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Lincoln Electric SVM168-B service manual Ranger 10,000

Models: SVM168-B

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G-4	ELECTRICAL DIAGRAMS	G-4
WIRING DIAGRAM - CODE 11150 T0 11393 - (M20431)

RANGER 10,000

LEADS 3 AND 6:

1 TURN

6

2 TURNS THRU TOROID IN

CCW

OPPOSITE DIRECTIONS

254

3

L1

261

R1

CHOKE

S2

260

OUTPUT

10

CONTROL

213

+

77A

76A

75A

S3

D1

GROUND SCREW

213A

2

1

ON UPPER

-

8

208C

CASEFRONT

211

GND-I

254

209A

1

2

3

4

J2

PCB1

CB7

5D

WORK

ELECTRODE

3

4

25A

GND-G GND-D GND-E

S1

5F

GND-C

GROUND SCREW

213A

R3

R5

C1

E

10

6

1

210

R1

S2

8

12

7

J1

ON LOWER CASEFRONT

SOLENOID

W2

S1

219

200A

215

224

5E

76A

77A

75A

IDLER

HOUR

REACTOR

6

3

7

9

C1

METER

W1

+

215

STATOR

224A

5D

6

3

9

7

224

5E

GND-E

12 VOLT

5

208 211

BATTERY

224C

209A

209

+

TERMINAL BLOCK

J5

6

6A

J2

(SEE CONN.)

GND-G

GND-D

1

2

3

4

P5

120V

-

CB1

W

R

40A

224A

V

R

5F

12

CB3

224C

U

ENGINE

11

5L

5K

FOOT

J4

20A

6B

3B

N.A.

GND-H

120V/240V

210

219

200A

SOLENOID

CR1

OIL

ENGINE

GND-C

J3

+

REGULATOR

CROSS

5K

PRESSURE

SUPPORT

120V

SWITCH

11

5L

5

AC

B+

AC

FUEL

ROTOR

B-

IGNITION

CB2

CB4

STARTER

SHUTOFF

MODULE

40A

20A

SOLENOID

3A

SLIP RING NEAREST LAMINATION

FLYWHEEL ALTERNATOR

3

ENGINE COMPONENTS

SILVER COLORED TERMINALS

Section TOC

Master TOC

	N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.			CONNECTOR PIN NUMBERS:
	LEAD COLOR CODE:		4	3	12			7
	LEAD COLOR CODE:
	B = BLACK OR GRAY	U = BLUE	2	1	6	3	2	1
	R = RED OR PINK	V = VIOLET	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

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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 of yourM20431machine.

RANGER® 10,000 & RANGER® 10,000 PLUS

Image 104

Lincoln Electric SVM168-B service manual Ranger 10,000

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 Safety Precautions Spark ArresterMachine Grounding TowingPRE-OPERATION Service GasolineVehicle Mounting Can cause fire or explosionWelding Output Cables Total Combined Length of Electrode and Work CablesAngle of Operation LiftingConnection of Lincoln Electric Wire Feeders InstructionsStacking Welder OperationAuxiliary Power 120/240 Volt Dual Voltage ReceptacleDuplex Receptacles 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 Polarity Switch Range SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialSTARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine 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 InstalledRecommended Equipment StickTIG Welding Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1Kohler Honda MaintenanceSafety Precautions AIR Cleaner and Other Maintenance OIL Filter ChangeEngine Adjustments BatteryOverspeed is Hazardous Slip RingsPre-Cleaner Oil FilterAir 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