  
ground (lead #5). See Wiring  
Diagram. If 12VDC is present,  
then check lead #215 for conti-  
nuity (zero ohms) from the Idler  
Solenoid to the Printed Circuit  
Board plug 3J1. If lead #215 is  
OK, then the Printed Circuit  
Board may be faulty. Replace.  
3. If there is NOT 12VDC from lead  
#213 to ground (lead #5), then  
check the Idler Switch (S4) for  
proper operation and as-  
sociated wires for loose or  
faulty connections.  
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  
1-888-935-3877.  
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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). Make sure  
their connections are tight at  
the Electrode Output Terminal  
and also at the Polarity Switch.  
See Wiring Diagram.  
2. Make sure the leads are looped  
three times through the current  
sensor on the Printed Circuit  
Board.  
Engine will not go to high idle when 1. Make sure the welding cables 1. Check for broken or faulty con-  
attempting to weld or when the  
auxiliary power is loaded. Welding  
output and auxiliary power output  
is normal when Idler Switch is in  
the “HIGH” position.  
and connections are tight.  
nections in the sensing leads.  
(#254 and #254A). Make sure  
their connections are tight at  
the Electrode Terminal and also  
at the Polarity Switch. See  
Wiring Diagram.  
2. Automatic idler may not func-  
tion if the auxiliary power is  
loaded to less than 150 Watts.  
2. Check lead #3, making sure it is  
looped through the current sen-  
sor on the Printed Circuit Board.  
3. The Printed Circuit 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  
1-888-935-3877.  
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F-12  
F-12  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
TROUBLESHOOTING GUIDE  
detailed in the beginning of this manual.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not crank or cranks very 1. Check for loose or faulty battery 1. If the battery is replaced or  
slow.  
cable connections.  
tests good, then the charging  
circuit may be faulty. Perform  
the Charging Circuit Test.  
2. The battery may be faulty.  
3. Check the ammeter to see if the  
battery is charging. If not, the  
charging circuit may be defec-  
tive.  
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.  
The Engine shuts off.  
1. The Engine may be low on or 1. The oil pressure switch may be  
out of fuel. faulty. Replace if necessary.  
2. The Oil level may be low. 2. The fuel shut off solenoid may  
Check and fill to proper level.  
be faulty (Kohler Engines only).  
3. The fuel filter may be clogged.  
Engine does not develop full 1. The fuel filter may be clogged. 1. Due to wear, the engine may be  
power.  
Replace if necessary.  
in need of repair.  
2. The air filter may be clogged.  
Replace if necessary.  
3. The spark plug(s) may be faulty.  
Replace if necessary.  
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  
1-888-935-3877.  
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F-13  
F-13  
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.” Engine 1. Check for loose or faulty con- 1. Check for the correct open cir-  
runs normally (3700 RPM no load).  
Auxiliary power is functioning nor-  
mally.  
nections at the weld output ter-  
minals and welding cable con-  
nections.  
cuit voltage (OCV) at the welder  
output terminals (80VAC Max.  
72VDC Max.). If the correct  
voltage is present at the output  
terminals, then check for loose  
connections on the heavy cur-  
rent carrying leads inside the  
2. The welding cable may be too  
long or coiled, causing an  
excessive voltage drop.  
RANGER® 8.  
See Wiring  
Diagram.  
2. If the OCV is low at the welder  
output terminals, then 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  
1-888-935-3877.  
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F-14  
F-14  
NOTES  
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F-15  
F-15  
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 1-888-935-3877.  
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  
Wiring Diagram  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
ROTOR VOLTAGE TEST (continued)  
FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST  
Brushes  
Slip Rings  
Lead 200A  
Lead 219  
+
-
TEST PROCEDURE  
1. With the 5/16” nut driver, remove the 6  
9. Connect the negative meter probe to the  
other brush (lead 219).  
sheet metal screws from the case top.  
2. Remove the rubber gasket (cover seal)  
from the lift bail.  
10. Start the engine and run it at high idle  
(3650 RPM). Set the output control to the  
MAXIMUM position (position 10).]  
3. Remove the fuel cap. The rubber gasket  
for the fill tube will come off with the case  
top.  
11. Check the voltage reading on the volt-  
meter. It should read between 37 and 46  
VDC.  
4. Remove the case top, then reinstall the  
12. If the voltage reading is low or not pre-  
sent, the generator field is not functioning  
properly. Perform the Rotor Resistance  
Test. The Field Diode Bridge (D2), the  
Field Capacitor (C1), and/or the Printed  
Circuit Board may be faulty.  
fuel cap.  
5. With the 5/16” nut driver, remove the 5  
screws holding the right case side.  
6. Remove the right case side by lifting up  
and out.  
7. Set the volt/ohmmeter to the DC volts  
position.  
13. If the voltage reading is normal, the field  
circuit is functioning properly. Install the  
right case side with the 5 sheet metal  
screws with the 5/16” nut driver. Remove  
the fuel cap; install the case top and tight-  
en the 6 sheet metal screws with the  
5/16” nut driver. Install the rubber gasket  
over the lift bail and install the fuel cap.  
8. Connect the positive meter probe to the  
brush nearest the rotor lamination (lead  
200A). See Figure F.1 for location.  
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F-17  
F-17  
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 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 1-888-935-3877.  
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  
Wiring Diagram  
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F-18  
F-18  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS  
+
-
Lead 200A  
Lead 219  
TEST PROCEDURE  
1. With the 5/16” nut driver, remove the 6  
sheet metal screws from the case top.  
9. Isolate the rotor electrically by removing  
the generator brush leads. Refer to  
Figure F.2 as you perform the remaining  
steps.  
2. Remove the rubber gasket (cover seal)  
from the lift bail.  
10. Remove lead 219 from the negative  
brush.  
3. Remove the fuel cap. The rubber gasket  
for the fill tube will come off with the case  
top.  
11. Remove lead 200A from the positive  
brush.  
4. Remove the case top, then replace the  
fuel cap.  
12. Measure the resistance across the rotor  
slip rings.  
5. With the 5/16” nut driver, remove the 5  
screws holding the right case side.  
A. Set the ohmmeter on the low scale  
(X1).  
6. Remove the right case side by lifting up  
and out.  
B. Place one meter probe on one of the  
rotor slip rings. Place the other probe  
on the other slip ring.  
7. Conduct the test with the gasoline engine  
OFF.  
C. Check the resistance across the slip  
rings. It should read between 4 and 5  
ohms.  
8. Remove the spark plug wires to prevent  
accidental engine kickback or starting.  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
13. Measure the resistance to ground.  
A. Set the ohmmeter on the high scale  
(X100,000).  
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.  
C. Check the resistance. It should read  
very high, at least 0.5 megohm  
(500,000 ohms).  
If the test does not meet the resistance  
specifications, then the rotor may be  
faulty. Replace the rotor.  
If the test does meet the resistance  
specifications, then the rotor is okay.  
14. Connect lead 200A to the positive  
brush, which is the one nearest the rotor  
lamination. Connect lead 219 to the  
negative brush.  
15. Reinstall the case side, case top, fuel  
cap, lift bail gasket and spark plug wires.  
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F-20  
F-20  
NOTES  
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F-21  
F-21  
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 1-888-935-3877.  
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  
Wiring Diagram  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.3 – LOCATION OF LEADS #3 AND #5  
Machine  
Case  
Front  
115V  
Receptacle  
Lead #3  
Lead #5  
TEST PROCEDURE  
To test the 115 VAC winding:  
To test the 230 VAC winding:  
1. Remove the fuel cap and lift bail rubber  
gasket. With the 5/16” nut driver, remove  
the case top and left side; then reinstall the  
fuel cap.  
1. Remove the fuel cap and lift bail rubber  
gasket. With the 5/16” nut driver, remove  
the case top and left side; then reinstall  
the fuel cap.  
2. Connect the volt/ohmmeter probes to  
leads #3 and #5 where they connect to the  
115 VAC receptacle. See Figure F.3.  
2. Connect the volt/ohmmeter probes to  
leads #6 and #3 where they connect to the  
230 VAC receptacle.  
3. Start the engine and run it at high idle (3650  
RPM).  
NOTE: It is easier to insert the probes direct-  
ly 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 gasoline  
engine, insert two test probes into the recep-  
tacle. Hold the test probes firmly in place to  
measure voltage (Step 5).  
4. Set the output control to the maximum  
position (position 10).  
5. Check the AC voltage reading. It should be  
approximately 125 VAC.  
3. Start the engine and run it at high idle (3650  
RPM)  
4. Set the output control to the maximum  
position (position 10).  
5. Check the AC voltage reading. It should be  
approximately 240 VAC.  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
To test the field winding:  
1. Remove the fuel cap and lift bail rubber  
If the voltage readings are within specifica-  
tions, then the windings are good and func-  
tioning properly.  
gasket. With the 5/16” nut driver, remove  
the case top and left side; then reinstall  
the fuel cap.  
6. Reinstall the case side, case top, fuel cap,  
and lift bail gasket.  
2. Connect the volt/ohmmeter probes to leads  
#7 and #9 where they connect to the Field  
Idle Control P.C. Board.  
3. Start the engine and run it at high idle (3650  
RPM).  
4. Set the output control to the maximum  
position (position 10).  
5. Check the AC voltage reading. It should be  
between 36 and 43 VAC.  
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.  
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F-24  
F-24  
NOTES  
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F-25  
F-25  
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 1-888-935-3877.  
TEST DESCRIPTION  
This test will determine if there are faulty diodes in the Output Rectifier Bridge.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
7/16” wrench or 7/16” socket wrench and 6” socket extension  
Wiring Diagram  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.4 – LOCATION OF OUTPUT RECTIFIER LEADS  
OUTPUT RECTIFIER  
(-)  
(+)  
(-)  
(+)  
(+)  
(-)  
ENGINE  
TEST PROCEDURE  
10. With the 7/16” wrench or socket wrench  
and 6” extension, remove the nuts and  
washers holding the diode bridge pigtails  
and the heavy current-carrying leads to  
the studs located in the middle of the rec-  
tifier assembly. Note their locations and  
the order of fasteners for reassembly.  
1. Remove the spark plug wires to prevent  
accidental engine kickback or starting.  
2. With the 5/16” nut driver, remove the 6  
sheet metal screws from the case top.  
3. Remove the rubber gasket (cover seal) from  
the lift bail.  
11. Electrically isolate the (-) diode connectors  
by slightly bending them back into “free  
air.”  
4. Remove the fuel cap. The rubber gasket for  
the fill tube will come off with the case top.  
5. Remove the case top, then replace the fuel  
12. With an ohmmeter or diode tester, check  
each of the four diodes from their connec-  
tor to their respective heat sinks. See  
Figure F.4.  
cap.  
6. With the 5/16” nut driver, remove the 5  
screws holding the right case side.  
7. Remove the right case side by lifting up and  
out.  
13. 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.  
8. Conduct the test with the gasoline engine  
OFF.  
14. Replace any “shorted” or “open” diode  
bridge assembly the tests indicate.  
