Lincoln Electric SVM168-B service manual Ranger 10,000

Page 104

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G-4

ELECTRICAL DIAGRAMS

G-4

WIRING DIAGRAM - CODE 11150 T0 11393 - (M20431)

 

 

RANGER 10,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LEADS 3 AND 6:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 TURN

 

6

2 TURNS THRU TOROID IN

 

 

 

 

CCW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPPOSITE DIRECTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

254

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

261

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S2

 

 

 

 

 

 

 

 

 

260

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

77A

76A

75A

 

S3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GROUND SCREW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213A

 

2

1

 

 

 

 

 

 

 

ON UPPER

 

 

 

 

 

 

-

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

208C

 

 

 

 

 

CASEFRONT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

211

 

 

GND-I

 

 

 

 

 

 

 

 

254

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

209A

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

2

 

 

 

 

 

 

3

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J2

 

PCB1

 

 

 

 

 

CB7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5D

 

 

WORK

ELECTRODE

 

 

 

 

 

 

 

 

 

3

 

4

 

 

 

 

 

 

 

 

 

 

 

 

25A

 

 

GND-G GND-D GND-E

 

S1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5F

GND-C

GROUND SCREW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213A

 

 

R3

R5

C1

E

 

 

10

6

 

 

 

 

 

 

 

1

 

210

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

S2

 

 

8

12

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J1

 

 

 

 

 

 

 

 

 

 

 

 

 

ON LOWER CASEFRONT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

 

 

W2

S1

 

 

 

 

 

 

 

219

200A

215

224

5E

76A

77A

75A

 

 

 

 

 

 

 

 

IDLER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HOUR

 

 

 

 

 

 

 

 

 

 

 

 

REACTOR

 

6

3

7

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

METER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

215

 

 

 

 

 

STATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224A

 

 

 

 

5D

 

 

 

 

 

 

 

 

 

6

 

3

9

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224

5E

 

 

 

 

 

 

 

 

 

GND-E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12 VOLT

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

208 211

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BATTERY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224C

 

 

 

209A

209

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL BLOCK

 

 

 

J5

 

 

 

 

6

6A

 

 

 

 

J2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(SEE CONN.)

 

 

 

 

 

 

 

 

GND-G

 

 

GND-D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

2

3

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P5

 

 

 

 

 

 

 

 

 

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-

 

 

CB1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

 

 

 

 

R

 

 

 

40A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224A

 

 

V

 

 

 

R

 

5F

 

 

12

 

CB3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224C

 

 

 

 

U

 

 

 

ENGINE

 

 

 

11

 

5L

 

5K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FOOT

 

 

J4

20A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6B

 

 

3B

 

 

 

 

 

 

 

 

 

 

 

 

 

N.A.

 

 

 

 

 

 

 

GND-H

 

 

120V/240V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

210

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

219

 

200A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

CR1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OIL

 

 

 

 

 

 

 

 

ENGINE

 

 

GND-C

 

 

 

J3

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

REGULATOR

 

 

 

 

CROSS

 

 

 

5K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRESSURE

 

 

 

 

 

 

SUPPORT

 

 

 

 

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

11

 

 

 

5L

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

B+

AC

 

 

 

 

 

FUEL

 

 

 

 

 

 

 

 

 

 

 

ROTOR

 

 

 

 

 

 

 

B-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IGNITION

 

 

 

 

 

 

 

 

 

CB2

 

 

 

 

 

 

 

CB4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STARTER

 

SHUTOFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MODULE

 

 

 

 

 

 

 

40A

 

 

 

 

 

 

 

20A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

 

 

 

3A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SLIP RING NEAREST LAMINATION

 

 

FLYWHEEL ALTERNATOR

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE COMPONENTS

 

 

 

 

 

 

 

 

 

SILVER COLORED TERMINALS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section TOC

Master TOC

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

 

CONNECTOR PIN NUMBERS:

 

LEAD COLOR CODE:

4

3

12

 

 

7

 

 

 

 

 

 

B = BLACK OR GRAY

U = BLUE

2

1

6

3

2

1

R = RED OR PINK

V = VIOLET

 

 

 

 

 

 

W = WHITE

 

J2

 

J1

 

 

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

S3 OPERATION

 

1

2

3

4

OFF

 

 

 

 

AUTO

X

X

X

 

HIGH

X

 

X

 

START

X

 

X

X

X = CLOSED CIRCUIT

GENERATOR LEAD END (NOTE CAVITY NUMBERS)

211 (CAVITY #3)

224C (CAVITY #4)

LOCATING TAB

208 (CAVITY #2)

TERMINAL BLOCK

CONNECTION

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ELECTRICAL SYMBOLS PER E1537

C

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 yourM20431machine.

