Lincoln Electric SVM168-B service manual Welding Problems

Page 53

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F-13

TROUBLESHOOTING & REPAIR

 

 

F-13

 

 

 

 

TROUBLESHOOTING GUIDE

 

Observe Safety Guidelines

 

 

 

detailed in the beginning of this manual.

PROBLEMS

 

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

WELDING PROBLEMS

 

 

 

 

The welding arc is “cold.”

Engine

 

1. Check for loose or faulty con-

1. Check for the correct open cir-

runs normally (3700 RPM no load).

 

nections at the weld output ter-

cuit voltage (OCV) at the welder

Auxiliary power is functioning nor-

 

minals and welding cable con-

output

terminals (80VAC Max.

mally.

 

 

nections.

72VDC Max.). If

the

correct

 

 

 

2. The welding cable may be too

voltage is present at the output

 

 

 

terminals, then check for loose

 

 

 

long or coiled, causing an

 

 

 

connections on the heavy cur-

 

 

 

excessive voltage drop.

 

 

 

rent carrying leads inside the

 

 

 

 

 

 

 

 

RANGER® 8.

See

Wiring

 

 

 

 

Diagram.

 

 

 

 

 

 

2. If the OCV is low at the welder

 

 

 

 

output terminals, then Perform

 

 

 

 

The

Engine

 

Throttle

 

 

 

 

Adjustment Test.

 

 

 

 

 

 

3. Perform the Output Rectifier

 

 

 

 

Bridge Test.

 

 

 

 

 

 

4. Check for shorted or grounded

 

 

 

 

windings in the reactor and also

 

 

 

 

in the main stator. See Wiring

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

 

 

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

Page 52 Page 54
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Page 52 Page 54
Contents Ranger 10,000 /10,000 Plus For Engine SafetyPowered equipment Fumes and Gases ARC Rays can burnIii 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 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 Operation SectionSection B-1 Welder Controls Function and Operation Engine SwitchOperation Range Switch Polarity SwitchKohler Honda Robin / Subaru 20 H.P. Command Control DialBREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick 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 SectionKohler Honda MaintenanceSafety Precautions 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 Theory of Operation SectionSection E-1 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 Materials Needed Rotor Voltage TestTest Description 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 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 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 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 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 Section G-1 Electrical Diagrams SectionElectrical Diagrams 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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