9. Locate the Output Rectifier Bridge behind  
the machine case front.  
15. Reconnect the diode connectors and  
heavy leads to their respective studs.  
16. Reinstall the case side, case top, fuel cap,  
lift bail gasket and spark plug wires.  
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F-27  
F-27  
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 1-888-935-3877.  
TEST DESCRIPTION  
This test will determine if the Flywheel Alternator, Regulator, and associated circuitry are  
functioning properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
Wiring Diagram  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
CHARGING CIRCUIT TEST (continued)  
FIGURE F.5 – LOCATION OF VOLTAGE REGULATOR  
Engine  
Ground  
Lead  
(Green)  
Voltage  
Regulator  
AC Lead  
DC Lead  
AC Lead  
TEST PROCEDURE  
1. Start the engine and run it at high idle  
(3650 RPM).  
5. If the DC voltage reading is incorrect or not  
present, the voltage regulator may be  
faulty. Replace the entire voltage regulator  
module.  
2. Set the voltmeter for AC volts and place  
one meter probe on each of the two out-  
side leads that attach to the engine voltage  
regulator. See Figure F.5 for location.  
Check for 42-52 VAC at the voltage regula-  
tor.  
6. If the DC voltage reading is correct, check  
the associated wiring and circuitry. See  
the Wiring Diagram.  
3. If the AC voltage is low or not present, the  
engine flywheel alternator may be faulty.  
This is an engine problem; consult your  
local engine repair facility.  
4. If the voltage reading is correct, then check  
the output of the voltage regulator to deter-  
mine the charging voltage for the battery.  
Run the engine at high idle (3650 RPM).  
Set the voltmeter for DC volts and place  
one meter probe on the middle lead and  
one probe on the green ground wire con-  
nected to the voltage regulator. See Figure  
F.5 for location. Check for 13-15 VDC.  
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F-29  
F-29  
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 1-888-935-3877.  
TEST DESCRIPTION  
If the machine output is low, this test will determine whether the gasoline engine is operating  
at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjust-  
ing the throttle to the correct RPM are given.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” open end or box wrench  
Strobe-tach, frequency counter, oscilloscope, or vibratach  
Black or red marking pencil  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD  
Blower Paddle  
TEST PROCEDURE  
This test can be conducted by any one of four  
methods.  
8. Connect the strobe-tach according the  
manufacturer’s instructions.  
Strobe-tach Method:  
9. Reconnect the spark plug wires and start  
the engine. Direct the strobe-tach light on  
the blower paddle and synchronize it to  
the rotating mark.  
1. With the 5/16” nut driver, remove the 6  
sheet metal screws from the case top.  
2. Remove the rubber gasket (cover seal) from  
the lift bail.  
10. With the machine at HIGH IDLE the tach  
should read between 3650 and 3750 RPM.  
3. Remove the fuel cap. The rubber gasket for  
the fill tube will come off with the case top.  
With the machine at LOW IDLE the tach  
should read between 2150 and 2250 RPM.  
4. Remove the case top, then replace the fuel  
cap.  
5. Conduct this procedure with the gasoline  
engine OFF.  
6. Remove the spark plug wires to prevent  
accidental engine kickback or starting.  
7. With the black or red marking pencil, place  
a mark on one of the blower paddles. See  
Figure F.6 for location.  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.7  
FIGURE F.8  
HIGH IDLE ADJUSTMENT NUT  
LOW IDLE ADJUSTMENT NUT  
Solenoid  
3/8" Low Idle  
Adjustment  
Nut  
Muffler  
Housing  
Throttle  
linkage  
Choke  
Cable  
Rod  
3/8" High Idle  
Adjustment Nut  
11. If either of the readings is incorrect, adjust  
the throttle as follows:  
2. Start the engine and check the frequency  
counter. At HIGH IDLE (3700 RPM), the  
counter should read 60.8 to 62.5 Hz. At  
LOW IDLE (2200 RPM), the counter  
should read 35.8 to 37.5 Hz. Note that  
these are median measurements; hertz  
readings may vary slightly above or below.  
Adjust HIGH IDLE: Use the 3/8” wrench to  
turn the spring-loaded adjustment nut.  
See Figure F.8 for location of the adjust-  
ment nut. Turn the nut clockwise to  
increase HIGH IDLE speed. Adjust the  
speed until the tach reads between 3650  
and 3750 RPM.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLE  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 3/8”  
wrench to adjust the solenoid nut, which  
changes the amount of throw in the throttle  
lever arm. See Figure F.8 for location of the  
adjustment nut. Adjust the nut until the  
tach reads between 2150 and 2250 RPM.  
Adjust HIGH IDLE: Use the 3/8” wrench to  
turn the spring-loaded adjustment nut.  
See Figure F.7 for location of the adjust-  
ment nut. Turn the nut clockwise to in-  
crease HIGH IDLE speed.  
Adjust the  
speed until the frequency reads between  
60.8 and 62.5 Hz.  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLER  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 3/8”  
wrench to adjust the solenoid nut, which  
changes the amount of throw in the throttle  
lever arm. See Figure F.8 for location of the  
adjustment nut. Adjust the nut until the fre-  
quency reads between 35.8 and 375.Hz.  
Frequency Counter Method  
1. Plug the frequency counter into one of the  
115 VAC auxiliary receptacles.  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
Oscilloscope Method:  
Vibratach 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 16.2 mil-  
liseconds. At 2200 RPM, the waveform  
should exhibit a period of 27.3 millisec-  
onds. Refer to NORMAL OPEN CIRCUIT  
VOLTAGE WAVEFORM (115 VAC SUP-  
PLY) HIGH IDLE – NO LOAD in this sec-  
tion of the manual.  
1. Place the vibratach as close to the engine  
as possible. With the machine case top  
removed, the top of the air cleaner is the  
best location.  
2. Start the engine and observe the whip  
handle of the vibratach. At HIGH IDLE  
(3700 RPM), the whip handle should  
exhibit maximum oscillation. At LOW IDLE  
(2200 RPM), the whip handle should  
exhibit minimum oscillation. Note that  
these are median measurements; vibrat-  
ach readings may vary slightly above or  
below:  
2. If either waveform periods is incorrect,  
adjust the throttle as follows:  
Adjust HIGH IDLE: Use the 3/8” wrench to  
turn the spring-loaded adjustment nut.  
See Figure F.8 for location of the adjust-  
ment nut. Adjust the speed until the period  
is 16.2 milliseconds.  
3. If either of the vibratach indications is  
incorrect, adjust the throttle as follows:  
Adjust HIGH IDLE: Use the 3/8” wrench to  
turn the spring-loaded adjustment nut.  
See Figure F.8 for location of the adjust-  
ment nut. Turn the nut clockwise to  
increase HIGH IDLE speed. Adjust the  
speed until the vibratach whip handle  
exhibits maximum oscillation at 3650 to  
3750 RPM.  
Adjust LOW IDLE: First make sure there is  
no load on the machine. Set the IDLER  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 3/8”  
wrench to adjust the solenoid nut, which  
changes the amount of throw in the throttle  
lever arm. See Figure F.9 for location of  
the adjustment nut. Adjust the speed until  
the period is 27.3 milliseconds.  
Adjust LOW IDLE: First make sure that  
there is no load on the machine. Set the  
IDLER switch to AUTO and wait for the  
engine to change to low idle speed. Use  
the 3/8” wrench to adjust the solenoid nut,  
which changes the amount of throw in the  
throttle lever arm. See Figure F.9 for loca-  
tion of the adjustment nut. Adjust the  
speed until the vibratach whip handle  
exhibits minimum oscillation at 2150 to  
2250 RPM.  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
16.2 ms  
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 115 VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE)  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 200 AMPS AT 20 VDC  
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  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 200 AMPS AT 26 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  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
TYPICAL AC WELD OUTPUT WAVEFORM  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 225 AMPS AT 25 VDC  
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  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)  
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM  
ONE OUTPUT DIODE NOT FUNCTIONING  
CH1  
0 volts  
5 ms  
20 volts  
This is NOT the typical CV 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  
nonfunctioning output diode. Each  
vertical division represents 20 volts  
and each horizontal division repre-  
sents 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  
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F-38  
F-38  
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  
nonfunctioning 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  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (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  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)  
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM  
CH1  
0 volts  
5 ms  
50 volts  
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  
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F-41  
F-41  
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  
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F-42  
F-42  
NOTES  
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F-43  
F-43  
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 1-888-935-3877.  
DESCRIPTION  
The following procedure will aid the technician in accessing the generator brushes for  
maintenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
5/16” open end wrench  
7/16” wrench  
Slot head screw driver  
Needle nose pliers  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
PROCEDURE  
1. Remove the spark plug wires.  
13. 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.  
2. With the 5/16” nut driver, remove the 6  
sheet metal screws from the case top.  
3. Remove the rubber gasket (cover seal)  
from the lift bail.  
14. 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. A cable tie works  
well; See Figure F.9. This will hold the  
brushes up so that you can easily install  
the holder.  
4. Remove the fuel cap. The rubber gasket  
for the fill tube with come off with the case  
top.  
5. Remove the case top, then reinstall the  
fuel cap.  
6. WIth the 5/16” nut driver, remove the 5  
screws holding the right case side.  
15. Slide the brush holder assembly back into  
the bracket and, with the 5/16” open end  
wrench, install the two screws that hold it  
in place.  
7. Remove the right case side by lifting up  
and out.  
8. With the needle nose pliers, gently remove  
the blue and the red wires from the  
brushes. See Figure F.9.  
16. With the 7/16” wrench, install the brush  
holder assembly bracket to the stator  
frame.  
9. With the 7/16” wrench, remove the brush  
holder assembly bracket from the stator  
frame.  
17. Slowly remove the non-metallic retainer  
from the brush holder and let the brushes  
snap back against the slip rings.  
10. With the 5/16” open end wrench, remove  
the two screws that secure the brush hold-  
er assembly to the bracket. Slide the  
brush holder assembly out of the bracket.  
18. With the needle nose pliers, connect the  
red and the black wires to the appropriate  
terminals on the brushes. The red wire is  
inboard.  
11. To change the brushes, use the slot head  
screw driver to pop off the plastic retainer  
on the back of the brush holder assembly.  
19. Check the wire connections for clearance  
and tightness.  
20. Reinstall the case side, fuel cap, lift bail  
gasket, case top, and spark plug wires.  
12. 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.  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
SLIP RINGS  
A slight amount of darkening and wear of the  
slip rings and brushes is normal. Brushes  
should be inspected when a general overhaul is  
necessary. If brushes are to be replaced, clean  
slip rings with a fine emery paper.  
CAUTION  
Do not attempt to polish slip rings while engine  
is running.  
FIGURE F.9 - BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE  
Cable  
Tie  
Brushes  
7/16" Brush  
Assembly  
Bracket Bolts  
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F-46  
F-46  
NOTES  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
PRINTED CIRCUIT 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 1-888-935-3877.  
