Lincoln Electric SVM168-B instruction

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RETURN TO MAIN MENU	SVM168-B
	April, 2010
	April, 2010

RANGER® 10,000 /10,000 PLUS

For use with machine code numbers: Kohler 11041, 11151, 11394

Honda 11095, 11398

Robin/Subaru 11253. 11395

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation

. . . and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON- TAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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

Contents

Ranger 10,000 /10,000 Plus Powered equipment SafetyFor Engine Fumes and Gases ARC Rays can burn Cylinder 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 Height Width Depth Weight Installation Horsepower Operating Speed RPM Spark Arrester Safety PrecautionsMachine Grounding Towing Gasoline PRE-OPERATION ServiceVehicle Mounting Can cause fire or explosion Total Combined Length of Electrode and Work Cables Welding Output CablesAngle of Operation Lifting Instructions Connection of Lincoln Electric Wire FeedersStacking Welder Operation 120/240 Volt Dual Voltage Receptacle Auxiliary PowerDuplex Receptacles Motor Starting Not USE These Devices With a Ranger 10,000 These Devices Without Additional Resistive Type Loads Standby Power Connections Simultaneous Welding and Power Figure A.1 Ranger 10,000 & Ranger 10,000 Plus Section B-1 Operation SectionOperation Operation Engine SwitchWelder Controls Function and Operation Range Switch Polarity SwitchKohler Honda Robin / Subaru 20 H.P. Command Control Dial BREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the Engine Stick Constant Current Welding Wire Feed Welding Processes Constant VoltageTIG Constant Current Welding Summary of Welding Processes Start Switch Wire FEED, LN-15 Section C-1 Accessories Section Optional Equipment Field Installed Accessories Stick Recommended EquipmentTIG Welding Plasma Cutting Ranger 10,000 & Ranger 10,000 Plus Section D-1 Maintenance Section Safety Precautions MaintenanceKohler Honda OIL Filter Change AIR Cleaner and Other Maintenance Battery Engine AdjustmentsOverspeed is Hazardous Slip Rings Oil Filter Pre-CleanerAir Filter Element Figure D.1 Major Component Location Section E-1 Theory of Operation SectionTheory of Operation Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler Solenoid Figure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback and Auxiliary Power Figure E.4 Weld WINDING, REACTOR, and Range Switch Weld WINDING, REACTOR, Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Section F-1 Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair Electric Shock PC Board Troubleshooting Procedures Output Problems Troubleshooting Guide Output 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 Figure F.2 Location of Rotor Slip Rings Rotor Resistance Test Troubleshooting & 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 Figure F.5 Location of Voltage Regulator Charging Circuit Test Engine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Engine Throttle Adjustment Test Figure 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 Machine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC Mode Machine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output Waveform Abnormal 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 Replacement Procedure Brush Removal and Replacement Figure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip Rings Ranger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Figure F.10 Printed Circuit Board Location Printed Circuit Board Removal and Replacement Printed Circuit Board Removal Replacement Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel cap Section TOC Ranger 10,000 & Ranger 10,000 Plus Instructions ENGINE/ROTOR Removal and Replacement Figure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR Removal Engine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal Procedure Reassembly Procedure Replacement KIT S20788 Retest After Repair Electrical Diagrams Electrical Diagrams SectionSection G-1 Wiring Diagram Code 11041 only -M20226 Electrical Diagrams Ranger 10,000 Honda Wiring Diagram Code 11095 only M20301 Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus L13105 Schematic Entire Machine Codes 11395 and 11398 L13105 L13103 Schematic Entire Machine CDE 11394 L13103 Schematic Entire Machine Code 11095 & 11253 only L12257 L12249 Schematic Entire Machine Code 11151 only L12249-1 Electrical Diagrams Electrical Diagrams