Lincoln Electric SVM168-B service manual Output Problems

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F-9

TROUBLESHOOTING & REPAIR

F-9

 

 

 

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 constant voltage (CV) welding

1. Make sure the Range Switch

1. Check the operation of the

output. Constant current (CC) and

(S1) is in the proper position

Range Switch (S1) and check

the auxiliary power are operating

(CV) and “seated” correctly.

the associated wires for loose

normally.

 

2. Make sure the wire feeder is

or faulty connections.

See

 

 

Wiring Diagram.

 

 

 

connected correctly.

 

 

 

 

 

 

 

 

2. Check for continuity from lead

 

 

 

C1 to lead W1 located in the

 

 

 

main stator. See Wiring Dia-

 

 

 

gram.

 

 

 

 

 

 

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 Powered equipment SafetyFor Engine Fumes and Gases ARC Rays can burnCylinder 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 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 Section B-1 Operation SectionOperation Operation Engine SwitchWelder 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 EngineStick Constant Current Welding Wire Feed Welding Processes Constant VoltageTIG 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 SectionSafety Precautions MaintenanceKohler 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 Section E-1 Theory of Operation SectionTheory 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 SectionHOW 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 Test Description Rotor Voltage TestMaterials 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 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 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 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 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 Electrical Diagrams SectionSection 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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