DESCRIPTION  
The following procedure will aid the technician in removing the printed circuit board for main-  
tenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
Phillips Head Screwdriver  
Diagonal cutters  
Wiring Diagram  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT  
(continued)  
FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION  
4 Self Tapping Screws (at corners)  
4 Pin Plug  
12 Pin Plug  
1/4" Q.C. Tabs  
PROCEDURE  
8. Remove the 12-pin molex plug from the  
Printed circuit board.  
Before starting the following procedure, refer to  
the topic “PC Board Troubleshooting  
Procedures” at the beginning of this section.  
9. Remove 4-pin molex from the current  
sensing leads.  
1. Remove the engine spark plug wires.  
10. Remove leads from two 1/4” Q.C. con-  
nectors.  
2. With the 5/16” nut driver, remove the 6  
sheet metal screws from the case top.  
3. Remove the rubber gasket (cover seal) from  
the lift bail.  
4. Remove the fuel cap. The rubber gasket for  
the fill tube will come off with the case top.  
5. Remove the case top, then reinstall the  
fuel cap.  
6. With the 5/16” nut driver, remove the 5  
screws holding the right case side.  
7. Remove the right case side by lifting up and  
out.  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
PRINTED CIRCUIT BOARD REMOVAL  
AND REPLACEMENT (continued)  
CAUTION  
Be sure to follow the recommended static-  
free methods for handling printed circuit  
boards. Failure to do so can result in perma-  
nent damage to the equipment.  
12. With the 1/4” phillips head screw driver,  
remove four self tapping screws holding  
the printed circuit board.  
13. Replace the old printed circuit board with  
a new one.  
14. Connect the 12-pin molex plug.  
15. Connect the 4-pin molex plug.  
16. Connect two 1/4” Q.C. wires to P.C.  
Board.  
17. Replace any cable ties that were cut dur-  
ing the removal procedure.  
18. Replace 4 self tapping screws previously  
removed.  
19. Reinstall the case side, fuel cap, lift bail  
gasket, case top, and spark plug wires.  
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F-50  
F-50  
NOTES  
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F-51  
F-51  
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 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 1-888-935-3877.  
DESCRIPTION  
The following procedure will aid the technician in removing the output rectifier bridge for  
maintenance or replacement.  
MATERIALS NEEDED  
1/2” wrench  
7/16” wrench  
3/8” wrench  
Dow Corning 340  
Wiring Diagram  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.11 - OUTPUT RECTIFIER CONNECTIONS  
#8  
L1 TO CHOKE  
TO POLARITY SWITCH  
W1  
TO S2  
(-)  
(3) 1/2"  
(+)  
(-)  
MOUNTING  
SCREWS  
(+)  
(+)  
(-)  
ENGINE  
(4) 7/16"  
MOUNTING  
SCREWS  
TO S2  
TO S1  
254  
NO NUT  
PROCEDURE  
1. Remove the engine spark plug wires.  
For the remaining steps, refer to Figure F.11.  
2. With the 5/16” nut driver, remove the 6 sheet  
metal screws from the case top.  
8. With the 1/2” wrench, remove the choke  
lead.  
3. Remove the rubber gasket (cover seal) from  
the lift bail.  
9. With the 1/2” wrench, remove the heavy  
cable and the #8 lead (White) from the rec-  
tifier negative heat sink.  
4. Remove the fuel cap. The rubber gasket for  
the fill tube will come off with the case top.  
10. WIth the 7/16” wrench, remove the W1 lead  
and the heavy lead going to the S2 Polarity  
switch.  
5. Remove the case top, then reinstall the fuel  
cap.  
11. With the 7/16” wrench, remove the S2 lead,  
the heavy lead going to the S1 Range  
switch, and 254 (White) lead to sense tur-  
roid.  
6. With the 5/16” nut driver, remove the 5  
screws holding the right case side.  
7. Remove the right case side by lifting up and  
out.  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT (continued)  
12. With the 1/2” wrench remove the three  
17. With the 7/16” socket wrench, install the  
W1 lead and the heavy lead going to the  
S2 Polarity switch. Note the order of fas-  
teners: flat washer at the bottom followed  
by pigtails, heavy leads, flat washer, lock  
washer, and nut.  
mounting nuts. Note the placement of the  
nylon insulators.  
13. Remove the rectifier assembly by tilting it  
up and lifting it toward the side of the  
machine.  
18. With the 1/2” socket wrench, install the  
heavy cable and the #8 lead (White) to the  
rectifier negative heat sink. Note the order  
of fasteners.  
14. Reassembly: Refer to the Wiring Diagram  
for proper connections to the positive and  
negative sides of the rectifier assembly.  
The two sides of the bridge are marked +  
and -, respectively.  
19. With the 1/2” socket wrench, install the  
choke lead and the #10 lead and note the  
order of fasteners.  
NOTE: Use Dow Corning 340 on all aluminum  
electrical connection surfaces.  
20. Reinstall the case side, fuel cap, lift bail  
gasket, case top, and spark plug wire.  
15. With the 1/2” wrench install the three  
mounting nuts.  
16. With the 7/16” socket wrench, install the  
S2 lead and the heavy lead going to the S1  
Range switch. Note the order of fasteners:  
flat washer at the bottom followed by pig-  
tails, heavy leads, flat washer, lock wash-  
er, and nut.  
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F-54  
F-54  
NOTES  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
ENGINE/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 1-888-935-3877.  
DESCRIPTION  
The following procedure will aid the technician in removing the engine and/or rotor for main-  
tenance or replacement of either component.  
NOTE: The procedures described here are for a Kohler engine. The same basic procedures  
apply to the other engines, although there may be a few slight wiring variations.  
MATERIALS NEEDED  
Lincoln Electric Rotor Removal Kit (S20788) - FOR ROTOR REMOVAL ONLY  
1/4” nut driver  
5/16” nut driver  
Slot head screw driver  
3/8” wrench  
7/16” wrench  
1/2” wrench  
9/16” wrench  
5/8” wrench  
Locking pliers  
Needle nose pliers  
Diagonal cutters  
Impact wrench  
Torque wrench (ft lbs)  
Feeler gauge (.017)  
INSTRUCTIONS  
For Engine and Rotor removal only, follow steps 1-25 under ENGINE AND ROTOR REMOVAL  
PROCEDURE. For reassembly of engine and rotor go to REASSEMBLY PROCEDURE.  
For rotor removal, follow the ENGINE AND ROTOR REMOVAL PROCEDURE and ROTOR  
REMOVAL PROCEDURE.  
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F-56  
F-56  
TROUBLESHOOTING & REPAIR  
ENGINE/ROTOR REMOVAL AND  
REPLACEMENT (continued)  
FIGURE F.12 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL  
5
3
1
6
8
7
1
2
9
1. STATOR COWLING COVER  
2. BLOWER FAN  
3. IDLE LINKAGE  
4
4. BRUSH HOLDER BRACKET  
5. ENGINE LIFT BAILS  
6. STATOR/ENGINE MOUNTING BOLTS  
7. ROTOR  
8. ROTOR SHAFT BEARING  
9. ROTOR THRU-BOLT  
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F-57  
F-57  
TROUBLESHOOTING & REPAIR  
ENGINE/ROTOR REMOVAL  
AND REPLACEMENT (continued)  
ENGINE AND ROTOR  
REMOVAL PROCEDURE  
1. Refer to Figure F.12 for component loca-  
15. With the 1/4” nut driver, disconnect the  
engine choke cable from the engine. Mark  
the location of the retainer for reassembly.  
The other end can remain connected.  
tions.  
2. Remove the engine spark plug wires.  
3. With the 5/16” nut driver, remove the 6  
sheet metal screws from the case top.  
16. Disconnect the idle linkage by unsnapping  
the plastic clip at the engine end of the  
idler rod. Snap the clip back onto the rod  
to avoid losing it; remove the rod for  
reassembly.  
4. Remove the rubber gasket (cover seal)  
from the lift bail.  
5. Remove the fuel cap. The rubber gasket  
for the fill tube will come off with the case  
top.  
17. Disconnect the fuel line from the fuel tank.  
Plug the hose and also plug the connec-  
tion at the fuel tank to prevent the escape  
of gasoline fumes.  
6. Remove the case top, the reinstall the fuel  
cap.  
18. Cut the cable ties and remove leads 224C  
and 210 from the oil pressure switch.  
7. WIth the 5/16” nut driver, remove the 5  
screws holding the right case side and the  
5 screws holding the left case side.  
19. With the 9/16” wrenches, remove the  
ground lead from the right engine foot  
mounting bolt.  
8. Remove the case sides by lifting up and  
out.  
20. With the 7/16” wrench, remove the brush  
holder bracket and leads #219 & 200A  
from the stator frame.  
9. WIth the 3/8” wrench, remove the battery  
cover.  
10. Disconnect the negative battery cable,  
then the positive battery cable. BE SURE  
TO DISCONNECT THE NEGATIVE BAT-  
TERY CABLE FIRST. Remove the battery  
and set it aside.  
21. Support the engine with a chain hoist. Lift  
bails are provided on the top of the engine  
for this purpose.  
22. With the 9/16” wrench, remove the right  
and left engine foot mounting bolts.  
11. With the diagonal cutters, cut the cable  
ties around the leads from the starter sole-  
noid and disconnect the leads. Remove  
lead 209A from the harness bundle.  
23. With the 9/16” wrench, remove the four  
bolts that hold the stator to the engine.  
There is one lock washer per bolt.  
12. Disconnect the large black plug in front of  
the fuel tank spout.  
24. With the chain hoist, unweight the engine  
gently. Use a pry bar to carefully pry  
between the engine and the stator frame in  
order to unseat the bearing on the end of  
the rotor shaft. Separate the engine and  
rotor from the stator frame, supporting the  
rotor by hand to prevent damage to the  
rotor core.  
13. With the 3/8” wrench, remove the cowling  
covers at the rear on the stator, both sides  
of the machine.  
14. WIth the 3/8” wrench, remove the two  
screws that hold the vertical fan baffle in  
place. Slide the baffle forward toward the  
rectifier bridge heat sink assembly.  
25. Move the engine and rotor assembly to a  
bench. The engine is off balance with the  
rotor still attached; therefore, support the  
end of the rotor with a wooden two-by-  
four before unhooking the chain hoist.  
15. Hold the rotor shaft with locking pliers and  
unscrew the blower fan. Turn the fan  
counterclockwise. You do not need to  
remove the fan from the machine, but be  
sure it is completely unscrewed from the  
rotor shaft.  
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F-58  
F-58  
TROUBLESHOOTING & REPAIR  
ENGINE/ROTOR REMOVAL AND  
REPLACEMENT (continued)  
FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR  
2
1. THRU-BOLT  
2. ROTOR  
1
ROTOR REMOVAL PROCEDURE  
1. To remove the rotor, double check that the  
engine spark plug wires are disconnect-  
ed. You will be turning the rotor during this  
procedure, and this could accidentally cause  
engine kickback.  
