Lincoln Electric SVM107-B service manual Troubleshooting & Repair

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F-6			F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines		TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS	POSSIBLE AREAS OF	RECOMMENDED
(SYMPTOMS)	MISADJUSTMENT(S)	COURSE OF ACTION

	OUTPUT PROBLEMS
No auxiliary power, welding output	1. If machine is equipped with cir-	1. Check the	auxiliary power
is normal. Engine runs normally.	cuit breakers, check circuit	receptacles	and associated
	breakers CB1 thru CB5. Reset	wires for loose or faulty connec-
	if tripped.	tions.
	2. Make sure the Output Control	2. Perform the Auxiliary and Field
	(R1) is set at the maximum	Winding Voltage Test.
	position.	3. If machine is equipped with cir-
		3. If machine is equipped with cir-
	3. Check for loose or faulty plug(s)	cuit breakers, check for faulty
	at the power receptacle(s).	breakers and loose or faulty
		connections	on associated
		wiring.

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 Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Auxiliary Power Welding Output50 100 150 200 20 B50 100 150 200 250 300 350 Output Amps Installation Instructions AWG Battery ConnectionsOil FuelAngle of Operation Ranger Connection of the LN-7 to the RangerWelder Output Constant CurrentDuplex Receptacles Motor StartingElectrical Device USE with the Ranger Type Common Electrical Devices Possible ConcernsAuxiliary Power While Welding Standby Power ConnectionsConnection of Ranger 8 to Premises Wiring Figure A.1Ranger Table of Contents Operation Section AC/DC Stick Welding Constant Current DC Semiautomatic Wire Feed Welding Constant VoltageAC/DC TIG Welding Constant Current Range Switch settings in the STICK/TIG mode Control SwitchProvides a fine welding current adjustment within Welding voltage control with the Range switch setStarting/Shutdown Instructions Stopping the EngineStick Constant Current Welding Wire Feed Welding Processes Constant VoltageTIG Constant Current Welding Summary of Welding Processes Stick AutoSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Engine OIL Refill Capacities Routine MaintenanceEngine OIL Change Kohler Onan HondaOIL Filter Change Pre-Cleaner Engine AdjustmentsEngine Maintenance Parts 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 Troubleshooting & Repair HOW to USE Troubleshooting GuideDevices PC board can be damaged by static electricityStatic-Sensitive Handle only atTroubleshooting Guide Output ProblemsObserve Safety Guidelines Detailed in the beginning of this manualTroubleshooting & 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 115 VAC winding To test the 230 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 Typical DC Weld Output Waveform CV Mode Machine LoadedTypical 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 Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureSlip Rings Figure F.10 Brush LEADS/BRUSHES Retained with Cable TIERanger Field Capacitor AND/OR Rectifier Bridge Removal Replacement Replacement Field Capacitor AND/OR Rectifier Bridge RemovalProcedure Rectifier Bridge Removal and Replacement Ranger Printed Circuit Board Removal Replacement Printed Circuit Board Removal and Replacement ProcedurePrinted Circuit Board Removal Ranger Output Rectifier Bridge Removal Replacement Remove the case top, then reinstall the fuel cap Output Rectifier Bridge RemovalSection TOC Ranger ENGINE/ROTOR Removal and Replacement InstructionsENGINE/ROTOR Removal Figure F.14 Component LOCATIONS, ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Rotor Removal Procedure Figure F.15 Engine and Rotor Removed from StatorReplacement KIT S20788 Reassembly ProcedureRetest After Repair Table of Contents Diagrams Section Dimension Dimension Print Ranger 8 Honda & Kohler RANGER8Diagrams Connection of Ranger 8 to LN-7 & K240 Contactor KITElectrical Diagrams Wiring Diagram Onan NON CSA ModelK1418-2 Ranger 8 Onan CSA Version Wiring Diagram Wiring Diagram Onan CSA ModelK1419-1 Ranger 8 Kohler Wiring Diagram Wiring Diagram Kohler NON CSA ModelK1419-2 Ranger 8 Kohler CSA Wiring Diagram Wiring Diagram Kohler CSA ModelK2160-1 Ranger 8 Honda CSA Wiring Diagram Schematic IDLER/CONTROL PC Board 16482PC Board Assembly IDLER/CONTROL SVM Error Reporting Form