Main
SVM107-B
RANGER 8
SERVICE MANUAL
Safety Depends on You
i i
FOR ENGINE powered equipment.
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dangerous.
iii iii
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
WELDING SPARKS can cause fire or explosion.
iv iv
PRCAUTIONS DE SRET
Mar. 93
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
- INSTALLATION SECTION -
INPUT - GASOLINE ENGINE
PHYSICAL DIMENSIONS
OUTPUT - GENERATOR
RATED OUTPUT - WELDER
A-3 A-3
SPECIFICATIONS
INSTALLATION INSTRUCTIONS
Safety Precautions
Machine Grounding
Spark Arrester
Trailers
Pre-Operation Service
Welding Output Cables
GASOLINE
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Angle of Operation
High Altitude Operation
Muffler Relocation
Location / Ventilation
Connection of Lincoln Electric Wire Feeders
INSTRUCTIONS
Additional Safety Precautions
Welder Operation
Auxiliary Power
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* **
A-11 A-11
Figure A.1
CONNECTION OF RANGER 8 TO PREMISES WIRING
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- OPERATION SECTION -
GENERAL DESCRIPTION
DESIGN FEATURES
OTHER FEATURES
ENGINE OPTIONS
*
Welder Controls - Function and Operation ENGINE ON-OFF Switch
ENGINE START Push-Button Switch
Range Switch
Ranger 8 Approximate Fuel Consumption
Starting/Shutdown Instructions
Break-in Period
Welding Process
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Page
ACCESSORIES
OPTIONAL EQUIPMENT
ACCESSORIES
RECOMMENDED EQUIPMENT
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-MAINTENANCE-
ENGINE OIL CHANGE
ENGINE OIL REFILL CAPACITIES
OIL FILTER CHANGE
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Page
-THEORY OF OPERATION SECTION-
BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOID
ROTOR FIELD FEEDBACK AND AUXILIARY POWER
WELD WINDING, REACTOR, AND RANGE SWITCH
OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, AND OUTPUT TERMINALS
Page
TROUBLE SHOOTING & REPAIR SECTION
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
Page
Page
Page
Page
Page
Page
Page
Page
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WELDING PROBLEMS
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ROTOR VOLTAGE TEST
ROTOR VOLTAGE TEST (continued)
-
ROTOR RESISTANCE TEST
ROTOR RESISTANCE TEST (continued)
+ -
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Page
AUXILIARY AND FIELD WINDING TEST
Page
AUXILIARY AND FIELD WINDING TEST (continued)
Page
OUTPUT RECTIFIER BRIDGE TEST
OUTPUT RECTIFIER BRIDGE TEST (continued)
+
-
CHARGING CIRCUIT TEST
CHARGING CIRCUIT TEST (continued)
ENGINE THROTTLE ADJUSTMENT TEST
Page
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NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM
TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE)
MACHINE LOADED TO 200 AMPS AT 26 VDC
TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
MACHINE LOADED TO 225 AMPS AT 25 VDC
TYPICAL AC WELD OUTPUT WAVEFORM
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
ONE OUTPUT DIODE NOT FUNCTIONING
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
ONE OUTPUT DIODE NOT FUNCTIONING
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
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BRUSH REMOVAL AND REPLACEMENT
BRUSH REMOVAL AND REPLACEMENT (continued)
SLIP RINGS
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AND REPLACEMENT (continued)
PROCEDURE - RECTIFIER BRIDGE REMOVALAND REPLACEMENT
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PRINTED CIRCUIT BOARD REMOVAL
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued)
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued)
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Page
+
-
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ENGINE/ROTOR REMOVAL AND REPLACEMENT
INSTRUCTIONS
REPLACEMENT (continued)
ENGINE/ROTOR REMOVAL
ENGINE AND ROTOR REMOVAL PROCEDURE
ROTOR REMOVALPROCEDURE
REPLACEMENT (continued)
REPLACEMENT (KIT S20788) (continued)
REASSEMBLYPROCEDURE
RETEST AFTER REPAIR
ENGINE OUTPUT
WELDER DC OUTPUT
WELDER AC OUTPUT
WELDER CV OUTPUT
DIAGRAMS SECTION
DIMENSION PRINT RANGER 8 (ONAN)
DIMENSION PRINT RANGER 8 (HONDA & KOHLER)
G-4 G-4
CONNECTION OF RANGER 8 TO LN-7 & K240 CONTACTOR KIT
S17742 10-2-92
WARNING
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ONAN NON CSA MODEL
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
R1
254A
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ONAN CSA MODEL
M18332
TERMINALS
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - KOHLER NON CSA MODEL
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
+
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - KOHLER CSA MODEL
S3
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
RA (CSA) - WIRING DIAGRAMK2160-1 NGER 8 HONDA
M19988
221
+
S3
ELECTRICAL DIAGRAMS
SCHEMATIC - IDLER/CONTROL PC BOARD
76
MOLEX
LABELS
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY- IDLER/CONTROL
L
G-11
SVM ERROR REPORTING FORM