Lincoln Electric SVM168-B service manual Wiring Diagram Code 11398 M21269

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G-5

ELECTRICAL DIAGRAMS

G-5

WIRING DIAGRAM - CODE 11398 - (M21269)

RANGER 10,000 (HONDA)

213A

LEADS 3 AND 6:

213

1 TURN

2 TURNS THRU TOROID IN

OPPOSITE DIRECTIONS

6

S3

3

261

CCW

254

260

WORK

OUTPUT

R1

209A

L1

CONTROL

211

NEGATIVE

CHOKE

POSITIVE

+

AC

10

77A

76A

75A

B

ELECTRODE

D1

GROUND SCREW

208C

ON MIDDLE

W1

-

8

208C 213

210

211

CASEFRONT

E

1

2

PCB1

OFF

5D

S3

J2

254

AUTO

X

X

X

CB7

3

213A

HONDA

WORK ELECTRODE

S1

4

25A

GND-I

HIGH

X

X

ENGINE

5F

S2

E

12

7

210

R1

START

X

X

X

COMPONENTS

8

J1

GND-E

WORK

R3

R5

C1

10

X = CLOSED CIRCUIT

IDLER

S1

6

1

GND-G

ELECTRODE

W2

200A

219

224

215

76A 5E 75A

224

+

SOLENOID

77A

224A

REACTOR

6

7

9

HOUR METER

215

GND-C

GROUND SCREW

C1

GND-D

STATOR

ON LOWER CASEFRONT

W1

5D

6

3

9

7

3

5E

GND-E

224A

W 211

6

75A

77A

76A

211B

6A

3

B/Y

209A

+

5

3A

+

CB4

CB1

20A

D9

211B

40A

GND-D

3B

209

J2

-

6A

-

225A

211

GND-G

120V

210

W

B/Y

STARTER

ENGINE

CB3

SOLENOID

FOOT

OIL

12

11

20A

PRESSURE

B/R

B/Y

CR1

GND-H

219

200A

SWITCH

IGNITION

5L

MODULE

FUEL

ENGINE

J4

5K

+

W/U

SHUTOFF

6B

120V/240V

SOLENOID

CROSS

GY

W W

SUPPORT

GY

GND-C

ROTOR

J3

20 AMP

1

2 3

4 5

STARTER

5K

120V

CHARGE COIL

6

5L

5

SLIP RING NEAREST LAMINATION

RECTIFIER/REGULATOR

SILVER COLORED TERMINALS

MODULE

B

HONDA ENGINE COMPONENTS

CONNECTOR PIN NUMBERS:

LEAD COLOR CODE:		4	3	12	7
B = BLACK OR GRAY	B/Y = BLACK/YELLOW
B/R = BLACK/RED	W/U = WHITE/BLUE	2	1	6	3 2 1
GY = GREY		J2			J1
		J2			J1

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

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 ofM21269PRINTyour machine.

RANGER® 10,000 & RANGER® 10,000 PLUS

Image 105

Contents Ranger 10,000 /10,000 Plus Safety Powered equipmentFor Engine Fumes and Gases ARC Rays can burnWelding and Cutting Sparks can cause fire or Explosion Cylinder may explode If damagedIii Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation SectionSection A-1 Height Width Depth Weight InstallationHorsepower Operating Speed RPM Spark Arrester Safety PrecautionsMachine Grounding TowingGasoline PRE-OPERATION ServiceVehicle Mounting Can cause fire or explosionTotal Combined Length of Electrode and Work Cables Welding Output CablesAngle of Operation LiftingInstructions Connection of Lincoln Electric Wire FeedersStacking Welder Operation120/240 Volt Dual Voltage Receptacle Auxiliary PowerDuplex Receptacles Motor StartingNot USE These Devices With a Ranger 10,000 These Devices Without Additional Resistive Type LoadsStandby Power Connections Simultaneous Welding and PowerFigure A.1 Ranger 10,000 & Ranger 10,000 Plus Operation Section Section B-1Operation Engine Switch OperationWelder Controls Function and Operation Range Switch Polarity SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialBREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG Constant Current Welding Summary of Welding Processes Start Switch Wire FEED, LN-15Section C-1 Accessories SectionOptional Equipment Field Installed AccessoriesStick Recommended EquipmentTIG Welding Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Section D-1 Maintenance SectionMaintenance Safety PrecautionsKohler Honda OIL Filter Change AIR Cleaner and Other MaintenanceBattery Engine AdjustmentsOverspeed is Hazardous Slip RingsOil Filter Pre-CleanerAir Filter ElementFigure D.1 Major Component Location Theory of Operation Section Section E-1Theory of Operation Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback and Auxiliary PowerFigure E.4 Weld WINDING, REACTOR, and Range Switch Weld WINDING, REACTOR, Range SwitchOutput BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Section F-1 Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideOutput Problems Field Winding Voltage Test Adjustment Test Troubleshooting Guide Output Problems Engine Problems Make sure the leads are looped Charging Circuit Test Welding Problems Ranger 10,000 & Ranger 10,000 Plus Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Rotor Resistance Test Figure F.2 Location of Rotor Slip Rings Rotor Resistance TestTroubleshooting & Repair Ranger 10,000 & Ranger 10,000 Plus Auxiliary and Field Winding Test Auxiliary and Field Winding Test To test the 115 VAC windingTo test the 230 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test 26TROUBLESHOOTING & REPAIRF-26 Output Rectifier Bridge TestFigutpure F.4 Locationctifof Output Rectifier Leads Charging Circuit Test Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Engine Throttle Adjustment TestFigure F.7 Oscilloscope Method Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh Idle no Load Output Control AT Maximum Typical DC Weld Output Waveform CV Mode Machine LoadedMachine Loaded to 200 Amps AT 20 VDC Machine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC ModeMachine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output WaveformAbnormal Open Circuit Weld Voltage Waveform CV Mode Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit Weld Voltage Waveform CV Mode Normal Open Circuit DC Weld Voltage Waveform CC Mode Normal Open Circuit AC Weld Voltage Waveform Ranger 10,000 & Ranger 10,000 Plus Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Figure F.10 Printed Circuit Board Location Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal ReplacementRanger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger 10,000 & Ranger 10,000 Plus Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Electrical Diagrams Section Electrical DiagramsSection G-1 Wiring Diagram Code 11041 only -M20226 Electrical DiagramsRanger 10,000 Honda Wiring Diagram Code 11095 only M20301Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus L13105 Schematic Entire Machine Codes 11395 and 11398 L13105L13103 Schematic Entire Machine CDE 11394 L13103Schematic Entire Machine Code 11095 & 11253 only L12257 L12249 Schematic Entire Machine Code 11151 only L12249-1Electrical Diagrams Electrical Diagrams