Lincoln Electric SVM168-B Safety Precautions, Spark Arrester, Machine Grounding, Towing

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A-4

INSTALLATION

 

 

A-4

SAFETY PRECAUTIONS

 

When this welder is mounted on a truck or trailer, itʼs

 

 

 

 

 

 

 

 

frame must be electrically bonded to the metal frame of

 

 

 

 

 

 

WARNING

the vehicle. Use a #8 or larger copper wire connected

Do not attempt to use this equipment until you

between the machine grounding stud and the frame of

have thoroughly read the engine manufacturer’s

the vehicle.

 

 

 

manual supplied with your welder. It includes

Where this engine driven welder is connected to

important safety precautions,

detailed engine

premises wiring such as that in your home or shop, itʼs

and------------------------------------------------------------------------parts lists.

frame must be connected to the system earth ground.

See further connection instructions in the section enti-

starting, operating and maintenance instructions,

tled “Standby Power Connections”, as well as the arti-

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

 

• Do not touch electrically live parts or

cle on grounding in the latest National Electrical Code

 

 

 

 

 

 

electrode with skin or wet clothing.

and the local code.

 

 

 

 

 

 

 

 

 

ground

from work and

In general, if the machine is to be grounded, it should

 

 

 

 

 

 

• Insulate yourself

be connected with a #8 or larger copper wire to a solid

 

 

 

 

 

 

• Always wear dry insulating gloves.

 

 

 

 

 

 

ENGINE EXHAUST can kill.

earth ground such as a metal water pipe going into the

 

 

 

 

 

 

• Use in open, well ventilated areas or

ground for at least ten feet and having no insulated

------------------------------------------------------------------------

joints, or to the metal framework of a building which

 

 

 

 

 

 

vent exhaust outside.

 

 

 

 

 

 

 

 

 

has been effectively grounded. The National Electrical

 

 

 

 

 

 

 

 

Code lists a number of alternate means of grounding

 

 

 

 

 

 

 

 

------------------------------------------------------------------------

 

 

 

 

 

 

 

electrical equipment. A machine grounding stud

 

 

 

 

 

 

MOVING PARTS can injure.

marked with the symbol

 

 

 

 

is provided on the front of

 

 

 

 

 

 

 

 

 

the welder.

 

 

 

 

•Do not operate with doors open or guards off.

• Stop engine before servicing.

SPARK ARRESTER

• Keep away from moving parts.

See additional warning information at

Some federal, state, or local laws may require that

------------------------------------------------------------------------

 

 

 

 

gasoline engines be equipped with exhaust spark

front of this operator’s manual.

arresters when they are operated in certain locations

-----------------------------------------------------------

where unarrested sparks may present a fire hazard.

 

The standard muffler included with this welder does not

 

qualify as a spark arrester. When required by local reg-

MACHINE GROUNDING

ulations, the K894-1 spark arrester must be installed

Because this portable engine driven welder or genera-

and properly maintained.

tor creates itʼs own power, it is not necessary to con-

 

CAUTION

 

nect itʼs frame to an earth ground, unless the machine

 

 

 

 

 

 

is connected to premises wiring (your home, shop,

An incorrect arrester may lead to damage to the

etc.).

engine or adversely affect performance.

 

------------------------------------------------------------------------

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WARNING

To prevent dangerous electric shock, other equip- ment to which this engine driven welder supplies power must:

•be grounded to the frame of the welder using a grounded type plug, or be double insulated.

Do not ground the machine to a pipe that carries

------------------------------------------------------------------------explosive or combustible material.

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincolnʼs K957-1. If the user adapts a non-Lincoln trail- er, he must assume responsibility that the method of attachment and usage does not result in a safety haz- ard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equip- ment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.

RANGER® 10,000 & RANGER® 10,000 PLUS

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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 Contents Section 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
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