4. Turning it counterclockwise, screw in the  
left-hand thread rotor removal tool from the  
kit into the rotor shaft. Support the rotor with  
one hand and tighten the tool to approxi-  
mately 50 ft lbs with the torque or impact  
wrench.  
2. With an impact wrench, remove the rotor  
thru-bolt. See Figure F.13. If an impact  
wrench is not available, use the 5/8” box  
wrench. Hold the rotor with one hand and  
shock the wrench with the mallet to loosen  
the thru-bolt. The thru-bolt has a star wash-  
er and lock washer, beveled to conform to  
the rotor shaft. Pull out the thru-bolt.  
5. If the rotor does not pop off, tighten the rotor  
removal tool an additional 5 ft lbs. Hold the  
rotor with one hand until the rotor pops off  
the engine crankshaft.  
HINT: If the rotor does not pop off, hit the end of  
the rotor removal tool with a hammer.  
6. Slide the rotor the rest of the way off the  
crankshaft. Be careful not to lose the wash-  
er that fits between the blower fan and the  
rotor.  
3. Install the appropriate long thru-bolt (two are  
provided) supplied with Lincoln Electric  
Rotor Removal Kit S20788. The slot head  
must face out. Screw in the bolt with the slot  
head screw driver until the bolt bottoms out  
on the engine crankshaft, about 3/4”.  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
ENGINE/ROTOR REMOVAL AND  
REPLACEMENT (KIT S20788) (continued)  
REASSEMBLY PROCEDURE  
8. Attach leads to the oil pressure switch refer  
to wiring diagram. Replace any cut cable  
ties.  
NOTE: Lincoln Electric recommends that a new  
bearing (Lincoln part #M9300-85) be installed  
when you replace the rotor and blower assem-  
bly.  
9. Unplug the fuel tank connection and fuel  
hose and connect them.  
1. Clean the tapered engine crankshaft. Slide  
the rotor onto the shaft.  
10. Connect the idle linkage to the idler rod.  
Snap the plastic clip back into place.  
2. Insert the rotor thru-bolt, and with the  
torque wrench tighten the bolt to 50 ft lbs.  
11. Connect the engine choke cable at the  
position marked during disassembly.  
3. Support the engine/rotor assembly with the  
chain hoist. Fit the rotor into the stator  
frame, being careful not to damage the  
rotor core against the stator. The bearing  
will seat into its race about half way.  
12. Screw the blower fan back onto the end of  
the rotor shaft. Be sure the washer is in  
place and hand tighten the fan only.  
13. Reposition the vertical fan baffle and secure  
it with the two screws.  
4. Insert the four bolts and lock washers that  
hold the engine to the stator. With the  
9/16” wrench, draw the bolts up evenly in  
order to seat the bearing properly. Tighten  
to 22 ft-lb. moving diagonally from bolt to  
bolt.  
14. Install the two cowling covers at the rear of  
the stator.  
15. Connect the black plug in front of the fuel  
tank fill spout.  
5. Check the rotor-stator air gap with the .017  
feeler gauge. The measurement is taken at  
the blower end of the rotor before the fan is  
reinstalled. Turn the rotor with a pair of  
locking pliers as necessary so that the rotor  
“iron” is up to take the measurement. (The  
rotor has two flat sides, which are not mea-  
sured for air gap.) Slide in the gauge. Then  
rotate the shaft 180 degrees and measure  
again. If the gauge does not clear, loosen  
the four engine/stator bolts; retighten the  
bolts and recheck the air gap. Repeat until  
the proper .017 minimum air gap is  
achieved.  
16. Connect the leads to the starter solenoid  
and replace any cable ties cut during disas-  
sembly.  
17. Install the battery. Connect the positive  
battery cable, then the negative battery  
cable. BE SURE TO CONNECT THE POS-  
ITIVE BATTERY CABLE FIRST.  
18. Replace the battery cover.  
19. Reinstall the case side, fuel cap, lift bail  
gasket, and case top. Connect the spark  
plug wires.  
20. Conduct the “Retest after Repair” proce-  
dure, the following topic in this section of  
the manual.  
6. Fasten the ground lead to the right engine  
mounting bolt and install both bolts.  
7. Install the brush holder bracket back into  
the stator frame. Refer to the topic “Brush  
Removal and Replacement” in this sec-  
tion of the manual.  
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F-60  
F-60  
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  
3700-3750  
Load RPM  
NA  
3100-3600  
WELDER DC OUTPUT1  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
65 - 72  
21 - 26.5  
205 - 240  
WELDER AC OUTPUT1  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
73 - 80  
25 - 32  
225 - 275  
WELDER CV OUTPUT1  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Wire Feed CV  
29 - 33  
19 - 22  
200 - 220  
AUXILIARY POWER RECEPTACLE OUTPUT1  
230 Volt Receptacle  
115 Volt Receptacle2  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
246 - 264  
216 - 250  
34 - 41.5  
123- 132  
114 - 126  
35 - 42  
FIELD AMPS AND VOLTS  
Slip Ring Volts  
Field Amps  
28.0 - 46.0 VDC  
6.5 - 7.5 VDC  
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.  
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Section G-1  
Section G-1  
TABLE OF CONTENTS  
- ELECTRICAL DIAGRAMS SECTION -  
Electrical Diagrams................................................................................................Section G  
Wiring Diagram - Entire Machine - Code 11041 Only - (M20226) . . . . . . . . . . . . . . .G-2  
Wiring Diagram - Entire Machine - Code 11095 Only - (M20301) . . . . . . . . . . . . . . .G-3  
Wiring Diagram - Entire Machine - Above Code 11150 to 11393 - (M20431) . . . . . . .G-4  
Wiring Diagram - Entire Machine - Code 11398 - (M21269) . . . . . . . . . . . . . . . . . . .G-5  
Wiring Diagram - Entire Machine - Code 11394 &11395 - (M21270) . . . . . . . . . . . .G-6  
Entire Machine - Schematic - Code 11394 & 11395 - (L13105) . . . . . . . . . . . . . . . . .G-7  
Entire Machine - Schematic - Code 11398 - (L13103) . . . . . . . . . . . . . . . . . . . . . . . .G-8  
Entire Machine - Schematic - Code 11095 & 11253 Only - (L12257) . . . . . . . . . . . . .G-9  
Entire Machine - Schematic - Code 11151 Only - (L12249-1) . . . . . . . . . . . . . . . . .G-10  
Idler/Field Control PC Board Schematic - Code 11041 Only - (L12049) . . . . . . . . . .G-11  
Idler/Field Control PC Board Schematic - Codes Above 11050 Only - (L12197) . . .G-12  
Idler/Field Control PC Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*  
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mount-  
ed and or multi-layered and are therefore considered to be unserviceable.  
Assembly drawings of these boards are no longer provided.  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CODE 11041 ONLY -(M20226)  
RANGER 10,000 (KOHLER) (CSA)  
LEADS 3 AND 6:  
2 TURNS THRU TOROID IN  
OPPOSITE DIRECTIONS  
213  
1 TURN  
6
3
S3  
261  
260  
CCW  
254  
OUTPUT  
CONTROL  
R1  
GROUND SCREW  
L1  
209A  
ON UPPER CASEFRONT  
CHOKE  
211  
+
10  
76A 75A  
77A  
S2  
D1  
208C  
8
-
213A  
PCB1  
1
3
2
4
+
-
5D  
254  
J2  
CB7  
25A  
D2  
GND-I  
S1  
WORK  
5F  
12  
7
S2  
C1  
E
R1  
8
10  
J1  
1
GND-E  
R3  
R5  
IDLER  
ELECTRODE  
6
210  
S1  
SOLENOID  
GND-G  
224  
W2  
W1  
7
9
+
224A  
215A  
REACTOR  
C1  
STATOR  
6
HOUR METER  
5D  
GND-C  
GND-D  
GROUND SCREW  
ON LOWER CASEFRONT  
215  
3
3
9
6
7
5E  
GND-E  
75A  
76A  
77A  
224A  
6
209  
208 211  
3
12 VOLT  
BATTERY  
224C  
5
209A  
J5  
+
-
GND-D  
TERMINAL BLOCK  
(SEE CONN.)  
B
B B  
1
2
3
4
6A  
P5  
R
R
W
J2  
120V  
V
6
CB1  
40A  
GND-G  
ENGINE  
FOOT  
U
210  
200A  
+
GND-H  
12  
3B  
5
CR1  
219  
N.A.  
OIL  
PRESSURE  
SWITCH  
5L  
6B  
5K  
STARTER  
SOLENOID  
ENGINE  
CROSS  
J4  
120V/240V  
11  
IGNITION  
MODULE  
AC B+  
REGULATOR  
AC  
SUPPORT  
CB4  
20A  
STARTER  
GND-C  
11  
CB2  
40A  
B-  
FUEL  
ROTOR  
J3  
120V  
SHUTOFF  
SOLENOID  
5K  
CB3  
20A  
5
FLYWHEEL ALTERNATOR  
SLIP RING NEAREST LAMINATION  
5L  
ENGINE COMPONENTS  
3A  
SILVER COLORED  
TERMINALS  
3A  
(WHITE WIRES)  
GENERATOR LEAD END  
(NOTE CAVITY NUMBERS)  
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.  
CONNECTOR PIN NUMBERS:  
LEAD COLOR CODE:  
4
2
3
12  
7
1
211 (CAVITY #3)  
B = BLACK OR GRAY  
R = RED OR PINK  
W = WHITE  
U = BLUE  
224C (CAVITY #4)  
208 (CAVITY #2)  
V = VIOLET  
1
3
2
6
LOCATING TAB  
J2  
J1  
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.  
