Lincoln Electric SVM107-B Observe Safety Guidelines, Detailed in the beginning of this manual

Page 45

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F-5

F-5

 

TROUBLESHOOTING & REPAIR

 

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 1-800-833-9353 (WELD).

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 Power20 B 50 100 150 20050 100 150 200 250 300 350 Output Amps Installation Instructions Oil Battery ConnectionsAWG FuelAngle of Operation Welder Output Connection of the LN-7 to the RangerRanger Constant CurrentMotor 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 DC Semiautomatic Wire Feed Welding Constant Voltage AC/DC Stick Welding Constant CurrentAC/DC TIG Welding Constant Current Provides a fine welding current adjustment within Control SwitchRange Switch settings in the STICK/TIG mode Welding voltage control with the Range switch setStopping the Engine Starting/Shutdown InstructionsWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG Constant Current Welding Stick Auto Summary of Welding ProcessesSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Engine OIL Change Routine MaintenanceEngine OIL Refill Capacities Kohler Onan HondaOIL Filter Change Engine Maintenance Parts Engine AdjustmentsPre-Cleaner Slip RingsFigure 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 & RepairStatic-Sensitive PC board can be damaged by static electricityDevices Handle only atOutput 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 Rotor Voltage Test Test DescriptionMaterials 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 Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh 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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