Lincoln Electric SVM168-B service manual Schematic Entire Machine Code 11151 only L12249-1

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G-10

ELECTRICAL DIAGRAMS

G-10

SCHEMATIC - ENTIRE MACHINE - CODE 11151 ONLY - (L12249-1)

 

 

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EN-168

1-L12249

NOCONNECTION

J51-1

IGNITION

MODULE

+

HOUR

METER

ENGINEERING CONTROLLED

 

CHANGE DETAIL: NEW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MANUFACTURER:

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

 

 

S2

 

 

 

 

front of generator.

 

 

 

 

 

 

 

 

 

210DC/225AC

 

 

STATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WINDINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

 

 

POLARITY

 

 

 

Choke mounted on base in

 

 

 

 

 

 

 

 

 

 

 

 

 

WELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1 CHOKE

D1 - BRIDGE RECTIFIER S1 - SELECTORSWITCH

 

145

 

 

 

 

 

W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

33TO 37 VACBETWEENW1

 

 

 

 

 

 

 

 

 

 

 

Open CircuitVolts:

 

 

 

 

 

 

 

 

 

 

 

DC+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

90

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DC-

 

AC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AND C1AT HIGH IDLE AND

 

 

 

 

 

 

 

 

 

 

 

AC

Max

Min

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CV

 

 

 

 

 

 

MAXIMUM RHEOSTAT NO LOAD.

 

 

 

 

 

 

 

 

 

 

 

 

76

 

38

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

74TO 78 VACBETWEENW1

 

 

 

 

 

 

 

 

 

 

 

DC

 

68

 

34

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

254

 

 

 

 

 

 

 

 

C1

 

 

 

 

 

 

 

 

 

 

 

CV

 

32

 

18

 

 

 

 

 

 

 

 

 

 

AC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AND W2AT HIGH IDLE AND

 

 

 

 

 

 

 

 

 

 

 

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DC+ DC-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R5

R3

R1 AC tapped reactor mounted

MAXIMUM RHEOSTAT NO LOAD.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

E

TWO POLE 3600

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rectifier mounted on top of choke and

T TOROID: SENSES

S2

 

on base in front of generator.

RPM ALTERNATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S1

 

W2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC reactor in front of generator..

U WELD OR AC

 

 

ACTAPPEDREACTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Torroid Core locatedon

R POWERLOADTO

 

 

STATORAUXILIARY

 

REVOLVING

BRUSHES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6A

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

wiring behind receptacles.

N ACTIVATE IDLER

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

2TURNS

 

 

LEADS 3 AND 6 PASS

POWERWINDINGS

 

FIELDS

+

 

 

 

 

 

 

 

 

 

 

 

 

 

CB3

 

 

 

 

 

 

 

 

 

 

3A

 

CB4

 

 

 

 

 

 

 

 

 

 

 

 

 

2TURNS

 

 

 

 

 

120 VAC

 

RESISTANCE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CB1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THROUGHTORROID

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20A

 

 

 

 

 

 

 

 

 

CB2

 

20A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TWO TIMES IN

 

 

240 VAC

 

 

APPROX. 5 OHMS @ 75F Rotor Flashing: 2.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6B

40A

12

 

 

 

 

11

 

40A

 

3B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPPOSITEDIRECTIONS

5

GNDE

 

10TO 50 VDC AT

volts @ 0.5 amps.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J3

 

 

 

 

 

 

 

 

J2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.7 TO 6.8 AMPS

until generator build-up.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J4

 

 

 

5K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

120 VAC

 

SLIP RINGS

-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GND-C

 

 

 

 

 

GND-G

 

 

 

GND-D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

219

200A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

41TO 45 VAC

EXCITATIONWINDING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VOLTSMEASUREDAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAX RHEOSTAT HIGH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+14V INAUTO IDLE / OV INHIGHIDLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

STATOR

IDLE NO LOAD

 

 

PC Board

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EXCITATION

 

 

 

 

located on rear

 

 

 

 

2

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WINDINGS

 

 

 

 

of fan

 

 

 

 

 

 

 

 

 

 

 

 

 

AUTO IDLE (2)

 

OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

baffle near top

 

 

 

 

4

 

 

 

+14V RUN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of machine.

