Lincoln Electric SVM120-A service manual

SVM120-A

March 1999

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However,

your overall safety can be

increased by proper installation .

. . and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,

most importantly, think before

you act and be careful.

SERVICE MANUAL

For use with machine code numbers 9815 and 9816

RANGER 10-LX

TM

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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Contents

Main SVM120-A RANGER 10-LX March 1999 SERVICE MANUAL Safety Depends on You i i 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 - TECHNICAL SPECIFICATIONS - RANGER 10-LX INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities RATED OUTPUT - WELDER Duty Cycle Amps Volts at Rated Amperes OUTPUT - WELDER AND GENERATOR SAFETY PRECAUTIONS LOCATION AND VENTILATION STORING STACKING TILTING PRE-OPERATION ENGINE SERVICE OIL FUEL ENGINE COOLANT HOT COOLANT can burn skin. BATTERYCONNECTIONS ELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONS MACHINE GROUNDING AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT CIRCUIT BREAKERS PREMISES WIRING A-8 A-8 RANGER 10-LX FIGURE A.2 - CONNECTION OF RANGER 10-LX TO PREMISES WIRING - OPERATION SECTION - OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. FUMES AND GASES can be dan- gerous. WELDING SPARKS can cause fire or explosion. RECOMMENDED APPLICATIONS WELDER GENERATOR DESIGN FEATURES AND ADVANTAGES WELDING CAPABILITY CONTROLS AND SETTINGS Page DIESEL ENGINE CONTROLS ENGINE OPERATION BEFORE STARTING THE ENGINE STARTING THE ENGINE STOPPING THE ENGINE BREAK-IN PERIOD Page WELDING OPERATION GENERAL INFORMATION To use the RANGER 10-LX for AC/DC Constant Current Stick Welding: To Use the RANGER10-LX for AC/DC TIG (Constant Current) Welding: To Use the RANGER 10-LX for DCWire Feed Welding (Constant Voltage): SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS AUXILIARY POWER GENERAL INFORMATION Page Page - ACCESSORIES - OPTIONS/ACCESSORIES Page CONNECTION OF THE RANGER 10-LX TO WIRE FEEDERS USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1) CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF THE LN-25 TO THE RANGER 10-LX ACROSS THE ARC (SEE FIGURE C.2.) CONNECTION OF THE LN-7 TO THE RANGER 10-LX USING K584 INPUT CABLE ASSEMBLY(SEE FIGURE C.3.) CONNECTION OF THE LN-7 TO THE RANGER 10-LX USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.4.) CONNECTION OF THE LN-8 TO THE RANGER 10-LX (SEE FIGURE C.5.) Page -MAINTENANCE- SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE Page Page Page Page Page BATTERY MAINTENANCE WELDER/GENERATOR MAINTENANCE Page D-10 D-10 RANGER 10-LX 5/96 FIGURE D.6 - MAJOR COMPONENT LOCATIONS -THEORY OF OPERATION SECTION- FIGURE E.1 RANGER 10-LX BLOCK LOGIC DIAGRAM BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION, ROTOR, STATOR AND IDLER SOLENOID ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER WELD WINDING, REACTOR, AND RANGE SWITCH OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, CV CONTACTOR AND OUTPUT TERMINALS TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page WELDING PROBLEMS ROTOR VOLTAGE TEST ROTOR VOLTAGE TEST (continued) ROTOR RESISTANCE TEST ROTOR RESISTANCE TEST (continued) AUXILIARY AND FIELD WINDING TEST Page Page Page OUTPUT RECTIFIER BRIDGE TEST OUTPUT RECTIFIER BRIDGE TEST (continued) CHARGING CIRCUIT TEST CHARGING CIRCUIT TEST (continued) PROTECTION RELAY (CR1) TEST PROTECTION RELAY (CR1) TEST (continued) ENGINE THROTTLE ADJUSTMENT TEST Page Page Page NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) MACHINE LOADED TO 250 AMPS AT 30VDC TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP) TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 250 AMPS AT 25VDC TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) OUTPUT CAPACITOR BANK NOT FUNCTIONING NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM BRUSH REMOVAL AND REPLACEMENT Page BRUSH REMOVAL AND REPLACEMENT (continued) Page AND REPLACEMENT (continued) PROCEDURE - RECTIFIER BRIDGE REMOVALAND REPLACEMENT CONTROL BOARD REMOVAL AND REPLACEMENT CONTROL BOARD REMOVAL AND REPLACEMENT (continued) CONTROL BOARD REMOVAL AND REPLACEMENT (continued) Page Page Page OUTPUT CAPACITOR BANK REMOVAL OUTPUT CAPACITOR BANK EMOVAL OUTPUT CONTACTOR REMOVAL OUTPUT CAPACITOR REMOVAL TROUBLESHOOTING & REPAIRs OUTPUT CAPACITOR REMOVAL STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT STATOR AND/OR REMOVAL AND REPLACEMENT (continued) FIGURE F.18 COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL STATOR AND/OR ROTOR REMOVAL PROCEDURE (Stator Removal) ROTOR REMOVALPROCEDURE REASSEMBLYNOTES LEAD RECONNECTION CHECKLIST Engine Front Panel/PC Board RETEST AFTER REPAIR ENGINE OUTPUT WELDER DC OUTPUT WELDER AC OUTPUT WELDER CV OUTPUT Page Page ELECTRICAL DIAGRAMS } NOTE: COMPONENTS SHOWN J8 } } } } L CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. ENGINE WELDER (RANGER 10-LX) } } } } L CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. J4 J1, J5 J2 Control PC Board (G2318) Schematic G-5 Control PC Board (G2318) Layout G2318 2318 G G-5 DIAGRAMS RF BYPASS BOARD SCHEMATIC DIAGRAMS DIMENSION PRINT M16706 3-24-95E SVM ERROR REPORTING FORM