ELECTRICAL SYMBOLS PER E1537  
TERMINAL BLOCK  
CONNECTION  
M20226  
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CODE 11095 ONLY - (M20301)  
RANGER 10,000 (HONDA)  
LEADS  
2 TURNS  
OPPOSITE DIRECTIONS  
3
AND 6:  
213A  
213  
T
HRU  
T
OROID  
IN  
1 TURN  
6
3
S3  
261  
260  
CCW  
R1  
254  
OUTPU  
CONTROL  
T
GROUND S  
ON MIDDLE CASEFRONT  
CREW  
L1  
HOKE  
209A  
C
211  
+
10  
76A  
7
5A  
7
7A  
S2  
D1  
208C  
8
-
208C 213 210 211  
PCB1  
1
3
2
4
5D  
OFF  
254  
J2  
213A  
CB7  
5A  
AUTO  
X
X
X
X
X
X
X
HONDA  
ENGINE  
COMPONENTS  
GND-I  
2
S1  
W
ORK  
HIG  
H
5F  
12  
7
S2  
C1  
E
210  
R1  
8
10  
START  
X
X
J1  
1
GND-E  
R3  
R5  
IDLER  
ELECTRODE  
= CLOSED CIRCUI  
T
6
S1  
SOLENOID  
GN  
D
-G  
224  
W2  
W1  
7
9
+
224A  
REACTOR  
C1  
STATOR  
6
GND-C  
HOUR ME  
TER  
GROUND SCREW  
ON OWER CASEFRONT  
215  
GND-D  
L
5D  
3
3
9
6
7
5E  
GND-E  
75A  
76A  
77A  
224A  
6
W 211  
3
211B  
B/Y  
5
209A  
+
-
+
GND-D  
6A  
D9  
211B  
209  
J2  
120V  
-
225A  
211  
STARTER  
SOLENOI  
6
CB1  
0A  
GND-G  
B/Y  
210  
W
ENGINE  
FOO  
4
D
T
OI  
L
PRESSURE  
SWITCH  
CR1  
B/R  
IGNITION  
MODULE  
200A  
+
GND-H  
12  
5
B/Y  
3B  
219  
5L  
6B  
5K  
FUEL  
SHUTOFF  
SOLENOID  
ENGINE  
ROSS  
SUPPORT  
W/U  
J4  
120V/240V  
11  
C
GY  
GY  
W W  
CB4  
0A  
GND-C  
11  
CB2  
2
ROTOR  
J3  
120V  
20 AMP  
CHARGE COIL  
5K  
CB3  
0A  
1
2
3
4
5
4
0A  
6
STARTER  
5
2
SLIP RING NEAREST LAMINATION  
5L  
3A  
SILVER COLORED  
ERMINALS  
(WHI E WIRES)  
3A  
RECTIFIER/R  
EGULATOR  
T
T
MODULE  
B
HONDA ENGINE COMPONENTS  
CONNECTOR PIN NUMBERS:  
4
2
3
12  
LEAD CO  
OR GRAY  
/R = BLAC /RED  
GREY  
L
OR CODE  
B/Y  
/U =  
:
7
1
B
B
GY  
=
BLACK  
=
BLACK/YELLOW  
WHITE/BLUE  
K
W
1
3
2
6
=
J2  
J1  
ALL CASE FRONT COMPONENTS SHOWN VIE  
ELECTRICAL SYMBOLS PER E1537  
WED FROM REAR.  
A
M20301  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CODE 11150 T0 11393 - (M20431)  
RANGER 10,000  
LEADS AND 6:  
3
2 TURNS  
T
HRU  
T
OROID  
I
N
1 TURN  
6
3
CCW  
R1  
OPPOSITE DIRECTIONS  
254  
L1  
CHOKE  
261  
260  
O
UTPUT  
S2  
10  
CONTROL  
213  
+
7
6A  
75A  
7
7A  
S3  
D1  
GROUND SCREW  
ON UPPER  
213A  
1
8
2
-
208C  
CASEFRONT  
254  
211  
GND-I  
1
3
2
4
209A  
4
PCB1  
J2  
3
CB7  
5A  
5D  
W
ORK ELECTRODE  
2
5F  
S1  
12  
6
S2  
C1  
E
7
R1  
8
10  
210  
J1  
GROUND SCREW  
ON LOWER CASEFRONT  
213A  
R3  
R5  
1
S1  
6
IDLE  
SOLENOI  
R
D
W2  
W1  
7
9
REACTOR  
C1  
6
3
HOUR  
METER  
215  
STATOR  
+
5D  
224A  
3
9
7
GND-E  
224  
5E  
5
12 VOLT  
211  
208  
BA  
T
TERY  
224C  
209A  
209  
+
TERMINAL BLOCK  
6
6A  
J5  
P5  
J2  
120V  
GND-D  
(
SEE CONN.)  
GND-G  
3
1
2
4
CB1  
4
0A  
W
R
R
-
5F  
V
12  
224A  
224C  
CB3  
0A  
U
ENGINE  
FOOT  
5L  
5L  
5K  
11  
2
J4  
6B  
3B  
GND-H  
120V/240V  
GND-C  
N.A.  
200A  
+
219  
210  
CR1  
SOLENOI  
D
ENGINE  
CROSS  
SUPPORT  
OIL  
PRESSURE  
J3  
120V  
5K  
REGULA  
AC  
T
OR  
B-  
SWITC  
IGNITIO  
MO ULE  
H
11  
CB2  
0A  
5
ROTOR  
AC B+  
F
UEL  
SHUTOFF  
SOLENOI  
CB4  
N
STARTER  
4
2
0A  
D
D
3A  
SLIP RING NEAREST LAMINATION  
FL  
YWHEEL ALTERNATOR  
3
SILVER COLORED TERMINALS  
ENGINE COMPONENTS  
GENERATOR LEAD END  
(NOTE AVITY NUMBE S)  
CO  
N
NECTOR PIN NUMBERS:  
12  
C
R
N
.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.  
S3 OPERATION  
4
2
3
7
1
LEAD CO  
OR GRAY  
R = RED OR IN  
HITE  
L
OR CODE  
:
1
3
4
2
B
=
BLAC  
K
211 (CAVITY #3)  
U =  
B
LU  
E
OFF  
2
3
6
1
224C (CAVITY #4)  
208 (CAVITY #2)  
P
K
V
=
VIOLET  
X
X
X
X
X
X
X
AUTO  
J2  
J1  
W
=
W
LOCATING TA  
B
H
IG  
START  
= CLO  
H
X
T
ALL CASE FRONT COMPONENTS SHOWN VIE  
ELECTRICAL SYMBOLS PER E1537  
WED FROM REAR.  
T
ERMINAL BLOCK  
CO NECTION  
X
S
ED CIRCUI  
N
C
M20431  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
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G-5  
G-5  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CODE 11398 - (M21269)  
RANGER 10,000 (HONDA)  
LEADS  
2 TURNS  
OPPOSITE DIRECTIONS  
3
AND 6:  
213A  
213  
T
HRU  
T
OROID  
IN  
1 TURN  
6
3
S3  
261  
260  
CCW  
R1  
254  
WORK  
OUTPU  
CONTROL  
T
L1  
HOKE  
209A  
C
NEGATIVE  
POSITIVE  
211  
+
AC  
10  
76A  
7
5A  
7
7A  
B
ELECTRODE  
D1  
-
GROUND SCREW  
ON MIDDLE  
208C  
W1  
8
CASEFRONT  
208C 213 210 211  
E
PCB1  
1
3
2
4
S3  
5D  
OFF  
J2  
254  
213A  
CB7  
5A  
AUTO  
HIG  
X
X
X
X
X
X
X
ELECTRODE  
WORK  
HONDA  
ENGINE  
COMPONENTS  
GND-I  
2
S1  
H
5F  
12  
7
S2  
C1  
E
210  
R1  
8
10  
START  
X
X
J1  
1
GN  
D
-E  
WORK  
ELECTRODE  
R3  
R5  
IDLER  
= CLOSED CIRCUI  
T
6
S1  
6
SOLENOID  
GN  
D
-G  
224  
W2  
7
9
+
224A  
REACTOR  
C1  
STATOR  
6
GND-C  
HOUR ME  
TER  
GROUND SCREW  
ON OWER CASEFRONT  
215  
GND-D  
L
W1  
5D  
3
3
9
7
5E  
GND-E  
75A  
76A  
77A  
224A  
6
W 211  
3
6A  
211B  
B/Y  
209A  
3A  
5
+
-
CB4  
+
CB1  
0A  
2
0A  
4
GND-D  
D9  
211B  
3B  
209  
J2  
120V  
6A  
-
225A  
GND-G  
211  
STARTER  
SOLENOI  
B/Y  
210  
W
ENGINE  
FOO  
CB3  
0A  
D
T
12  
11  
OI  
L
2
PRESSURE  
SWITCH  
CR1  
B/R  
200A  
+
GND-H  
B/Y  
219  
IGNITION  
MODULE  
5L  
5L  
FUEL  
SHUTOFF  
SOLENOID  
5K  
J4  
120V/240V  
ENGINE  
ROSS  
SUPPORT  
W/U  
6B  
C
GY  
GY  
W W  
GND-C  
ROTOR  
J3  
120V  
20 AMP  
CHARGE COIL  
5K  
1
2
3
4
5
6
STARTER  
5
SLIP RING NEAREST LAMINATION  
RECTIFIER/REGULATOR  
SILVER COLORED TERMINALS  
MODULE  
B
HONDA ENGINE COMPONENTS  
CONNECTOR PIN NUMBERS:  
4
2
3
12  
LEAD CO  
OR GRAY  
/R = BLAC /RED  
GREY  
L
OR CODE  
B/Y  
/U =  
:
7
1
B
B
GY  
=
BLACK  
=
BLACK/YELLOW  
WHITE/BLUE  
K
W
1
3
2
6
=
J2  
J1  
ALL CASE FRONT COMPONENTS SHOWN VIE  
ELECTRICAL SYMBOLS PER E1537  
WED FROM REAR.  
C
M21269PRINT  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
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G-6  
G-6  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM CODE 11394 AND 11395 (M21270)  
RANGER 10,000 PLUS  
LEADS AND 6:  
3
2 TURNS  
T
HRU  
T
OROID  
I
N
1 TURN  
6
3
OPPOSITE DIRECTIONS  
254  
CCW  
R1  
WOR  
K
261  
260  
L1  
CHOKE  
AC  
O
UTPUT  
10  
S2  
CONTROL  
ELECTRODE  
NEGATIVE  
POSITIVE  
213  
C
HOKE  
+
7
6A  
75A  
7
7A  
S3  
S2  
W1  
D1  
GROUND SCREW  
ON UPPER  
E
ELECTRODE  
W
ORK  
213A  
1
8
2
-
208C  
CASEFRONT  
254  
211  
GND-I  
1
3
2
4
S3  
209A  
4
PCB1  
J2  
3
CB7  
5A  
5D  
W
ORK ELECTRODE  
2
5F  
S1  
12  
6
S2  
C1  
E
7
R1  
8
10  
210  
J1  
GROUND SCREW  
ON LOWER CASEFRONT  
213A  
R3  
R5  
1
S1  
6
IDLE  
SOLENOI  
R
D
W2  
7
9
REACTOR  
C1  
STATOR  
6
3
HOUR  
METER  
+
215  
W1  
5D  
224A  
3
9
7
GND-E  
224  
5E  
12 VOLT  
6
211  
208  
3
BA  
T
TERY  
6A  
GND-G  
224C  
209A  
209  
3A  
5
+
CB4  
TERMINAL BLOCK  
J5  
P5  
CB1  
(
SEE CONN.)  
20A  
4
0A  
3
1
2
4
GND-D  
3B  
J2  
120V  
6A  
W
R
R
-
5F  
V
224A  
224C  
U
ENGINE  
FOOT  
GND-H  
CB3  
12  
11  
20A  
N.A.  
200A  
+
219  
210  
CR1  
SOLENOI  
D
5L  
5L  
ENGINE  
CROSS  
SUPPORT  
5K  
J4  
OIL  
PRESSURE  
SWITC  
IGNITIO  
MO ULE  
6B  
120V/240V  
REGULA  
AC  
T
OR  
B-  
H
ROTOR  
AC B+  
F
UEL  
SHUTOFF  
SOLENOI  
GND-C  
N
STARTER  
J3  
120V  
D
D
5K  
SLIP RING NEAREST LAMINATION  
5
FLYWHEEL ALTERNATOR  
ENGINE COMPONENTS  
SILVER COLORED TERMINALS  
GENERATOR LEAD END  
(NOTE AVITY NUMBE S)  
CO  
N
NECTOR PIN NUMBERS:  
12  
C
R
N
.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.  
