Lincoln Electric SVM168-B Welding and Cutting Sparks can cause fire or Explosion, Iii

Page 4

iii

SAFETY

iii

Return to Master TOC

Return to Master TOC

Return to Master TOC

WELDING and CUTTING SPARKS can cause fire or

explosion.

6.a. Remove fire hazards from the welding area.If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjcent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690, -9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturerʼs recommendations.

Return to Master TOC

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ʻ09

RANGER® 10,000 & RANGER® 10,000 PLUS

Image 4
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 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 Section B-1 Operation SectionOperation Operation Engine SwitchWelder Controls Function and Operation Polarity Switch Range SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialSTARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine 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 InstalledRecommended Equipment StickTIG Welding Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1Safety Precautions MaintenanceKohler Honda AIR Cleaner and Other Maintenance OIL Filter ChangeEngine Adjustments BatteryOverspeed is Hazardous Slip RingsPre-Cleaner Oil FilterAir 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