 

 

 

 

3

 

 

 

 

 

 

HIGHIDLE (3)

 

 

 

 

 

 

 

 

IDLE SOLENOIDCOIL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S3 OPERATION

 

 

 

 

 

 

 

START (4)

 

 

S3

 

 

 

 

 

 

 

 

 

 

 

 

 

SUPPRESSOR FOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OFF

1

2

3

4

 

 

 

 

 

 

 

 

 

 

+BAT (1)

 

-ENERGIZEDFOR

213

 

 

 

 

 

 

 

 

261

260

 

 

 

 

 

 

7

9

 

219

200A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOW IDLE.

 

 

 

 

 

 

 

 

D1 RECTIFIER

 

 

 

LOAD

 

+10V

 

FIELD

 

 

 

 

 

AUTO

X

X

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Idle solenoid is

 

 

 

 

 

 

 

8(J1-12)

 

.05

 

 

(J2-3)

(J2-4)

 

 

 

 

 

 

(J1-5)

(J1-11)

 

 

 

 

HIGH

X

 

X

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

located on top of

 

12 to 14 volts

 

 

 

 

5K

 

130V

 

 

 

+

SENSOR

IDLE TIMER

 

FLASHING

 

 

 

 

 

 

 

 

 

START X

 

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

generator stator

 

 

 

 

 

 

 

 

 

 

 

 

 

CIRCUIT

 

 

 

 

 

 

 

 

 

X=CLOSEDCIRCUIT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

assembly

15 Ohms

 

across coilwhen

 

 

 

10(J1-6)

 

 

 

38J

 

 

 

-

 

(12 SEC.)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

energized

 

 

 

 

 

 

 

 

DIODE

 

 

 

 

 

 

20

 

 

 

 

FLYBACK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213A(J2-1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

211 224C

 

 

 

 

 

 

 

 

 

215 (J1-3)

 

 

 

 

FLYBACK

 

 

 

 

 

 

 

 

 

 

DIODE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CB7 25A

 

 

208C

 

 

 

 

 

 

 

 

 

 

+14V @ NORMALOILPRES.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J51-4

 

 

 

 

 

224(J1-9)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

208

 

 

 

209A

 

 

J51- Engine J51-3

 

 

 

 

 

 

IDLE SOLENOID

 

 

 

 

+10 VOLT

+10V

 

 

 

FIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COIL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connector

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCHING

 

 

 

 

REGULATOR

 

 

 

 

 

CURRENT

 

 

 

 

 

 

 

 

224A 224C

 

 

BATTERY

 

 

 

 

 

 

 

Engine diodes

 

Fuel solenoid is mounted

 

 

 

 

 

 

 

TRANSISTOR

 

 

 

 

CIRCUIT

 

 

 

 

 

 

FEEDBACK 0.1

 

 

 

 

 

 

 

J51-2

 

 

 

 

 

 

 

 

R

Battery voltage:

OUTPUT

 

 

(OVER-CURRENT PROTECTED)

 

 

 

 

 

 

 

 

 

RESISTOR

 

 

 

 

 

 

 

 

 

 

 

 

CHARGING

 

 

 

 

 

 

 

are in engine

R on engine carburetor.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B+

ALT/REG

U

 

 

 

 

 

 

wire harness.

 

 

 

 

 

 

12.6 volts at rest

CONTROL

 

 

 

 

+10V

HYSTERESIS SWITCH

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE

 

 

 

 

 

 

 

 

14 volts enginerunning

10K

5.64 V

77A (J1-1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

 

 

 

 

 

 

 

 

 

ENGINE DIODES

+ 12 VOLT

 

R1

 

47.5

 

 

 

 

68.1K

 

 

LEVEL

 

 

 

4700uF

 

 

 

 

 

 

 

 

 

 

 

 

210

AC

 

 

 

 

 

 

STARTER

 

 

 

 

 

76A (J1-8)

 

 

 

 

 

 

+

 

 

CHANGING

 

 

 

80VDC

 

 

 

 

 

 

 

ENGINE OIL

44TO 45 VAC

 

 

SOLENOID

 

 

 

FUEL

 

 

 

BATTERY

 

 

1.28 V

75A (J1-7)

 

47.5

 

