Lincoln Electric SVM168-B service manual Output Problems

Page 45

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F-5

TROUBLESHOOTING & REPAIR

F-5

 

 

 

 

 

 

TROUBLESHOOTING GUIDE

 

 

 

 

Observe Safety Guidelines

 

 

 

 

 

detailed in the beginning of this manual.

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

No weld output, the auxiliary

1.

Check the open circuit voltage

1. Disconnect lead W1 from the

power (230-115VAC) is operating

 

(OCV) at the welder output ter-

Output Bridge (D1) and check

normally. Engine runs normally.

 

minals, engine at high idle (3650

for the presence of 80VAC from

 

 

 

RPM). Normal maximum is 73

lead W1 to lead W2 on the main

 

 

 

to 80VAC.

Normal DC maxi-

stator winding. See wiring dia-

 

 

 

mum is 67 to 72VDC.

If the

gram. If the AC voltage is NOT

 

 

 

OCV is OK then proceed to

present, the winding in the sta-

 

 

 

Step #2. If the OCV is not pre-

tor may be faulty.

Check the

 

 

 

sent at the welder output termi-

winding for continuity and test

 

 

 

nals, contact your local Lincoln

to be sure it is NOT grounded to

 

 

 

Authorized

Field

Service

the stator iron. Replace if nec-

 

 

 

Facility.

 

 

essary. If the correct AC volt-

 

 

2.

Check the

welding

cables,

age is present, proceed to step

 

 

#2.

 

 

 

 

clamps and electrode holder for

 

 

 

 

 

 

 

 

 

loose or broken connections.

2. Check the Reactor, Range

 

 

 

 

 

 

Switch (S1) and

associated

 

 

 

 

 

 

wires for loose or faulty connec-

 

 

 

 

 

 

tions. Check the reactor wind-

 

 

 

 

 

 

ing for continuity and test to be

 

 

 

 

 

 

sure it is NOT grounded to the

 

 

 

 

 

 

reactor iron.

 

 

 

 

 

 

 

3. Check the Choke (L1), Polarity

 

 

 

 

 

 

Switch (S2) and

associated

 

 

 

 

 

 

wires for loose or faulty connec-

 

 

 

 

 

 

tions. Check the choke winding

 

 

 

 

 

 

for continuity and test to be

 

 

 

 

 

 

sure it is NOT grounded to the

 

 

 

 

 

 

choke iron.

 

 

 

 

 

 

 

4. Check the weld output termi-

 

 

 

 

 

 

nals and associated wires for

 

 

 

 

 

 

loose or faulty connections.

 

 

 

 

 

 

5. Perform the Output Bridge

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

 

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 Safety Powered equipmentFor Engine Fumes and Gases ARC Rays can burnWelding 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 Height Width Depth Weight InstallationHorsepower Operating Speed RPM Spark Arrester Safety PrecautionsMachine Grounding TowingGasoline PRE-OPERATION ServiceVehicle Mounting Can cause fire or explosionTotal Combined Length of Electrode and Work Cables Welding Output CablesAngle of Operation LiftingInstructions Connection of Lincoln Electric Wire FeedersStacking Welder Operation120/240 Volt Dual Voltage Receptacle Auxiliary PowerDuplex Receptacles Motor StartingNot USE These Devices With a Ranger 10,000 These Devices Without Additional Resistive Type LoadsStandby Power Connections Simultaneous Welding and PowerFigure A.1 Ranger 10,000 & Ranger 10,000 Plus Operation Section Section B-1Operation Engine Switch OperationWelder Controls Function and Operation Range Switch Polarity SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialBREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG Constant Current Welding Summary of Welding Processes Start Switch Wire FEED, LN-15Section C-1 Accessories SectionOptional Equipment Field Installed AccessoriesStick Recommended EquipmentTIG Welding Plasma CuttingRanger 10,000 & Ranger 10,000 Plus Section D-1 Maintenance SectionMaintenance Safety PrecautionsKohler Honda OIL Filter Change AIR Cleaner and Other MaintenanceBattery Engine AdjustmentsOverspeed is Hazardous Slip RingsOil Filter Pre-CleanerAir Filter ElementFigure D.1 Major Component Location Theory of Operation Section Section E-1Theory of Operation Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback and Auxiliary PowerFigure E.4 Weld WINDING, REACTOR, and Range Switch Weld WINDING, REACTOR, Range SwitchOutput BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Section F-1 Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideOutput 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 Figure F.2 Location of Rotor Slip Rings Rotor Resistance TestTroubleshooting & 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 Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Engine Throttle Adjustment TestFigure 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 Machine 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 10,000 & Ranger 10,000 Plus Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Figure F.10 Printed Circuit Board Location Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal ReplacementRanger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger 10,000 & Ranger 10,000 Plus Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Electrical Diagrams Section Electrical DiagramsSection G-1 Wiring Diagram Code 11041 only -M20226 Electrical DiagramsRanger 10,000 Honda Wiring Diagram Code 11095 only M20301Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus L13105 Schematic Entire Machine Codes 11395 and 11398 L13105L13103 Schematic Entire Machine CDE 11394 L13103Schematic Entire Machine Code 11095 & 11253 only L12257 L12249 Schematic Entire Machine Code 11151 only L12249-1Electrical Diagrams Electrical Diagrams
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