S3 OPERATION  
4
2
3
7
1
LEAD CO  
OR GRAY  
R = RED OR IN  
HITE  
L
OR CODE  
:
1
3
4
2
B
=
BLAC  
K
211 (CAVITY #3)  
U =  
B
LU  
E
OFF  
2
3
6
1
224C (CAVITY #4)  
208 (CAVITY #2)  
P
K
V
=
VIOLET  
X
X
X
X
X
X
X
AUTO  
IG  
START  
= CLO  
J2  
J1  
W
=
W
LOCATING TA  
B
H
H
X
ALL CASE FRONT COMPONENTS SHOWN VIE  
ELECTRICAL SYMBOLS PER E1537  
WED FROM REAR.  
T
ERMINAL BLOCK  
CO NECTION  
X
SED CIRCUIT  
N
C
M21270PRINT  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENTIRE MACHINE - CODES 11395 AND 11398 - (L13105)  
5 1 0 1 3 L  
CHANGE DETAIL: NEW.  
ENGINEERING CONTROLLED  
MANUFACTURER: No  
STATOR  
WELD  
WINDINGS  
Choke mounted on base in  
front of generator.  
ELECTRODE  
TERMINAL  
210DC/225AC  
145  
S2  
L1 CHOKE  
POLARITY  
SWITCH  
DC+  
D1 - BRIDGE RECTIFIER  
S1 - SELECTOR SWITCH  
W1  
33 TO 37 VAC BETWEEN W1  
AND C1 AT HIGH IDLE AND  
MAXIMUM RHEOSTAT NO LOAD.  
90  
Open Circuit Volts:  
DC-  
AC  
Max  
76  
68  
Min  
38  
34  
CV  
AC  
DC  
74 TO 78 VAC BETWEEN W1  
AND W2 AT HIGH IDLE AND  
MAXIMUM RHEOSTAT NO LOAD.  
254  
C1  
32  
18  
CV  
AC  
DC-  
DC+  
R3  
R5  
S2  
R1  
WORK  
TERMINAL  
AC tapped reactor mounted  
on base in front of generator.  
TWO POLE 3600  
RPM ALTERNATOR  
1
E
Rectifier mounted on top of choke and  
AC reactor in front of generator..  
T
TOROID: SENSES  
WELD OR AC  
POWER LOAD TO  
ACTIVATE IDLER  
S1  
W2  
U
R
N
AC TAPPED REACTOR  
STATOR AUXILIARY  
POWER WINDINGS  
Torroid Core located on  
wiring behind receptacles.  
REVOLVING  
FIELDS  
BRUSHES  
3
2 TURNS  
2 TURNS  
6A  
6
+
3
LEADS 3 AND 6 PASS  
THROUGH TORROID  
TWO TIMES IN  
3A  
RESISTANCE  
APPROX. 5 OHMS @ 75F  
120 V AC  
CB3  
20A  
CB4  
20A  
CB1  
40A  
Rotor Flashing: 2.5  
volts @ 0.5 amps.  
until generator build-up.  
240 V AC  
OPPOSITE DIRECTIONS  
10 TO 50 VDC AT  
1.7 TO 6.8 AMPS  
5
6B  
3B  
11  
12  
GND E  
120 V AC  
-
J3  
J2  
SLIP RINGS  
J4  
5K  
6
5L  
5
GND-D  
GND-G  
GND-C  
7
219  
200A  
EXCITATION WINDING  
VOLTS MEASURED AT  
MAX RHEOSTAT HIGH  
IDLE NO LOAD  
41 TO 45 VAC  
9
PC Board  
located on rear  
of fan  
STATOR  
EXCITATION  
WINDINGS  
+14V IN AUTO IDLE / OV IN HIGH IDLE  
baffle near top  
of machine.  
2
1
AUTO IDLE (2)  
OFF  
4
3
HIGH IDLE (3)  
+14V RUN  
IDLE SOLENOID COIL  
-ENERGIZED FOR  
LOW IDLE.  
S3 OPERATION  
S3  
START (4)  
1
3
2
4
+BAT (1)  
SUPPRESSOR FOR  
D1 RECTIFIER  
9
260  
219  
(J1-5)  
200A  
(J1-11)  
7
261  
(J2-3)  
OFF  
213A  
213  
(J2-4)  
LOAD  
SENSOR  
+
+10V  
X
X
X
X
X
X
X
AUTO  
HIGH  
START  
FIELD  
FLASHING  
CIRCUIT  
Idle solenoid is  
8 (J1-12)  
located on top of  
generator stator  
assembly 15 Ohms  
.05  
X
IDLE TIMER  
(12 SEC.)  
12 to 14 volts  
across coil when  
energized  
130V  
38J  
5K  
X= CLOSED CIRCUIT  
-
10 (J1-6)  
FLYBACK  
DIODE  
211B  
213A (J2-1)  
20  
FLYBACK  
DIODE  
211  
215 (J1-3)  
CB7 25A  
208C  
D9 BYPASSES  
OIL PRESSURE  
SWITCH DURING  
START  
209A  
+14V @ NORMAL OIL PRES.  
224 (J1-9)  
IDLE SOLENOID  
COIL  
SWITCHING  
TRANSISTOR  
+10 VOLT  
REGULATOR  
CIRCUIT  
+10V  
W
FIELD  
CURRENT  
FEEDBACK  
RESISTOR  
44 TO 45  
VAC  
BETWEEN  
GY LEADS  
AT HIGH  
IDLE  
0.1  
225A  
B/Y  
224A  
+
D9  
OUTPUT  
CONTROL  
10K  
B/Y  
B/Y  
(OVER-CURRENT PROTECTED)  
+10V  
Battery voltage:  
12.6 volts at rest  
14 volts engine running  
HYSTERESIS SWITCH  
+
5.64 V  
77A (J1-1)  
76A (J1-8)  
68.1K  
GY  
GY  
47.5  
-
4700uF  
80VDC  
W
W
B
B/R  
D9 located on rear  
of fan baffle on right  
side of machine.  
ENGINE  
STARTER  
SOLENOID  
LEVEL  
CHANGING  
AND DRIVER  
CIRCUIT  
+
W/U  
R1  
12 VOLT  
BATTERY  
+
210  
FUEL  
SHUTOFF  
SOLENOID  
1.28 V  
-
75A (J1-7)  
ENGINE OIL  
PRESSURE  
SWITCH  
OPENS ON  
LOW OIL  
PRESSURE  
47.5  
IGNITION  
MODULE  
FIELD CURRENT  
SWITCHING  
TRANSISTOR  
1 2  
3
4
6
5
+
ENGINE  
STARTER  
+
-
FRAME  
GROUND  
5E (J1-2)  
HOUR  
METER  
RECTIFIER/REGULATOR  
MODULE  
Control board common is  
one diode drop above  
welder frame ground.  
FIELD CURRENT FEEDBACK (0.1V PER AMP)  
(OVER-CURRENT PROTECTED)  
REVERSE VOLTAGE  
PROTECTION DIODE  
FEEDBACK AMP  
Fuel solenoid is mounted  
on engine carburetor.  
CONNECTOR PIN NUMBERS:  
If engine oil pressure drops below safe  
operating pressure, the oil pressure  
switch opens removing 12 volts from  
circuit 224 shutting off fuel solenoid to  
stop engine. Hourmeter will also stop  
running and PCB1 will denergize idle  
solenoid.  
FIELD & IDLE CONTROL  
PC BOARD (L12198-1)  
4
2
3
12  
7
1
LEAD COLOR CODE:  
GY = GRAY  
W = WHITE  
B/Y = BLACK/YELLOW W/U = WHITE/BLUE  
1
6
3
2
20 AMP  
CHARGE COIL  
J2  
J1  
B = BLACK  
B/R = BLACK/RED  
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED  
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
PROPRIETARY & CONFIDENTIAL:  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
DESIGN INFORMATION  
REFERENCE:  
L12257  
SCALE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:RANGER 10,000 (HONDA), RANGER 10,000 PLUS (SUBARU ROBIN)  
1
1
PAGE ___ OF ___  
MAP  
DJS  
-
DRAWN BY:  
ON 3 PLACE DECIMALS IS .002  
DOCUMENT  
REVISION:  
DOCUMENT  
NUMBER:  
ON ALL ANGLES IS .5 OF A DEGREE  
WITH PUBLISHED STANDARDS.  
DO NOT SCALE THIS DRAWING  
SUBJECT:  
MACHINE SCHEMATIC  
PROJECT  
NUMBER:  
MATERIAL TOLERANCE (" ") TO AGREE  
t
ENGINEER:  
APPROVED:  
MATERIAL  
DISPOSITION:  
APPROVAL  
DATE:  
L13105  
A
CRM38366  
NA  
NONE  
11/10/2006  
STRP  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENTIRE MACHINE - CDE 11394 - (L13103)  
3 1 0 1 3 L  
CHANGE DETAIL: REVISED EQUIPMENT TYPE.  
ENGINEERING CONTROLLED  
MANUFACTURER: No  
STATOR  
WELD  
WINDINGS  
Choke mounted on base in  
front of generator.  
ELECTRODE  
TERMINAL  
210DC/225AC  
145  
S2  
SWITCH  
DC+  
L1 CHOKE  
POLARITY  
D1 - BRIDGE RECTIFIER  
S1 - SELECTOR SWITCH  
W1  
33 TO 37 VAC BETWEEN W1  
AND C1 AT HIGH IDLE AND  
MAXIMUM RHEOSTAT NO LOAD.  
90  
Open Circuit Volts:  
DC-  
AC  
Max  
76  
68  
Min  
38  
34  
CV  
AC  
DC  
74 TO 78 VAC BETWEEN W1  
AND W2 AT HIGH IDLE AND  
MAXIMUM RHEOSTAT NO LOAD.  
254  
C1  
32  
18  
CV  
AC  
DC-  
DC+  
R3  
R5  
S2  
R1  
WORK  
TERMINAL  
AC tapped reactor mounted  
on base in front of generator.  
TWO POLE 3600  
RPM ALTERNATOR  
1
E
T
Rectifier mounted on top of choke and  
AC reactor in front of generator..  
TOROID: SENSES  
WELD OR AC  
POWER LOAD TO  
ACTIVATE IDLER  
S1  
W2  
U
R
N
AC TAPPED REACTOR  
STATOR AUXILIARY  
POWER WINDINGS  
Torroid Core located on  
wiring behind receptacles.  
