Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM148-B service manual Description

Models: SVM148-B

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F-62

F-62

TROUBLESHOOTING & REPAIR

OUTPUT CAPACITOR BANK REMOVAL AND REPLACEMENT

(RANGER 300 DLX ONLY)

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manu- al.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the output capacitor bank for maintenance or replacement. Ranger 300 D models do not have the capacitor bank.

MATERIALS NEEDED

Volt/Ohmmeter 25-watt resistor 5/16” Nut driver 3/8” Nut driver 1/2” Wrench Wiring Diagram

This procedure requires approximately 25 minutes to perform.

RANGER 300 D AND 300 DLX

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Lincoln Electric SVM148-B service manual Description

Contents

Ranger TM300 D and 300 DLX Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Ranger 300 D and 300 DLX Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Ranger 300 D and 300 DLX InstallationLocation and Ventilation Safety PrecautionsStoring StackingPRE-OPERATION Engine Service Gases from Battery can explode Battery ConnectionsFuel Engine CoolantHigh Frequency Generators for TIG Applications Remote ControlWelding Terminals Electrical ConnectionsWelding Cable Connections Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentTable A.1 Total Combined Length of Electrode and Work CablesPremises Wiring Figure A.2 Connection of Ranger 300 to Premises Wiring Ranger 300 D and 300 DLX Table of Contents Operation Section Operation Safety InstructionsOperating Instructions For Auxiliary Power Design Features ALL ModelsOther Features General DescriptionRanger 300 D K1522-1 Additional FeaturesWELDER/GENERATOR Controls Controls and SettingsOperation Figure B.2 Engine Controls Engine ControlsOperation Before Starting the Engine Engine OperationStopping the Engine Cold Weather Starting and OperationBREAK-IN Period Welding Operation Welding AC/DC TIG Constant CurrentPure EWP Range Appropriate Tungsten Diameter Switch Settings DC Wire Feed Welding CV with Ranger 300 DLXElectrode Wire Speed Approximate DC Wire Feed Welding CV with Ranger 300 DSummary of Welding Processes and Machine Settings Summary of Welding Processes and Machine Settings Simultaneous Welding and Power Loads Auxiliary PowerDuplex Receptacles 120/240 V Dual Voltage ReceptacleTable of Contents Accessories TIG Welding Options Accessories General Options AccessoriesING Terminals Always on Connection of Lincoln Electric Wire FeedersPIN Remotely Controlled ING Terminals Remotely Controlled To Work Return Ranger 300 D and 300 DLX Ranger 300 D and 300 DLX Table of Contents Maintenance Frequency Safety Precautions Kubota Engine Maintenance ScheduleEngine Maintenance MaintenanceRoutine and Periodic Fuel Feedfuel Feedpumppumplever To prevent Electrical Damage when Battery MaintenanceCharging the Battery Welder / Generator MaintenanceFigure D.3 Major Component Locations Ranger 300 D and 300 DLX Table of Contents Theory of Operation Section Theory of Operation BATTERY, STARTER, EngineGlow PLUGS, Engine PROTECTION, ROTOR, StatorRotor Field FEEDBACK, Auxiliary and Wire Feeder Power Figure E-4 Weld WINDING, Reactor and Range Switch Weld WINDING, Reactor and Range SwitchReturn to Ranger 300 D and 300 DLX Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Output Problems Troubleshooting GuideOn page F-6 Output Problems Field Winding Voltage Test Troubleshooting Guide No DC welding output. AC welding Make sure the polarity mode Troubleshooting & Repair Volts is normal. If 12VDC is Engine ProblemsSymptoms Misadjustments Course of Action Problems Possible AreasHigh Speed Solenoid Resistance Test Perform the Fuel Shutdown Shutdown Solenoid Resis Function Problems Perform the Auxiliary 12VDC is Nections at the battery Battery does not stay charged Check for loose or faulty conEngine charging system Welding Problems Test Description Rotor Resistance TestMaterials Needed Rotor Resistance Test Test ProcedureConduct the test with the engine OFF Output Rectifier Bridge Test Conduct this test with the engine off Output Rectifier Bridge TestFuel Shutdown Solenoid Resistance Test Figure F.3 Plug J12 Location Fuel Shutdown Solenoid Resistance TestHigh Speed Solenoid Test High Speed Solenoid Test Engine Throttle Adjustment Test Conduct this procedure with the engine OFF Engine Throttle Adjustment TestFigure F.7 High Idle Adjustment Oscilloscope Method Frequency Counter MethodTest Description Auxiliary and Field Winding TestTo test the 115 VAC winding Auxiliary and Field Winding TestTo test the 230 VAC winding To test the field winding To test the feeder winding Ranger 300 DLX Models Figure F.11 14-PIN Amphenol PIN AssignmentsTest Description Rotor Voltage TestRotor Voltage Test Test ProcedureCharging Circuit Test InstallationCharging Circuit Test Alternator Test ProcedureNormal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Voltage Waveform CV Mode High TAPMachine Loaded to 250 Amps AT 30VDC Machine Loaded to 250 Amps AT 25 VDC Typical DC Weld Output Voltage WaveformMachine Loaded to 250 Amps AT 25VDC Typical AC Weld Output Voltage WaveformAbnormal Open Circuit DC Weld Voltage Waveform Abnormal Open Circuit Weld Voltage Waveform High CV Mode High Idle no Load Output Control AT Maximum Normal Open Circuit Weld Voltage Waveform High CV ModeNormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit AC Weld Voltage Waveform Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementSection TOC Description Field Capacitor AND/OR Rectifier Bridge Removal ReplacementField Capacitor AND/OR Rectifier Bridge Removal ReplacementTo Section TOC Description Control Board Removal and ReplacementFigure F.16 Printed Circuit Board Location Control Board Removal and ReplacementTo Section TOC Description Output Rectifier Bridge Removal ReplacementFigure F.17 Output Rectifier Connections Output Rectifier Bridge Removal and ReplacementReassembly Description Ranger 300 DLX only Output Capacitor Bank Removal and ReplacementOutput Contactor Removal and Replacement Ranger 300 DLX only Figure F.19 Output Contactor Location Output Contactor Removal and ReplacementTroubleshooting & REPAIRs Description Stator AND/OR Rotor Removal and ReplacementFigure F.21 Component LOCATIONS, STATOR/ROTOR Removal Stator AND/OR Removal and ReplacementConduct this procedure with the engine OFF Stator Removal ProcedureRotor Removal Procedure Stator AND/OR Rotor Removal and ReplacementLead Reconnection Checklist Engine Reassembly NotesFront Panel Retest After Repair Electrical Diagrams R I N G D I a G R a M R a N G E R 3 0 0 D Wiring Diagram Ranger 300 D CodeR I N G D I a G R a M R a N G E R 3 0 0 D L Wiring Diagram Ranger 300 DLX CodeWiring Diagram Ranger 300 DLX Schematic Control PC Board PC Board Assembly Control Board Schematic Bypass PC Board PC Board Assembly Bypass Board SVM Error Reporting Form