 

 

-

 

 

AND DRIVER

 

 

 

 

 

FIELD CURRENT

 

 

 

 

 

 

 

 

 

 

 

ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CIRCUIT

 

 

 

 

 

 

 

 

 

PRESSURE

 

 

GNDBETWEENAC

 

 

 

 

 

 

 

 

 

FRAME

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

SWITCHING

 

 

 

 

SWITCH

 

 

 

 

 

 

TERMINALS

 

 

 

STARTER

 

 

 

SHUTOFF

 

 

Control board common is

5E (J1-2)

 

 

 

 

 

 

 

 

 

FIELD CURRENT FEEDBACK

 

 

TRANSISTOR

 

 

 

 

OPENS ON

 

 

 

 

 

AT HIGH IDLE

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

GROUND

 

 

 

 

 

 

-

 

 

 

(OVER-CURRENT PROTECTED)

 

 

 

 

LOW OIL

 

 

 

 

 

 

 

 

 

 

 

 

 

Resistance of fuel

 

 

 

 

 

 

 

one diode drop above

 

REVERSE VOLTAGE

 

 

 

 

FEEDBACK AMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRESSURE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

welder frameground.

 

PROTECTION DIODE

 

 

 

 

 

 

FIELD & IDLE CONTROL

 

 

 

 

 

 

 

 

 

operating pressure, the oil pressure

 

 

 

 

 

 

 

 

 

accurately

 

 

 

 

 

 

 

3

12

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If engine oil pressure dropsbelowsafe

 

 

 

 

 

 

 

 

solenoid cannot be

 

 

 

 

 

 

 

CONNECTOR PIN NUMBERS:

 

 

 

 

 

 

 

 

 

PC BOARD (L12198-1)

 

 

 

 

 

 

 

 

 

 

switch opensremoving 12 volts from

 

 

 

 

 

 

 

 

 

measured through

 

 

 

 

 

 

2J2 1

6

J1 3 2 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

circuit 224 shutting off fuel solenoid to

 

 

 

 

 

 

 

 

 

diodes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

stop engine. Hourmeter will also stop

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROPRIETARY & CONFIDENTIAL:TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

 

 

 

 

running and PCB1will denergize idle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ON 2 PLACE DECIMALS IS ± .

 

 

 

 

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

solenoid.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DESIGN INFORMATION

REFERENCE: EQUIPMENT TYPE:

 

 

RANGER 10,000KOHLER

 

PAGE 1

OF

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MANUFACTURING TOLERANCE PER E2056

 

 

 

 

 

 

 

 

 

 

___

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

UNLESS OTHERWISE SPECIFIED TOLERANCE

ENGINEER:

BAM

SCALE:

 

SUBJECT:

 

 

 

MACHINE SCHEMATIC

 

 

NUMBER:

 

REVISION:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MATERIAL TOLERANCE ("t") TO AGREE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ON 3 PLACE DECIMALS IS ± .002

 

 

DRAWN BY:

 

BAM

L11942

 

 

 

 

 

 

 

 

 

DOCUMENT

 

DOCUMENT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DO NOT SCALE THIS DRAWING

 

APPROVED:

 

-

NONE

DISPOSITION: NA

DATE:

 

12/12/03 NUMBER:

CRM33679

 

 

L12249-1

 

 

A

SOLID

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ON ALL ANGLES IS ± .5 OF A DEGREE

 

 

 

 

 

MATERIAL

 

APPROVAL

 

PROJECT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WITH PUBLISHED STANDARDS.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

 

 

 

 

 

 

 

 

 

STRP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RANGER® 10,000 & RANGER® 10,000 PLUS

Page 109 Page 111
Image 110
Page 109 Page 111
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 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 Operation Operation SectionSection B-1 Welder Controls Function and Operation Engine SwitchOperation Kohler Honda Robin / Subaru 20 H.P. Command Polarity SwitchRange Switch Control DialStarting the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period 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 InstalledTIG Welding Recommended EquipmentStick Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1Kohler Honda MaintenanceSafety Precautions AIR Cleaner and Other Maintenance OIL Filter ChangeOverspeed is Hazardous Engine AdjustmentsBattery Slip RingsAir Filter Pre-CleanerOil 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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