Lincoln Electric SVM107-B service manual Troubleshooting Guide

Page 48

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F-8

 

 

 

F-8

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 DC welding output. AC welding

1. Make sure the Polarity Switch is

1. Perform the Output Bridge Test.

output and auxiliary power is nor-

in the proper position and is

2.

Check the Choke (L1),

the

mal.

“seated” correctly.

 

Polarity Switch (S2) and associ-

 

 

 

 

2. Make sure the electrode and

 

ated wires for loose or faulty

 

polarity are correct for the

 

connections. Check the choke

 

process being used.

 

winding for continuity and test

 

 

 

to be sure it is NOT grounded

 

 

 

the choke iron.

 

 

 

 

 

No AC welding output. DC welding

1. Make sure the Polarity Switch is

1. Check the operation of

the

output and auxiliary power is nor-

in the proper position and is

 

Polarity Switch (S2). Also check

mal.

“seated” correctly.

 

the associated wires for loose

 

2. Make sure the electrode is cor-

 

or faulty connections.

See

 

 

Wiring Diagram.

 

 

rect for the process being used.

 

 

 

 

 

 

 

3. Make sure the welding cables

2.

Check for continuity from lead

 

 

“S2” to lead “E” located in the

 

are not coiled or too long.

 

 

 

main stator. See Wiring Dia-

 

 

 

 

 

 

gram.

 

 

 

 

 

 

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 Output20 B 50 100 150 20050 100 150 200 250 300 350 Output Amps Installation Instructions Battery Connections OilAWG FuelAngle of Operation Connection of the LN-7 to the Ranger Welder OutputRanger 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 DC Semiautomatic Wire Feed Welding Constant Voltage AC/DC Stick Welding Constant CurrentAC/DC TIG Welding Constant Current Control Switch Provides a fine welding current adjustment withinRange Switch settings in the STICK/TIG mode Welding voltage control with the Range switch setStarting/Shutdown Instructions Stopping the EngineWire Feed Welding Processes Constant Voltage Stick Constant Current WeldingTIG Constant Current Welding Summary of Welding Processes Stick AutoSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Routine Maintenance Engine OIL ChangeEngine OIL Refill Capacities Kohler Onan HondaOIL Filter Change Engine Adjustments Engine Maintenance PartsPre-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 Troubleshooting & Repair HOW to USE Troubleshooting GuidePC board can be damaged by static electricity Static-SensitiveDevices 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 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 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 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 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