Lincoln Electric SVM207-A service manual Troubleshooting and Repair

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F-9

TROUBLESHOOTING AND REPAIR

 

 

 

F-9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE PROBLEMS

 

 

 

 

 

 

The Engine shuts off.

 

1.

The Engine may be low on or out

1.

The oil pressure switch may be

 

 

 

of fuel.

 

 

 

faulty. Replace if necessary.

 

 

2.

The Oil level may be low. Check

2.

The fuel shut off solenoid may

 

 

 

and fill to proper level.

 

be faulty (Kohler Engines only).

 

 

3. The fuel filter may be clogged.

 

 

 

 

 

 

 

 

 

 

Engine does not develop full

1. The fuel filter may be clogged.

1.

Due to wear, the engine may be

power.

 

 

Replace if necessary.

 

in need of repair.

 

 

 

 

2. The air

filter may

be clogged.

 

 

 

 

 

 

 

 

 

Replace if necessary.

 

 

 

 

 

 

 

 

3. The spark plug(s) may be faulty.

 

 

 

 

 

 

 

 

 

Replace if necessary.

 

 

 

 

 

 

 

 

 

Engine tries to start when S3 is in

1. Oil pressure switch may be

1. Check Oil Switch should show

start position, then shuts off when

 

faulty.

 

 

 

continuity when running/open

switched to run.

 

2. Fuel Shutoff Solenoid Diodes

 

when off Switch.

Replace oil

 

 

 

pressure switch if necessary.

 

 

 

may be open.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Check engine diodes in engine

 

 

 

 

 

 

 

wiring harness. Replace if

 

 

 

 

 

 

 

necessary (Engine Mfg. Part).

 

 

 

 

 

Engine will not start with S3 in

1. Engine

shutdown

solenoid

1. Check Engine diodes in engine

start position, but then tries to

 

diodes may be open.

 

wiring harness.

Replace if

start or does start when S3 is

2. Start switch (S3) may be faulty.

 

necessary (Engine Mfg. Part).

switched to run position.

 

 

 

 

 

 

 

 

 

 

2. Check

start

switch

(S3).

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace if necessary.

 

 

 

 

Engine will not shut off when S3

1. Fuel shutoff solenoid may be

1. Feel solenoid for clicking open

is placed “OFF” position.

 

faulty or stuck open.

 

or closed.

 

Replace if

 

 

2. Start switch (S3) may be faulty.

 

necessary.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Check

start

switch

(S3).

 

 

 

 

 

 

 

Replace if necessary.

 

 

 

 

 

 

Engine continues to crank when

1. Engine

shutdown

solenoid

1. Check diodes. Replace Engine

S3 is switched to “RUN” position.

 

diodes may be shorted.

 

Diodes (Engine Mfg. Part) if

 

 

 

 

 

 

 

necessary.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

RANGER® 3 PHASE

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Contents Ranger 3 Phase Ranger 3 Phase SafetyFumes and Gases Welding Cutting Précautions DE Sûreté Safety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Height Width Depth Weight InstallationTechnical Specifications Ranger 3 Phase K2337-1 & K2337-2 Auxiliary PowerTowing Safety PrecautionsMachine Grounding Spark ArresterCan cause fire or explosion PRE-OPERATION ServiceGasoline Vehicle MountingAngle of Operation Welding Output CablesTotal Combined Length of Electrode and Work Cables High Altitude OperationInstructions 120/240 Volt Dual Voltage Receptacle Auxiliary PowerVolt 3 Phase Receptacle with Ground Gfci Duplex ReceptaclesTABLE A.1 Simultaneous Welding and Power Ground WireStandby Power Connections Auxiliary Power While WeldingFigure A.3 Connection of Ranger 3 Phase to Premises WiringDevices Without Addi Tional Resistive Type Loads Electrical Device USE with the Ranger 3 PhaseUSE These Devices with a Ranger 3 Phase Table of Contents Operation Section Welder Controls Function and Operation Engine SwitchOperation GENERAL DESCRIPTIONControl Dial Polarity SwitchRanger 3 Phase Approximate Fuel Consumption Range SwitchTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageWelding Process Stick Constant Current WeldingStick Auto Stopping the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Starting the EngineTable of Contents Accessories Section K1745-1 Welding GAS Cylinder LPG Tank Holder AccessoriesTIG WIRE FEEDRECOMMENDED EQUIPMENT StickRanger 3 Phase Table of Contents Maintenance Section Safety Precautions MaintenanceDo not attempt to polish slip rings while engine is running Gfci Receptacle Testing and RESET- Ting ProcedureAIR Cleaner and Other Maintenance Slip Rings OIL Filter ChangeCHAMPION RC12YC BatteryEngine Maintenance Parts KOHLER C23S Fram CA79Figure D.1 Major Component Location MAINTENANCED-5Ranger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine Components and Operation Theory of OperationGeneral Description Figure E.2 ROTOR, Stator and Control Circuits ROTOR, Stator & Control CircuitsFigure E.2 Weld Circuitry Weld Circuitry1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairReturn to Section PC Board Troubleshooting ProceduresDiagram Perform the Output Bridge Test Gram Wiring Wiring Diagram Troubleshooting and Repair Figure F.4 and/or the Wiring Materials Needed Rotor Voltage Test ProcedureTest Description Rotor Voltage Test Test ProcedureRotor Resistance Test Figure F.2 Slip Rings TEST PROCEDUREAuxiliary and Field Winding Test To test the 120 VAC winding To test the 480 VAC 3 Phase windingProbes Reading Auxiliary WindingsField Winding Figure F.4 Control PC BoardRanger 3 Phase Output Rectifier Bridge Test + Meter Lead Meter Reading Figure F.5 OUTPUT RECTIFIERToroid Test Toroid Test Charging Circuit Test Voltage Regulator AC Lead DC Lead Engine Throttle Adjustment Test Engine Throttle Adjustment Test Low Idle Adjustment SolenoidNut Housing Figure F.9 115VAC Supply Waveform High IDLE- no Load 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 3 Phase Brush Removal and Replacement Procedure Procedure Brush Removal and Replacement ProcedureBrush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Figure F.10 Door Removal Printed Circuit Board RemovalOutput Rectifier Bridge Removal Replacement Procedure Figure F.11 OUTPUT RECTIFIER Output Rectifier Bridge RemovalENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Figure F.13 Engine and Rotor Removed from Stator Rotor Removal ProcedureReassembly Procedure Retest After Repair Table of Contents Diagram Section RaNGEr 3 phaSE Ranger 3-PHASEL12259 SchEmaTic cOmplETE machiNE l12259ElEcTrical DiaGramS
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