Lincoln Electric SVM168-B service manual Troubleshooting Guide, Output Problems

Page 44

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F-4

TROUBLESHOOTING & REPAIR

 

 

 

F-4

 

 

 

Observe Safety Guidelines

 

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

Major Physical or

Electrical

1. Contact your local Lincoln

1. Contact The Lincoln Electric

Damage is Evident.

 

Authorized Field Service

Service Dept. 1-888-935-3877.

 

 

Facility.

 

 

 

 

 

 

 

 

No weld output and no auxiliary

1. Check the brushes for wear and

1. Perform the Rotor Voltage

power. Engine runs normally.

proper contact to the rotor slip

Test.

 

 

 

 

 

 

rings.

2. Check for the presence of

 

 

 

 

 

 

12VDC (at the pc board) from

 

 

 

lead #216 to frame ground.

 

 

 

This is the “flashing” voltage

 

 

 

and is present only when the

 

 

 

Start, Run, Stop switch S3 is in

 

 

 

the “Start” position. If the 12

 

 

 

VDC is missing check the leads,

 

 

 

switches

and

connections

 

 

 

associated with the lead #216.

 

 

 

See Wiring Diagram.

 

 

 

 

Check for the presence of 12

 

 

 

VDC (at the pc board) from lead

 

 

 

#224 to frame ground. This is

 

 

 

the supply voltage to the board

 

 

 

and is present when the engine

 

 

 

is running and the S3 switch is

 

 

 

in the “Run” position. If the

 

 

 

12VDC is missing check the

 

 

 

leads, switches and connec-

 

 

 

tions associated with the lead

 

 

 

#224. See Wiring Diagram.

 

 

 

3. If Rotor Voltage Test is normal,

 

 

 

then

preform

the

Rotor

 

 

 

Resistance Test.

 

 

 

 

 

4. If the Rotor Voltage Test is NOT

 

 

 

normal, perform

the Auxiliary

 

 

 

and

Field

Winding

Voltage

 

 

 

Test. Then check the Field

 

 

 

Diode Bridge (D2) and the Field

 

 

 

Capacitor (C1). Replace if nec-

 

 

 

essary. If the Field Bridge and

 

 

 

Field Capacitor are good, then

 

 

 

the Printed Circuit Board may

 

 

 

be faulty. Replace.

 

CAUTION

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

RANGER® 10,000 & RANGER® 10,000 PLUS

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Contents Ranger 10,000 /10,000 Plus For Engine SafetyPowered equipment ARC Rays can burn Fumes and GasesIii Welding and Cutting Sparks can cause fire or ExplosionCylinder may explode If damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section 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 Operation Operation SectionSection B-1 Welder Controls Function and Operation Engine SwitchOperation Polarity Switch Range SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialSTARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine Stopping the EngineTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick 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-1Kohler Honda MaintenanceSafety Precautions AIR Cleaner and Other Maintenance OIL Filter ChangeEngine Adjustments BatteryOverspeed is Hazardous Slip RingsPre-Cleaner Oil FilterAir Filter ElementFigure D.1 Major Component Location Theory of Operation Theory of Operation SectionSection E-1 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 Materials Needed Rotor Voltage TestTest Description 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 230 VAC winding Auxiliary and Field Winding TestTo test the 115 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test Figutpure F.4 Locationctifof Output Rectifier Leads 26TROUBLESHOOTING & REPAIRF-26Output Rectifier Bridge Test 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 High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 200 Amps AT 20 VDC Typical DC Weld Output Waveform CV ModeMachine Loaded 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 Section G-1 Electrical Diagrams SectionElectrical Diagrams 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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