Lincoln Electric SVM168-B service manual Maintenance, Safety Precautions, Kohler Honda

Page 30

TOC

TOC

D-2

MAINTENANCE

D-2

 

 

 

SAFETY PRECAUTIONS

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WARNING

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their removal is complete. Always use the greatest care when working near moving parts.

Do not put your hands near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

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ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

Insulate yourself from work and ground

Always wear dry insulating gloves.

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ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

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MOVING PARTS can injure.

Do not operate with doors open or guards off.

• Stop engine before servicing.

Keep away from moving parts.

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See additional warning information throughout this operator’s manual and the Engine manual as well.

Read------------------------------------------------------------the Safety Precautions in the front of this manual

and the engine instruction manual before working on this machine.

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, cloth- ing, and tools away from gears, fans, and all other mov- ing parts when starting, operating, or repairing the equipment.

ROUTINEAt the MAINTENANCEend of each dayʼs use, refill the fuel tank to minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated.

CAUTION

Make certain that the oil filler cap is securely tight- ened after checking or adding oil. If the cap is not tight, oil consumption can increase significantly which may be evidenced by white smoke coming

from the exhaust.

• OIL - Maintenance schedule for changing the oil and oil filter after break-in :

 

 

KOHLER

HONDA

 

ROBIN / SUBARU

Oil

 

100 HRS.

6 Months

 

100 HRS.

 

100 HRS.

 

Oil Filter

200 HRS.

1 Year or

 

200 HRS.

200 HRS.

 

The above

schedule is

for normal

operating conditions.

More frequent oil changes are required with dusty, high

temperature and other severe operating conditions.

Refer to the maintenance section of the Engine

Owner's Manual for more information.

 

NOTE:

Engine life will be reduced if the oil and oil fil-

 

ter are not changed according to the manufac-

 

turerʼs recommendation.

 

DrainENGINEthe oilOILwhileCHANGEthe engine is warm to assure rapid and complete draining.

• Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flex- ible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drain the oil into a suitable container.

• Close the drain valve by pushing in and twisting clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the recommended oil. Tighten the oil filler cap securely.

WithoutENGINEoil OILfilter replacement:REFILL CAPACITIES

• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

•1.6 US qt. (1.3 IMP qt., 1.5 liter)-Honda GX620KI •1.5 US qt. (1.2 IMP qt., 1.4 liter)-Robin / Subaru

With oil filter replacement:

• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

•1.9 US qt. (1.6 Imp qt. , 1.8 liter)-Honda GX620KI •1.6 US qt. (1.4 IMP qt., 1.6 liter)-Robin / Subaru

RANGER® 10,000 & RANGER® 10,000 PLUS

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Contents Ranger 10,000 /10,000 Plus Safety Powered equipmentFor Engine ARC Rays can burn Fumes and GasesWelding and Cutting Sparks can cause fire or Explosion Cylinder may explode If damagedIii Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation SectionSection 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 Operation Section Section B-1Operation Engine Switch OperationWelder 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 EngineWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG 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-1Maintenance Safety PrecautionsKohler 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 Theory of Operation Section Section E-1Theory 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 Rotor Voltage Test Test DescriptionMaterials 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 Auxiliary and Field Winding Test To test the 115 VAC windingTo test the 230 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test 26TROUBLESHOOTING & REPAIRF-26 Output Rectifier Bridge TestFigutpure 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 Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh Idle no Load Output Control AT Maximum Typical DC Weld Output Waveform CV Mode Machine LoadedMachine 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 Section Electrical DiagramsSection 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