REVOLVING  
FIELDS  
BRUSHES  
3
6A  
6
2 TURNS  
2 TURNS  
+
3
LEADS 3 AND 6 PASS  
THROUGH TORROID  
TWO TIMES IN  
3A  
RESISTANCE  
APPROX. 5 OHMS @ 75F  
120 V AC  
CB3  
20A  
CB4  
20A  
CB1  
40A  
Rotor Flashing: 2.5  
volts @ 0.5 amps.  
until generator build-up.  
240 V AC  
OPPOSITE DIRECTIONS  
10 TO 50 VDC AT  
1.7 TO 6.8 AMPS  
6B  
5
3B  
11  
12  
GND E  
120 V AC  
-
J3  
J2  
SLIP RINGS  
J4  
5K  
5L  
5
6
GND-D  
GND-C  
GND-G  
7
219  
200A  
EXCITATION WINDING  
VOLTS MEASURED AT  
MAX RHEOSTAT HIGH  
IDLE NO LOAD  
41 TO 45 VAC  
9
PC Board  
located on rear  
of fan  
STATOR  
EXCITATION  
WINDINGS  
+14V IN AUTO IDLE / OV IN HIGH IDLE  
baffle near top  
of machine.  
2
1
AUTO IDLE (2)  
OFF  
4
3
HIGH IDLE (3)  
+14V RUN  
IDLE SOLENOID COIL  
-ENERGIZED FOR  
LOW IDLE.  
S3 OPERATION  
S3  
START (4)  
1
3
2
4
+BAT (1)  
SUPPRESSOR FOR  
D1 RECTIFIER  
9
260  
219  
(J1-5)  
200A  
(J1-11)  
7
261  
(J2-3)  
OFF  
213  
(J2-4)  
LOAD  
SENSOR  
+
+10V  
X
X
X
X
X
X
X
AUTO  
HIGH  
START  
FIELD  
FLASHING  
CIRCUIT  
Idle solenoid is  
8 (J1-12)  
located on top of  
generator stator  
assembly 15 Ohms  
.05  
X
IDLE TIMER  
(12 SEC.)  
12 to 14 volts  
across coil when  
energized  
130V  
38J  
5K  
X= CLOSED CIRCUIT  
-
10 (J1-6)  
FLYBACK  
DIODE  
213A (J2-1)  
20  
FLYBACK  
DIODE  
211 224C  
215 (J1-3)  
CB7 25A  
208C  
+14V @ NORMAL OIL PRES.  
224 (J1-9)  
J51-4  
J51-3  
IDLE SOLENOID  
COIL  
SWITCHING  
TRANSISTOR  
+10 VOLT  
REGULATOR  
CIRCUIT  
J51 - Engine  
Connector  
+10V  
208  
FIELD  
209A  
CURRENT  
FEEDBACK  
RESISTOR  
0.1  
BATTERY  
CHARGING  
ALT/REG  
Engine diodes  
are in engine  
wire harness.  
224A 224C  
Fuel solenoid is mounted  
on engine carburetor.  
OUTPUT  
CONTROL  
10K  
J51-2  
(OVER-CURRENT PROTECTED)  
R
R
Battery voltage:  
12.6 volts at rest  
14 volts engine running  
J51-1  
U
+10V  
HYSTERESIS SWITCH  
68.1K  
+
B+  
5.64 V  
1.28 V  
77A (J1-1)  
76A (J1-8)  
75A (J1-7)  
47.5  
47.5  
4700uF  
80VDC  
IGNITION  
MODULE  
AC  
ENGINE  
STARTER  
SOLENOID  
LEVEL  
CHANGING  
AND DRIVER  
CIRCUIT  
+
ENGINE DIODES  
R1  
12 VOLT  
BATTERY  
+
-
210  
AC  
ENGINE OIL  
PRESSURE  
SWITCH  
OPENS ON  
LOW OIL  
PRESSURE  
FIELD CURRENT  
SWITCHING  
TRANSISTOR  
44 TO 45 VAC  
BETWEEN AC  
TERMINALS  
FUEL  
SHUTOFF  
SOLENOID  
+
GND  
ENGINE  
STARTER  
+
FRAME  
GROUND  
5E (J1-2)  
HOUR  
METER  
Control board common is  
one diode drop above  
welder frame ground.  
-
(OVER-CURRENT PROTECTED)  
AT HIGH IDLE  
FIELD CURRENT FEEDBACK  
REVERSE VOLTAGE  
PROTECTION DIODE  
FEEDBACK AMP  
Resistance of fuel  
solenoid cannot be  
accurately  
measured through  
diodes.  
CONNECTOR PIN NUMBERS:  
If engine oil pressure drops below safe  
operating pressure, the oil pressure  
switch opens removing 12 volts from  
circuit 224 shutting off fuel solenoid to  
stop engine. Hourmeter will also stop  
running and PCB1 will denergize idle  
solenoid.  
FIELD & IDLE CONTROL  
PC BOARD (L12198-1)  
4
2
3
12  
7
1
1
6
3
2
J2  
J1  
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED  
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
PROPRIETARY & CONFIDENTIAL:  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
DESIGN INFORMATION  
REFERENCE:  
L12249-1  
SCALE:  
MANUFACTURING TOLERANCE PER E2056  
ON 2 PLACE DECIMALS IS .02  
EQUIPMENT TYPE:  
SUBJECT:  
1
1
RANGER 10,000 PLUS (KOHLER)  
PAGE ___ OF ___  
MAP  
DJS  
-
DRAWN BY:  
ON 3 PLACE DECIMALS IS .002  
DOCUMENT  
REVISION:  
DOCUMENT  
NUMBER:  
ON ALL ANGLES IS .5 OF A DEGREE  
MACHINE SCHEMATIC  
PROJECT  
CRM38313-B  
MATERIAL TOLERANCE (" ") TO AGREE  
t
ENGINEER:  
WITH PUBLISHED STANDARDS.  
MATERIAL  
UF  
APPROVAL  
DATE:  
L13103  
B
APPROVED:  
NONE  
4/12/2007  
DISPOSITION:  
NUMBER:  
DO NOT SCALE THIS DRAWING  
STRP  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENTIRE MACHINE - CODE 11095 & 11253 ONLY - (L12257)  
7
2 1 2 5 L  
RELEASED A.01 FROM "X"  
CHANGE DETAIL:  
ENGINEERING CONTROLLED  
MANUFACTURER: No  
STATOR  
WELD  
Choke mounted on base in  
front of generator.  
ELECTRODE  
TERMINAL  
210DC/225AC  
145  
WINDINGS  
S2  
SWITCH  
L1 CHOKE  
POLARITY  
D1 - BRIDGE RECTIFIER  
W1  
S1 - SELECTORSWITCH  
DC+  
33 TO 37 VAC BETWEEN W1  
AND C1 AT HIGH IDLEAND  
MAXIMUMRHEOSTAT NO LOAD.  
90  
Open CircuitVolts:  
DC-  
AC  
Max  
Min  
38  
CV  
AC  
DC  
CV  
76  
68  
34  
74 TO 78 VAC BETWEEN W1  
AND W2 AT HIGH IDLEAND  
MAXIMUMRHEOSTAT NO LOAD.  
254  
C1  
32  
18  
AC  
DC-  
DC+  
R3  
R5  
R1  
WORK  
AC tapped reactor mounted  
on base in front of generator.  
TWOPOLE 3600  
1
E
S2  
TERMINAL  
RPMALTERNATOR  
Rectifier mounted on top of choke and T TOROID:SENSES  
S1  
W2  
AC reactor in front of generator..  
U WELD OR AC  
R POWER LOAD TO  
N ACTIVATEIDLER  
AC TAPPED REACTOR  
STATORAUXILIARY  
POWER WINDINGS  
Torroid Core locatedon  
wiring behind receptacles.  
REVOLVING  
FIELDS  
BRUSHES  
3
2TURNS  
2TURNS  
6A  
6
+
3
LEADS 3 AND6 PASS  
THROUGH TORROID  
TWO TIMES IN  
3A  
RESISTANCE  
120 VAC  
APPROX. 5 OHMS @ 75F  
CB3  
20A  
CB4  
20A  
CB1  
40A  
CB2  
40A  
Rotor Flashing: 2.5  
volts @0.5 amps.  
240 VAC  
OPPOSITE DIRECTIONS  
10 TO 50 VDCAT  
1.7 TO 6.8 AMPS  
until generator build-up.  
5
6B  
3B  
11  
12  
GND E  
120 VAC  
-
J3  
5L  
J2  
SLIP RINGS  
J4  
5K  
6
7
GND-D  
GND-G  
GND-C  
219  
200A  
EXCITATIONWINDING  
VOLTS MEASURED AT  
MAX RHEOSTAT HIGH  
IDLE NOLOAD  
41TO 45 VAC  
5
9
PC Board  
locatedon rear  
of fan  
baffle near top  
of machine.  
STATOR  
+14VIN AUTO IDLE / OV IN HIGH IDLE  
EXCITATION  
WINDINGS  
2
1
AUTO IDLE (2)  
HIGH IDLE (3)  
OFF  
4
3
+14VRUN  
IDLE SOLENOID COIL  
S3 OPERATION  
S3  
-ENERGIZED FOR  
+BAT (1)  
START (4)  
1
3
2
4
SUPPRESSOR FOR  
D1 RECTIFIER  
9
260  
219  
200A  
7
261  
LOWIDLE.  
OFF  
213A  
213  
(J2-4)  
LOAD  
SENSOR  
+
(J1-5)  
(J1-11)  
(J2-3)  
+10V  
X
X
X
AUTO  
HIGH  
FIELD  
FLASHING  
CIRCUIT  
Idle solenoid is  
locatedon top of  
generator stator  
assembly 15 Ohms  
8(J1-12)  
X
X
X
X
.05  
X
IDLE TIMER  
(12 SEC.)  
START  
12 to 14 volts  
across coil when  
energized  
130V  
38J  
5K  
X= CLOSED CIRCUIT  
-
10 (J1-6)  
213A (J2-1)  
215 (J1-3)  
FLYBACK  
DIODE  
211B  
20  
FLYBACK  
DIODE  
211  
CB7 25A  
208C  
D9 BYPASSES  
OIL PRESSURE  
SWITCHDURING  
START  
209A  
+14V @NORMAL OIL PRES.  
224 (J1-9)  
IDLE SOLENOID  
COIL  
+10 VOLT  
REGULATOR  
CIRCUIT  
+10V  
W
FIELD  
CURRENT  
FEEDBACK  
RESISTOR  
44 TO 45  
VAC  
SWITCHING  
TRANSISTOR  
0.1  
225A  
BETWEEN  
GY LEADS  
AT HIGH  
IDLE  
B/Y  
224A  
+
OUTPUT  
CONTROL  
10K  
B/Y  
B/Y  
(OVER-CURRENT PROTECTED)  
Battery voltage:  
D9  
12.6 volts at rest  
+10V  
HYSTERESIS SWITCH  
68.1K  
+
14 volts enginerunning  
5.64 V  
77A (J1-1)  
76A (J1-8)  
GY  
47.5  
47.5  
-
4700uF  
80VDC  
W W B  
B/R  
D9 located on rear  
ENGINE  
GY  
LEVEL  
CHANGING  
AND DRIVER  
CIRCUIT  
+
W/U  
of fan baffle onright  
side of machine.  
