Lincoln Electric SVM107-B service manual K2160-1 Ranger 8 Honda CSA Wiring Diagram

Page 113

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G-9

ELECTRICAL DIAGRAMS

G-9

WIRING DIAGRAM - HONDA CSA MODEL

K2160-1 RANGER 8 HONDA (CSA) - WIRING DIAGRAM

254

CCW

"S3" SHOWN

GROUND SCREW

OUTPUT

R1

IN "RUN"

L1

CONTROL

AT BLOWER BAFFLE

POSITION

+

-

CHOKE

S3

208A

209A

S2

+

10

77A

76A

75A

S5

AM1

221

START

D1

BUTTON

254

208C

-

8

254A

208B

254A

CURRENT

PCB1

5H

211

5D

SENSOR

3 TURNS

254A

CB7

S1

210

25A

5F

WORK

E

12

7

S4

213

213

R1

8

GND-E

R2

R6

S2

10

J1

"S4" SHOWN

ELECTRODE

R3 R5

C1

6

1

IDLER

S1

R4

201A

IN "AUTO"

224B

GND-G

W2

200B 219

224 215

76 5E 75 77

+

SOLENOID

POSITION

224A

REACTOR

HOUR METER

GND-C

C1

224

215

GND-D

W1

STATOR

5H

5D

6

3

9

7

5E

GND-E

P5

12 VOLT

5

3

1

2

3

4

224A

J5

208

211

BATTERY

3

211B

75A

77A

224C

209A

+

76A

D9

221

209

GND-D

4 AMP

7

SEE DETAIL

1 2

3 4

IN LINE

211B

210

9

200B

DIODE

NO

-

J2

225A

224E

CONNECTION

211A

211C

3E

CB3

6 CB1

GND-G

115V

+

208D

221A

224D STARTER

ENGINE

35A

15A

CB5

210A

SOLENOID

FOOT

D2

C1 FIELD

OIL

15A

3D

N.A.

B/R

CR1

-

CAPACITOR

200

PRESSURE

GND-H

12

3C

5

200A

B/Y

219

5L

SWITCH

IGNITION

ENGINE

5K

FUEL

W/U

MODULE

CROSS

201

+

SHUTOFF

SUPPORT

J4

11

GY

W

SOLENOID

5P

212

115V/230V

201A

CB6

GY

GND-C

15A

ROTOR

J3

11

20 AMP

CB2

5K

CB4

115V

3D

CHARGE COIL

1 2 3 4 5 6

STARTER

3E

35A

3A

5

3A

SLIP RING NEAREST LAMINATION

SILVER COLORED 3B

15A

5L

RECTIFIER/REGULATOR

3B

TERMINALS

MODULE

B

(WHITE WIRES)

HONDA ENGINE COMPONENTS

GENERATOR LEAD END

CONNECTOR PIN NUMBERS:

(NOTE CAVITY NUMBERS)

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

4

3

12

7

LEAD COLOR CODE:

211 (CAVITY #3)

2

1

6

3

2

1

224C (CAVITY #4)

B = BLACK OR GRAY

J5

J1

LOCATING TAB

R = RED OR PINK

208 (CAVITY #2)

W = WHITE

221 (CAVITY #1)

U = BLUE

TERMINAL BLOCK

GY = GRAY

CONNECTION

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

ELECTRICAL SYMBOLS PER E1537

A

M19988

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.

Image 113

Contents Rangertm Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Welding Output Auxiliary Power50 100 150 200 250 300 350 Output Amps 20 B50 100 150 200 Installation Instructions Oil Battery ConnectionsAWG FuelAngle of Operation Welder Output Connection of the LN-7 to the RangerRanger Constant CurrentMotor Starting Duplex ReceptaclesType Common Electrical Devices Possible Concerns Electrical Device USE with the RangerStandby Power Connections Auxiliary Power While WeldingFigure A.1 Connection of Ranger 8 to Premises WiringRanger Table of Contents Operation Section AC/DC TIG Welding Constant Current DC Semiautomatic Wire Feed Welding Constant VoltageAC/DC Stick Welding Constant Current Provides a fine welding current adjustment within Control SwitchRange Switch settings in the STICK/TIG mode Welding voltage control with the Range switch setStopping the Engine Starting/Shutdown InstructionsTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick Constant Current Welding Stick Auto Summary of Welding ProcessesSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Engine OIL Change Routine MaintenanceEngine OIL Refill Capacities Kohler Onan HondaOIL Filter Change Engine Maintenance Parts Engine AdjustmentsPre-Cleaner Slip RingsFigure D.1 Major Component Locations Ranger Table of Contents Theory of Operation Section Theory of Operation Rotor Field Feedback and Auxiliary Power Weld WINDING, REACTOR, Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger Table of Contents Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairStatic-Sensitive PC board can be damaged by static electricityDevices Handle only atOutput Problems Troubleshooting GuideDetailed in the beginning of this manual Observe Safety GuidelinesTroubleshooting & Repair Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Engine Problems Troubleshooting & Repair Troubleshooting & Repair Welding Problems Ranger Materials Needed Rotor Voltage TestTest Description Test Procedure Rotor Resistance Test Rotor Resistance Test Troubleshooting & Repair Ranger Auxiliary and Field Winding Test To test the 230 VAC winding To test the 115 VAC windingTo test the field winding Ranger Output Rectifier Bridge Test Output Rectifier Bridge Test Charging Circuit Test Charging Circuit Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Oscilloscope Method High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical DC Weld Output Waveform CV ModeMachine 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 Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.10 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger Field Capacitor AND/OR Rectifier Bridge Removal Replacement Field Capacitor AND/OR Rectifier Bridge Removal ReplacementProcedure Rectifier Bridge Removal and Replacement Ranger Printed Circuit Board Removal Replacement Procedure Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal Ranger Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger Instructions ENGINE/ROTOR Removal and ReplacementFigure F.14 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.15 Engine and Rotor Removed from Stator Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Table of Contents Diagrams Section Dimension RANGER8 Dimension Print Ranger 8 Honda & KohlerConnection of Ranger 8 to LN-7 & K240 Contactor KIT DiagramsWiring Diagram Onan NON CSA Model Electrical DiagramsWiring Diagram Onan CSA Model K1418-2 Ranger 8 Onan CSA Version Wiring DiagramWiring Diagram Kohler NON CSA Model K1419-1 Ranger 8 Kohler Wiring DiagramWiring Diagram Kohler CSA Model K1419-2 Ranger 8 Kohler CSA Wiring DiagramK2160-1 Ranger 8 Honda CSA Wiring Diagram 16482 Schematic IDLER/CONTROL PC BoardPC Board Assembly IDLER/CONTROL SVM Error Reporting Form