Lincoln Electric SVM107-B service manual Replacement KIT S20788, Reassembly Procedure

Page 103

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F-63

F-63

TROUBLESHOOTING & REPAIR

ENGINE/ROTOR REMOVAL AND

REPLACEMENT (KIT S20788) (continued)

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REASSEMBLY PROCEDURE

NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace the rotor and blower assem- bly.

1.Clean the tapered engine crankshaft. Slide the rotor onto the shaft.

2.Insert the rotor thru-bolt, and with the torque wrench tighten the bolt to 50 ft lbs.

3.Support the engine/rotor assembly with the chain hoist. Fit the rotor into the stator frame, being careful not to damage the rotor core against the stator. The bearing will seat into its race about half way.

4.Insert the four bolts and lock washers that hold the engine to the stator. With the 9/16” wrench, draw the bolts up evenly in order to seat the bearing properly. Tighten to 22 ft-lb. moving diagonally from bolt to bolt.

5.Check the rotor-stator air gap with the .017 feeler gauge. The measurement is taken at the blower end of the rotor before the fan is reinstalled. Turn the rotor with a pair of locking pliers as necessary so that the rotor “iron” is up to take the measurement. (The rotor has two flat sides, which are not mea- sured for air gap.) Slide in the gauge. Then rotate the shaft 180 degrees and measure again. If the gauge does not clear, loosen the four engine/stator bolts; retighten the bolts and recheck the air gap. Repeat until the proper .017 minimum air gap is achieved.

6.Fasten the ground lead to the right engine mounting bolt and install both bolts.

7.Install the brush holder bracket back into the stator frame. Refer to the topic “Brush Removal and Replacement” in this section of the manual.

8.Attach leads to the oil pressure switch refer to wiring diagram. Replace any cut cable ties.

9.Unplug the fuel tank connection and fuel hose and connect them.

10.Connect the idle linkage to the idler rod. Snap the plastic clip back into place.

11.Connect the engine choke cable at the position marked during disassembly.

12.Screw the blower fan back onto the end of the rotor shaft. Be sure the washer is in place and hand tighten the fan only.

13.Reposition the vertical fan baffle and secure it with the two screws.

13A. (For Onan Engine only) Install the muffler support hardware on the Onan engine.

14.Install the two cowling covers at the rear of the stator.

15.Connect the black plug in front of the fuel tank fill spout.

16.Connect the leads to the starter solenoid and replace any cable ties cut during disas- sembly.

17.Install the battery. Connect the positive battery cable, then the negative battery cable. BE SURE TO CONNECT THE POS-

ITIVE BATTERY CABLE FIRST.

18.Replace the battery cover.

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

20.Conduct the “Retest after Repair” proce- dure, the following topic in this section of the manual.

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RANGER 8

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Contents Rangertm Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Welding Output Auxiliary Power50 100 150 200 20 B50 100 150 200 250 300 350 Output Amps Installation Instructions Fuel Battery ConnectionsOil AWGAngle of Operation Constant Current Connection of the LN-7 to the RangerWelder Output RangerMotor Starting Duplex ReceptaclesType Common Electrical Devices Possible Concerns Electrical Device USE with the RangerStandby Power Connections Auxiliary Power While WeldingFigure A.1 Connection of Ranger 8 to Premises WiringRanger Table of Contents Operation Section AC/DC Stick Welding Constant Current DC Semiautomatic Wire Feed Welding Constant VoltageAC/DC TIG Welding Constant Current Welding voltage control with the Range switch set Control SwitchProvides a fine welding current adjustment within Range Switch settings in the STICK/TIG modeStopping the Engine Starting/Shutdown InstructionsStick Constant Current Welding Wire Feed Welding Processes Constant VoltageTIG Constant Current Welding Stick Auto Summary of Welding ProcessesSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Kohler Onan Honda Routine MaintenanceEngine OIL Change Engine OIL Refill CapacitiesOIL Filter Change Slip Rings Engine AdjustmentsEngine Maintenance Parts Pre-CleanerFigure D.1 Major Component Locations Ranger Table of Contents Theory of Operation Section Theory of Operation Rotor Field Feedback and Auxiliary Power Weld WINDING, REACTOR, Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger Table of Contents Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairHandle only at PC board can be damaged by static electricityStatic-Sensitive DevicesOutput Problems Troubleshooting GuideDetailed in the beginning of this manual Observe Safety GuidelinesTroubleshooting & Repair Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Engine Problems Troubleshooting & Repair Troubleshooting & Repair Welding Problems Ranger Test Description Rotor Voltage TestMaterials Needed Test Procedure Rotor Resistance Test Rotor Resistance Test Troubleshooting & Repair Ranger Auxiliary and Field Winding Test To test the 230 VAC winding To test the 115 VAC windingTo test the field winding Ranger Output Rectifier Bridge Test Output Rectifier Bridge Test Charging Circuit Test Charging Circuit Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test 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 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 Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.10 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger Field Capacitor AND/OR Rectifier Bridge Removal Replacement Field Capacitor AND/OR Rectifier Bridge Removal ReplacementProcedure Rectifier Bridge Removal and Replacement Ranger Printed Circuit Board Removal Replacement Procedure Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal Ranger Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger Instructions ENGINE/ROTOR Removal and ReplacementFigure F.14 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.15 Engine and Rotor Removed from Stator Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Table of Contents Diagrams Section Dimension RANGER8 Dimension Print Ranger 8 Honda & KohlerConnection of Ranger 8 to LN-7 & K240 Contactor KIT DiagramsWiring Diagram Onan NON CSA Model Electrical DiagramsWiring Diagram Onan CSA Model K1418-2 Ranger 8 Onan CSA Version Wiring DiagramWiring Diagram Kohler NON CSA Model K1419-1 Ranger 8 Kohler Wiring DiagramWiring Diagram Kohler CSA Model K1419-2 Ranger 8 Kohler CSA Wiring DiagramK2160-1 Ranger 8 Honda CSA Wiring Diagram 16482 Schematic IDLER/CONTROL PC BoardPC Board Assembly IDLER/CONTROL SVM Error Reporting Form
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