Lincoln Electric SVM168-B service manual Ranger 10,000 Plus

Page 106

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G-6

ELECTRICAL DIAGRAMS

G-6

WIRING DIAGRAM CODE 11394 AND 11395 (M21270)

 

 

RANGER 10,000 PLUS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LEADS 3 AND 6:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 TURN

 

6

2 TURNS THRU TOROID IN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPPOSITE DIRECTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

254

 

3

 

 

 

 

CCW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WORK

 

 

 

 

 

261

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

260

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

CHOKE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S2

 

 

 

 

10

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POSITIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NEGATIVE

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

77A

76A

75A

 

S3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D1

 

S2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GROUND SCREW

 

 

 

E

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213A

 

2

 

 

 

 

 

 

ON UPPER

 

 

 

 

 

 

 

-

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

208C

 

 

 

 

CASEFRONT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

211

 

 

GND-I

 

 

 

 

 

 

 

 

254

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

209A

 

 

 

 

 

 

S3

 

 

 

 

 

1

 

2

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J2

 

PCB1

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CB7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5D

 

 

 

 

WORK

ELECTRODE

 

 

 

 

 

 

 

 

3

 

4

 

 

 

 

 

 

 

 

 

 

 

25A

 

 

 

GND-E

 

S1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5F

GND-G GND-D

GROUND SCREW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213A

GND-C

 

R3

R5

C1

E

 

 

10

6

 

 

 

 

 

 

 

1

 

210

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

S2

 

 

8

12

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J1

 

 

 

 

 

 

 

 

 

 

 

 

 

ON LOWER CASEFRONT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

 

 

W2

 

 

 

 

 

 

 

 

219

200A

215

224

5E

76A

77A

75A

 

 

 

 

 

 

 

IDLER

 

 

 

 

 

 

 

S1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HOUR

 

 

 

 

 

 

 

 

 

 

 

 

REACTOR

 

6

3

7

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

METER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

215

 

 

 

 

 

 

STATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224A

 

 

 

5D

 

 

 

 

 

 

 

 

 

6

 

 

3

9

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224

5E

 

 

 

 

 

 

 

 

 

 

GND-E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

208 211

 

 

12 VOLT

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BATTERY

 

GND-G

 

 

 

6A

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224C

 

 

209A

209

+

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL BLOCK

 

 

J5

 

 

 

 

 

CB1

 

 

CB4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(SEE CONN.)

 

 

 

 

 

 

 

 

 

 

20A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

2

3 4

P5

 

 

 

 

 

40A

 

GND-D

 

3B

 

J2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-

 

 

 

 

 

6A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W

 

 

 

 

R

 

 

 

 

 

 

 

 

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

 

224A

 

 

V

 

 

R

 

5F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U

 

 

ENGINE

 

 

 

 

 

 

CB3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FOOT

 

 

 

12

11

20A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

210

N.A.

 

 

 

 

 

 

GND-H

 

 

 

 

 

 

 

 

 

 

 

219

 

200A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

CR1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OIL

 

 

 

 

 

 

 

ENGINE

 

 

 

J4

 

 

 

5L

 

5K

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

CROSS

 

 

 

 

 

 

6B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

120V/240V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRESSURE

 

 

REGULATOR

 

 

 

SUPPORT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

AC

B+

AC

 

 

 

 

FUEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ROTOR

 

 

 

 

 

 

IGNITION

B-

 

 

 

 

 

GND-C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STARTER

 

SHUTOFF

 

 

 

 

 

 

J3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MODULE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

 

 

5K

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5L

 

5

 

 

 

 

SLIP RING NEAREST LAMINATION

 

 

FLYWHEEL ALTERNATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE COMPONENTS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section TOC

Master TOC

 

 

 

 

SILVER COLORED TERMINALS

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

Return to

Return to

ELECTRICAL SYMBOLS PER E1537

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

Page 105 Page 107
Image 106
Page 105 Page 107
Contents Ranger 10,000 /10,000 Plus Powered equipment SafetyFor Engine ARC Rays can burn Fumes and GasesCylinder may explode If damaged Welding and Cutting Sparks can cause fire or ExplosionIii Précautions DE Sûreté Master Table of Contents for ALL Sections Installation Section Table of ContentsSection A-1 Installation Height Width Depth WeightHorsepower Operating Speed RPM Machine Grounding Safety PrecautionsSpark Arrester TowingVehicle Mounting PRE-OPERATION ServiceGasoline Can cause fire or explosionAngle of Operation Welding Output CablesTotal Combined Length of Electrode and Work Cables LiftingStacking Connection of Lincoln Electric Wire FeedersInstructions Welder OperationDuplex Receptacles Auxiliary Power120/240 Volt Dual Voltage Receptacle 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 Section B-1 Operation SectionOperation Operation Engine SwitchWelder Controls Function and Operation Kohler Honda Robin / Subaru 20 H.P. Command Polarity SwitchRange Switch Control DialStarting the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Stopping the EngineStick Constant Current Welding Wire Feed Welding Processes Constant VoltageTIG Constant Current Welding Start Switch Wire FEED, LN-15 Summary of Welding ProcessesAccessories Section Section C-1Accessories Optional Equipment Field InstalledTIG Welding Recommended EquipmentStick Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1Safety Precautions MaintenanceKohler Honda AIR Cleaner and Other Maintenance OIL Filter ChangeOverspeed is Hazardous Engine AdjustmentsBattery Slip RingsAir Filter Pre-CleanerOil Filter ElementFigure D.1 Major Component Location Section E-1 Theory of Operation SectionTheory of Operation 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 Test Description Rotor Voltage TestMaterials Needed 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 115 VAC winding Auxiliary and Field Winding TestTo test the 230 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test Output Rectifier Bridge Test 26TROUBLESHOOTING & REPAIRF-26Figutpure F.4 Locationctifof Output Rectifier Leads 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 Normal Open Circuit Voltage Waveform 115 VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Waveform CV ModeMachine Loaded to 200 Amps AT 20 VDC 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 Electrical Diagrams Electrical Diagrams SectionSection G-1 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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