Lincoln Electric SVM168-B service manual Brush Removal and Replacement, Procedure

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F-44

TROUBLESHOOTING & REPAIR

F-44

 

 

 

BRUSH REMOVAL AND REPLACEMENT (continued)

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PROCEDURE

1.Remove the spark plug wires.

2.With the 5/16” nut driver, remove the 6 sheet metal screws from the case top.

3.Remove the rubber gasket (cover seal) from the lift bail.

4.Remove the fuel cap. The rubber gasket for the fill tube with come off with the case top.

5.Remove the case top, then reinstall the fuel cap.

6.WIth the 5/16” nut driver, remove the 5 screws holding the right case side.

7.Remove the right case side by lifting up and out.

8.With the needle nose pliers, gently remove the blue and the red wires from the brushes. See Figure F.9.

9.With the 7/16” wrench, remove the brush holder assembly bracket from the stator frame.

10.With the 5/16” open end wrench, remove the two screws that secure the brush hold- er assembly to the bracket. Slide the brush holder assembly out of the bracket.

11.To change the brushes, use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly.

12.Remove the old brushes and insert the new ones. One corner of the terminal clip is beveled so that the brush can go in only one way.

13.Snap the plastic retainer back onto the brush holder. The brushes may need some repositioning; wiggle them slightly to help them seat properly on the slip rings.

14.To reinstall the brushes, depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder. A cable tie works well; See Figure F.9. This will hold the brushes up so that you can easily install the holder.

15.Slide the brush holder assembly back into the bracket and, with the 5/16” open end wrench, install the two screws that hold it in place.

16.With the 7/16” wrench, install the brush holder assembly bracket to the stator frame.

17.Slowly remove the non-metallic retainer from the brush holder and let the brushes snap back against the slip rings.

18.With the needle nose pliers, connect the red and the black wires to the appropriate terminals on the brushes. The red wire is inboard.

19.Check the wire connections for clearance and tightness.

20.Reinstall the case side, fuel cap, lift bail gasket, case top, and spark plug wires.

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RANGER® 10,000 & RANGER® 10,000 PLUS

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Contents Ranger 10,000 /10,000 Plus Safety Powered equipmentFor Engine ARC Rays can burn Fumes and GasesWelding 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 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 Section Section B-1Operation Engine Switch OperationWelder 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 EngineWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG 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-1Maintenance Safety PrecautionsKohler 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 Theory of Operation Section Section E-1Theory 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 Rotor Voltage Test Test DescriptionMaterials 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 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 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 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 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 Section Electrical DiagramsSection 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
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