Troubleshooting Guide, Output Problems | Lincoln Electric SVM168-B

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F-4	TROUBLESHOOTING & REPAIR						F-4

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
Major Physical or	Electrical	1. Contact your local Lincoln	1. Contact The Lincoln Electric
Damage is Evident.		Authorized Field Service	Service Dept. 1-888-935-3877.
		Facility.

No weld output and no auxiliary		1. Check the brushes for wear and	1. Perform the Rotor Voltage
power. Engine runs normally.		proper contact to the rotor slip	Test.
		rings.	2. Check for the presence of
			2. Check for the presence of
			12VDC (at the pc board) from
			lead #216 to frame ground.
			This is the “flashing” voltage
			and is present only when the
			Start, Run, Stop switch S3 is in
			the “Start” position. If the 12
			VDC is missing check the leads,
			switches		and	connections
			associated with the lead #216.
			See Wiring Diagram.
			Check for the presence of 12
			VDC (at the pc board) from lead
			#224 to frame ground. This is
			the supply voltage to the board
			and is present when the engine
			is running and the S3 switch is
			in the “Run” position. If the
			12VDC is missing check the
			leads, switches and connec-
			tions associated with the lead
			#224. See Wiring Diagram.
			3. If Rotor Voltage Test is normal,
			then	preform		the	Rotor
			Resistance Test.
			4. If the Rotor Voltage Test is NOT
			normal, perform			the Auxiliary
			and	Field	Winding		Voltage
			Test. Then check the Field
			Diode Bridge (D2) and the Field
			Capacitor (C1). Replace if nec-
			essary. If the Field Bridge and
			Field Capacitor are good, then
			the Printed Circuit Board may
			be faulty. Replace.

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 1-888-935-3877.

RANGER® 10,000 & RANGER® 10,000 PLUS

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Lincoln Electric SVM168-B service manual Troubleshooting Guide, Output Problems

Contents

Ranger 10,000 /10,000 Plus For Engine SafetyPowered equipment ARC Rays can burn Fumes and Gases Iii Welding and Cutting Sparks can cause fire or ExplosionCylinder may explode If damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section Installation Height Width Depth Weight Horsepower Operating Speed RPM Safety Precautions Spark ArresterMachine Grounding Towing PRE-OPERATION Service GasolineVehicle Mounting Can cause fire or explosion Welding Output Cables Total Combined Length of Electrode and Work CablesAngle of Operation Lifting Connection of Lincoln Electric Wire Feeders InstructionsStacking Welder Operation Auxiliary Power 120/240 Volt Dual Voltage ReceptacleDuplex Receptacles Motor Starting These Devices Without Additional Resistive Type Loads Not USE These Devices With a Ranger 10,000 Simultaneous Welding and Power Standby Power Connections Figure A.1 Ranger 10,000 & Ranger 10,000 Plus Operation Operation SectionSection B-1 Welder Controls Function and Operation Engine SwitchOperation Polarity Switch Range SwitchKohler Honda Robin / Subaru 20 H.P. Command Control Dial STARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine Stopping the Engine TIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick Constant Current Welding Start Switch Wire FEED, LN-15 Summary of Welding Processes Accessories Section Section C-1 Accessories Optional Equipment Field Installed Recommended Equipment StickTIG Welding Plasma Cutting Ranger 10,000 & Ranger 10,000 Plus Maintenance Section Section D-1 Kohler Honda MaintenanceSafety Precautions AIR Cleaner and Other Maintenance OIL Filter Change Engine Adjustments BatteryOverspeed is Hazardous Slip Rings Pre-Cleaner Oil FilterAir Filter Element Figure D.1 Major Component Location Theory of Operation Theory of Operation SectionSection E-1 BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler Solenoid Theory of Operation Rotor Field Feedback and Auxiliary Power Figure E.3 Rotor Field Feedback and Auxiliary Power Weld WINDING, REACTOR, Range Switch Figure E.4 Weld WINDING, REACTOR, and Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Troubleshooting & Repair Section Section F-1 Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Electric Shock Troubleshooting Guide Output Problems Output Problems Field Winding Voltage Test Adjustment Test Troubleshooting Guide Output Problems Engine Problems Make sure the leads are looped Charging Circuit Test Welding Problems Ranger 10,000 & Ranger 10,000 Plus Materials Needed Rotor Voltage TestTest Description Test Procedure Rotor Resistance Test Rotor Resistance Test Figure F.2 Location of Rotor Slip Rings Troubleshooting & Repair Ranger 10,000 & Ranger 10,000 Plus Auxiliary and Field Winding Test To test the 230 VAC winding Auxiliary and Field Winding TestTo test the 115 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test Figutpure F.4 Locationctifof Output Rectifier Leads 26TROUBLESHOOTING & REPAIRF-26Output Rectifier Bridge Test Charging Circuit Test Charging Circuit Test Figure F.5 Location of Voltage Regulator Engine Throttle Adjustment Test Engine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Figure F.7 Oscilloscope Method High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 200 Amps AT 20 VDC Typical DC Weld Output Waveform CV ModeMachine Loaded Typical DC Weld Output Waveform CC Mode Machine Loaded to 200 Amps AT 26 VDC Typical AC Weld Output Waveform Machine Loaded to 225 Amps AT 25 VDC Abnormal 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 10,000 & Ranger 10,000 Plus Brush Removal and Replacement Description Brush Removal and Replacement Procedure Slip Rings Figure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Ranger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Printed Circuit Board Removal and Replacement Figure F.10 Printed Circuit Board Location Replacement Printed Circuit Board Removal Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Remove the case top, then reinstall the fuel cap Output Rectifier Bridge Removal Section TOC Ranger 10,000 & Ranger 10,000 Plus ENGINE/ROTOR Removal and Replacement Instructions ENGINE/ROTOR Removal Figure F.12 Component LOCATIONS, ENGINE/ROTOR Removal Engine and Rotor Removal Procedure Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Replacement KIT S20788 Reassembly Procedure Retest After Repair Section G-1 Electrical Diagrams SectionElectrical Diagrams Electrical Diagrams Wiring Diagram Code 11041 only -M20226 Wiring Diagram Code 11095 only M20301 Ranger 10,000 Honda Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus Schematic Entire Machine Codes 11395 and 11398 L13105 L13105 Schematic Entire Machine CDE 11394 L13103 L13103 Schematic Entire Machine Code 11095 & 11253 only L12257 Schematic Entire Machine Code 11151 only L12249-1 L12249 Electrical Diagrams Electrical Diagrams