R1  
STARTER  
SOLENOID  
12 VOLT  
+
-
210  
FUEL  
BATTERY  
1.28 V  
75A (J1-7)  
SHUTOFF  
SOLENOID  
ENGINE OIL  
IGNITION  
MODULE  
FIELD CURRENT  
SWITCHING  
TRANSISTOR  
1 2  
3
4
6
5
+
HOUR  
PRESSURE  
SWITCH  
ENGINE  
+
FRAME  
STARTER  
5E (J1-2)  
REVERSE VOLTAGE  
PROTECTION DIODE  
OPENS ON  
LOWOIL  
RECTIFIER/REGULATOR  
MODULE  
Control board common is  
-
GROUND  
FIELD CURRENT FEEDBACK (0.1V PER AMP)  
(OVER-CURRENT PROTECTED)  
METER  
one diode drop above  
FEEDBACK AMP  
PRESSURE  
welder frame ground.  
Fuel solenoid is mounted  
on engine carburetor.  
CONNECTOR PIN NUMBERS:  
If engine oil pressure drops below safe  
operating pressure, the oil pressure  
switch opens removing 12 volts from  
circuit 224 shutting off fuelsolenoid to  
stop engine. Hourmeter will also stop  
running and PCB1 will denergize idle  
solenoid.  
FIELD & IDLE CONTROL  
PC BOARD (L12198-1)  
4
2
3
12  
7
1
LEADCOLORCODE:  
GY = GRAY  
W=WHITE  
B/Y = BLACK/YELLOW W/U = WHITE/BLUE  
1
3
2
20AMP  
6
J2  
J1  
CHARGE COIL  
B=BLACK  
B/R = BLACK/RED  
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED  
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
PROPRIETARY & CONFIDENTIAL:  
MANUFACTURING TOLERANCE PER E2056  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
DESIGN INFORMATION  
REFERENCE:  
L12249  
SCALE:  
EQUIPMENT TYPE:  
SUBJECT:  
PAGE _1__ OF ___  
1
RANGER 10,000 HONDA  
MACHINE SCHEMATIC  
ON 2 PLACE DECIMALS IS .02  
BAM  
BAM  
-
DRAWN BY:  
ENGINEER:  
APPROVED:  
ON 3 PLACE DECIMALS IS .002  
DOCUMENT  
DOCUMENT  
NUMBER:  
ON ALL ANGLES IS .5 OF A DEGREE  
WITH PUBLISHED STANDARDS.  
DO NOT SCALE THIS DRAWING  
REVISION:  
MATERIAL TOLERANCE (" ") TO AGREE  
t
MATERIAL  
UF  
APPROVAL  
DATE:  
PROJECT  
L12257  
A
CRM33675  
NUMBER:  
NONE  
8/20/03  
DISPOSITION:  
STRP  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-10  
G-10  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ENTIRE MACHINE - CODE 11151 ONLY - (L12249-1)  
1 4 2 9 - 1 2 L  
NEW  
CHANGE DETAIL:  
ENGINEERING CONTROLLED  
MANUFACTURER: No  
STATOR  
WELD  
Choke mounted on base in  
front of generator.  
ELECTRODE  
TERMINAL  
210DC/225AC  
145  
WINDINGS  
S2  
SWITCH  
L1 CHOKE  
POLARITY  
D1 - BRIDGE RECTIFIER  
W1  
S1 - SELECTORSWITCH  
DC+  
33 TO 37 VAC BETWEEN W1  
AND C1 AT HIGH IDLEAND  
MAXIMUMRHEOSTAT NO LOAD.  
90  
Open CircuitVolts:  
DC-  
AC  
Max  
Min  
38  
CV  
AC  
DC  
CV  
76  
68  
34  
74 TO 78 VAC BETWEEN W1  
AND W2 AT HIGH IDLEAND  
MAXIMUMRHEOSTAT NO LOAD.  
254  
C1  
32  
18  
AC  
DC-  
DC+  
R3  
R5  
R1  
WORK  
AC tapped reactor mounted  
on base in front of generator.  
TWOPOLE 3600  
1
E
S2  
TERMINAL  
RPMALTERNATOR  
T
Rectifier mounted on top of choke and  
AC reactor in front of generator..  
TOROID:SENSES  
WELD OR AC  
S1  
W2  
U
R
N
POWER LOAD TO  
ACTIVATEIDLER  
AC TAPPED REACTOR  
STATORAUXILIARY  
POWER WINDINGS  
Torroid Core locatedon  
wiring behind receptacles.  
REVOLVING  
FIELDS  
BRUSHES  
3
6A  
6
2TURNS  
2TURNS  
+
3
LEADS 3 AND6 PASS  
THROUGH TORROID  
TWO TIMES IN  
3A  
RESISTANCE  
120 VAC  
CB3  
20A  
CB4  
20A  
CB1  
40A  
CB2  
40A  
APPROX. 5 OHMS @ 75F  
Rotor Flashing: 2.5  
volts @0.5 amps.  
240 VAC  
OPPOSITE DIRECTIONS  
10 TO 50 VDCAT  
1.7 TO 6.8 AMPS  
6B  
until generator build-up.  
5
3B  
11  
12  
GND E  
120 VAC  
-
J3  
J2  
SLIP RINGS  
J4  
5K  
5L  
5
6
7
GND-D  
GND-G  
GND-C  
219  
200A  
EXCITATIONWINDING  
VOLTS MEASURED AT  
MAX RHEOSTAT HIGH  
IDLE NOLOAD  
41 TO 45 VAC  
9
PC Board  
locatedon rear  
of fan  
STATOR  
+14VIN AUTO IDLE / OV IN HIGH IDLE  
EXCITATION  
WINDINGS  
baffle near top  
of machine.  
2
1
AUTO IDLE (2)  
HIGH IDLE (3)  
OFF  
4
3
+14VRUN  
IDLE SOLENOID COIL  
S3 OPERATION  
S3  
-ENERGIZED FOR  
+BAT (1)  
START (4)  
1
3
2
4
SUPPRESSOR FOR  
D1 RECTIFIER  
9
260  
219  
200A  
7
261  
LOWIDLE.  
Idle solenoid is  
locatedon top of  
generator stator  
assembly 15 Ohms  
OFF  
213  
(J2-4)  
LOAD  
SENSOR  
+
(J1-5)  
(J1-11)  
(J2-3)  
+10V  
X
X
X
AUTO  
HIGH  
FIELD  
FLASHING  
CIRCUIT  
8(J1-12)  
X
X
X
X
.05  
X
IDLE TIMER  
(12 SEC.)  
START  
12 to 14 volts  
across coil when  
energized  
130V  
38J  
5K  
X= CLOSED CIRCUIT  
-
10 (J1-6)  
213A (J2-1)  
215 (J1-3)  
FLYBACK  
DIODE  
20  
FLYBACK  
DIODE  
224C  
211  
R
CB7 25A  
208C  
+14V @NORMAL OIL PRES.  
224 (J1-9)  
J51-4  
J51-3  
IDLE SOLENOID  
COIL  
SWITCHING  
TRANSISTOR  
+10 VOLT  
REGULATOR  
CIRCUIT  
J51 - Engine  
Connector  
+10V  
208  
FIELD  
209A  
CURRENT  
FEEDBACK  
RESISTOR  
0.1  
BATTERY  
CHARGING  
ALT/REG  
Engine diodes  
are in engine  
wire harness.  
224A 224C  
Fuel solenoid is mounted  
on engine carburetor.  
OUTPUT  
J51-2  
(OVER-CURRENT PROTECTED)  
+10V  
R
Battery voltage:  
J51-1  
CONTROL  
12.6 volts at rest  
10K  
U
HYSTERESIS SWITCH  
+
B+  
AC  
14 volts enginerunning  
5.64 V  
77A (J1-1)  
76A (J1-8)  
68.1K  
47.5  
4700uF  
80VDC  
IGNITION  
MODULE  
ENGINE  
LEVEL  
CHANGING  
AND DRIVER  
CIRCUIT  
+
ENGINE DIODES  
R1  
STARTER  
SOLENOID  
12 VOLT  
+
210  
BATTERY  
AC  
1.28 V  
-
75A (J1-7)  
ENGINE OIL  
PRESSURE  
SWITCH  
47.5  
FIELD CURRENT  
SWITCHING  
TRANSISTOR  
44 TO 45 VAC  
FUEL  
+
GND  
BETWEEN AC  
ENGINE  
SHUTOFF  
SOLENOID  
+
-
FRAME  
TERMINALS  
STARTER  
5E (J1-2)  
HOUR  
OPENS ON  
LOWOIL  
Control board common is  
one diode drop above  
welder frame ground.  
(OVER-CURRENT PROTECTED)  
GROUND  
AT HIGHIDLE  
FIELD CURRENT FEEDBACK  
METER  
REVERSE VOLTAGE  
PROTECTION DIODE  
FEEDBACK AMP  
PRESSURE  
Resistance of fuel  
solenoid cannot be  
accurately  
CONNECTOR PIN NUMBERS:  
If engine oil pressure drops below safe  
operating pressure, the oil pressure  
switch opens removing 12 volts from  
circuit 224 shutting off fuelsolenoid to  
stop engine. Hourmeter will also stop  
running and PCB1 will denergize idle  
solenoid.  
FIELD & IDLE CONTROL  
PC BOARD (L12198-1)  
4
2
3
12  
7
1
measured through  
diodes.  
1
3
2
6
J2  
J1  
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED  
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
PROPRIETARY & CONFIDENTIAL:  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
DESIGN INFORMATION  
REFERENCE:  
L11942  
SCALE:  
MANUFACTURING TOLERANCE PER E2056  
EQUIPMENT TYPE:  
SUBJECT:  
PAGE _1__ OF ___  
1
RANGER 10,000 KOHLER  
MACHINE SCHEMATIC  
ON 2 PLACE DECIMALS IS .02  
BAM  
BAM  
-
DRAWN BY:  
ENGINEER:  
APPROVED:  
ON 3 PLACE DECIMALS IS .002  
DOCUMENT  
DOCUMENT  
NUMBER:  
ON ALL ANGLES IS .5 OF A DEGREE  
REVISION:  
MATERIAL TOLERANCE (" ") TO AGREE  
t
WITH PUBLISHED STANDARDS.  
MATERIAL  
NA  
APPROVAL  
DATE:  
PROJECT  
L12249-1  
A
CRM33679  
NUMBER:  
NONE  
12/12/03  
DISPOSITION:  
DO NOT SCALE THIS DRAWING  
STRP  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-11  
G-11  
ELECTRICAL DIAGRAMS  
SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD - CODE 11041 ONLY - (L12049)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-12  
SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD - CODES ABOVE 11050 ONLY - (L12197-1)  
G-12  
ELECTRICAL DIAGRAMS  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER® 10,000 & RANGER® 10,000 PLUS  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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