RANGER® 10,000 & RANGER® 10,000 PLUS

Page 103 Page 105
Image 104
Page 103 Page 105
Contents Ranger 10,000 /10,000 Plus For Engine SafetyPowered equipment ARC Rays can burn Fumes and GasesIii Welding and Cutting Sparks can cause fire or ExplosionCylinder may explode If damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section Installation Height Width Depth WeightHorsepower Operating Speed RPM Safety Precautions Spark ArresterMachine Grounding TowingPRE-OPERATION Service GasolineVehicle Mounting Can cause fire or explosionWelding Output Cables Total Combined Length of Electrode and Work CablesAngle of Operation LiftingConnection of Lincoln Electric Wire Feeders InstructionsStacking Welder OperationAuxiliary Power 120/240 Volt Dual Voltage ReceptacleDuplex Receptacles Motor StartingThese Devices Without Additional Resistive Type Loads Not USE These Devices With a Ranger 10,000Simultaneous Welding and Power Standby Power ConnectionsFigure A.1 Ranger 10,000 & Ranger 10,000 Plus Operation Operation SectionSection B-1 Welder Controls Function and Operation Engine SwitchOperation Polarity Switch Range SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialSTARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine Stopping the EngineTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick Constant Current Welding Start Switch Wire FEED, LN-15 Summary of Welding ProcessesAccessories Section Section C-1Accessories Optional Equipment Field InstalledRecommended Equipment StickTIG Welding Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1Kohler Honda MaintenanceSafety Precautions AIR Cleaner and Other Maintenance OIL Filter ChangeEngine Adjustments BatteryOverspeed is Hazardous Slip RingsPre-Cleaner Oil FilterAir Filter ElementFigure D.1 Major Component Location Theory of Operation Theory of Operation SectionSection E-1 BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler Solenoid Theory of OperationRotor Field Feedback and Auxiliary Power Figure E.3 Rotor Field Feedback and Auxiliary PowerWeld WINDING, REACTOR, Range Switch Figure E.4 Weld WINDING, REACTOR, and Range SwitchOutput BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Troubleshooting & Repair Section Section F-1Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric ShockTroubleshooting Guide Output ProblemsOutput Problems Field Winding Voltage Test Adjustment Test Troubleshooting Guide Output Problems Engine Problems Make sure the leads are looped Charging Circuit Test Welding Problems Ranger 10,000 & Ranger 10,000 Plus Materials Needed Rotor Voltage TestTest Description Test Procedure Rotor Resistance Test Rotor Resistance Test Figure F.2 Location of Rotor Slip RingsTroubleshooting & Repair Ranger 10,000 & Ranger 10,000 Plus Auxiliary and Field Winding Test To test the 230 VAC winding Auxiliary and Field Winding TestTo test the 115 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test Figutpure F.4 Locationctifof Output Rectifier Leads 26TROUBLESHOOTING & REPAIRF-26Output Rectifier Bridge Test Charging Circuit Test Charging Circuit Test Figure F.5 Location of Voltage RegulatorEngine Throttle Adjustment Test Engine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH MethodFigure F.7 Oscilloscope Method High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 200 Amps AT 20 VDC Typical DC Weld Output Waveform CV ModeMachine Loaded Typical DC Weld Output Waveform CC Mode Machine Loaded to 200 Amps AT 26 VDCTypical AC Weld Output Waveform Machine Loaded to 225 Amps AT 25 VDCAbnormal Open Circuit Weld Voltage Waveform CV Mode Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit Weld Voltage Waveform CV Mode Normal Open Circuit DC Weld Voltage Waveform CC Mode Normal Open Circuit AC Weld Voltage Waveform Ranger 10,000 & Ranger 10,000 Plus Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureSlip Rings Figure F.9 Brush LEADS/BRUSHES Retained with Cable TIERanger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Printed Circuit Board Removal and Replacement Figure F.10 Printed Circuit Board LocationReplacement Printed Circuit Board RemovalRanger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Remove the case top, then reinstall the fuel cap Output Rectifier Bridge RemovalSection TOC Ranger 10,000 & Ranger 10,000 Plus ENGINE/ROTOR Removal and Replacement InstructionsENGINE/ROTOR Removal Figure F.12 Component LOCATIONS, ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLTReplacement KIT S20788 Reassembly ProcedureRetest After Repair Section G-1 Electrical Diagrams SectionElectrical Diagrams Electrical Diagrams Wiring Diagram Code 11041 only -M20226Wiring Diagram Code 11095 only M20301 Ranger 10,000 HondaRanger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus Schematic Entire Machine Codes 11395 and 11398 L13105 L13105Schematic Entire Machine CDE 11394 L13103 L13103Schematic Entire Machine Code 11095 & 11253 only L12257 Schematic Entire Machine Code 11151 only L12249-1 L12249Electrical Diagrams Electrical Diagrams
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