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

Models: SVM168-B

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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
	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

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

Image 106

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

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