Lincoln Electric SVM120-A - Manual

Lincoln Electric SVM120-A

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
  • Page 7 – TABLE OF CONTENTS; Installation; Tilting
  • Page 8 – INSTALLATION; INPUT - DIESEL ENGINE
  • Page 9 – SAFETY PRECAUTIONS; LOCATION AND VENTILATION; STORING
  • Page 10 – PRE-OPERATION ENGINE SERVICE
  • Page 12 – WELDING CABLE CONNECTIONS; CABLE SIZE AND LENGTH; TABLE A.1 - RECOMMENDED WELDING CABLE SIZE AND LENGTH; Tighten the flanged nuts securely.; MACHINE GROUNDING; CAUTION
  • Page 15 – Operation
  • Page 16 – GENERAL DESCRIPTION; OPERATION
  • Page 17 – RECOMMENDED APPLICATIONS; WELDER; WELDING CAPABILITY
  • Page 18 – FIGURE B.1 – OUTPUT PANEL CONTROLS; WELDER/GENERATOR CONTROLS; CONTROLS AND SETTINGS
  • Page 20 – DIESEL ENGINE CONTROLS; GLOW PLUG PUSHBUTTON:; FIGURE B.2 – ENGINE CONTROLS
  • Page 21 – ENGINE OPERATION; BEFORE STARTING THE ENGINE; Check and fill the engine oil level:
  • Page 22 – STARTING THE ENGINE; Set “IDLER” switch to “AUTO”.; STOPPING THE ENGINE; FIGURE B.3 – FUEL SHUTOFF VALVE
  • Page 23 – TYPICAL RANGER 10-LX FUEL CONSUMPTION; Low Idle – No Load, 2150 RPM
  • Page 24 – WELDING OPERATION; GENERAL INFORMATION; After you finish welding:; FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
  • Page 25 – Allow the electrode and work to cool completely.
  • Page 26 – Remove the work clamp from the work.
  • Page 28 – AUXILIARY POWER; Powering Motors; To use the generator as an auxiliary power supply:; NOTE: The 115 volt auxillary power receptacles
  • Page 29 – None
  • Page 31 – Accessories
  • Page 32 – ACCESSORIES
  • Page 33 – Gas-shielded welding requires a Magnum
  • Page 34 – FIGURE C.1 – RANGER 10-LX/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM; CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
  • Page 36 – NOTE: If your LN-7 comes equipped with a K291 or
  • Page 37 – NOTE: Welding cable must be sized for current and
  • Page 40 – Maintenance
  • Page 41 – ENGINE MAINTENANCE; CHANGE THE OIL; MAINTENANCE
  • Page 42 – CHANGE THE OIL FILTER; FIGURE D.1 – OIL DRAIN AND REFILL LOCATION
  • Page 43 – BLEEDING THE FUEL SYSTEM:; FIGURE D.2 – FUEL FILTER
  • Page 44 – FIGURE D.3 – FUEL SYSTEM BLEEDING
  • Page 45 – FIGURE D.4 – COOLING SYSTEM
  • Page 46 – KUBOTA ENGINE MAINTENANCE SCHEDULE; • Check fuel lines and clamps.
  • Page 47 – CLEANING THE BATTERY
  • Page 48 – Keep the electrical receptacles in; FIGURE D.5 - BRUSH REMOVAL AND REPLACEMENT
  • Page 50 – FIGURE E.1 – RANGER 10-LX BLOCK LOGIC DIAGRAM
  • Page 51 – THEORY OF OPERATION; ROTOR, STATOR AND IDLER SOLENOID
  • Page 52 – FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY, AND WIRE FEEDER POWER
  • Page 54 – OUTPUT TERMINALS
  • Page 55 – Test Procedures
  • Page 56 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The
  • Page 57 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 58 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Contact The Lincoln Electric
  • Page 59 – With the Polarity mode switch
  • Page 60 – If the machine is equipped with
  • Page 61 – If a remote control unit is NOT
  • Page 64 – ENGINE PROBLEMS; is in the “Auto” position.
  • Page 65 – Make sure the welding cables
  • Page 67 – The engine may be low on or
  • Page 68 – Make sure there is NOT an
  • Page 69 – FUNCTION PROBLEMS; Make sure the Remote switch
  • Page 70 – The wire feeder control cable
  • Page 71 – Make sure the Wire Feeder
  • Page 72 – Make sure the wire feeder is
  • Page 74 – WELDING PROBLEMS; The welding cables may be too
  • Page 75 – ROTOR VOLTAGE TEST; TEST DESCRIPTION
  • Page 76 – FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST; TEST PROCEDURE
  • Page 77 – ROTOR RESISTANCE TEST
  • Page 80 – To test the 115 VAC winding:; AUXILIARY AND FIELD WINDING TEST
  • Page 81 – FIGURE F.4 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER
  • Page 82 – FIGURE F.4A – 14 PIN AMPHENOL PIN ASSIGNMENTS
  • Page 84 – OUTPUT RECTIFIER BRIDGE TEST; FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS
  • Page 86 – CHARGING CIRCUIT TEST; FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR
  • Page 88 – FIGURE F.7 – CR1 LEAD CONNECTIONS; Conduct this test with the engine OFF.
  • Page 90 – ENGINE THROTTLE ADJUSTMENT TEST
  • Page 91 – Frequency Counter Method; Plug the frequency counter into one of the; FIGURE F.9 – HIGH IDLE ADJUSTMENT NUT
  • Page 92 – Connect the oscilloscope to the 115 VAC; FIGURE F.10 – LOW IDLE ADJUSTMENT NUT
  • Page 93 – SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY); HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM; volts
  • Page 94 – TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP); MACHINE LOADED
  • Page 95 – TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM; MACHINE LOADED TO 250 AMPS AT 25 VDC
  • Page 96 – TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM
  • Page 97 – ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM; HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
  • Page 98 – ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM
  • Page 99 – NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)
  • Page 100 – NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
  • Page 101 – NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
  • Page 102 – BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
  • Page 103 – PROCEDURE
  • Page 106 – FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL; RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR
  • Page 109 – CONTROL BOARD REMOVAL AND REPLACEMENT
  • Page 110 – Connect current sensing leads #254 and; CONTROL BOARD REMOVAL
  • Page 112 – OUTPUT RECTIFIER BRIDGE REMOVAL; FIGURE F.14 - OUTPUT RECTIFIER CONNECTIONS; Perform this procedure with the engine OFF.; For the remaining steps refer to FIgure F.14.
  • Page 113 – Clear the leads and carefully remove the
  • Page 115 – OUTPUT CAPACITOR BANK EMOVAL; FIGURE F.15 - OUTPUT CAPACITOR BANK/PRINTED CIRCUIT BOARD LOCATION
  • Page 117 – OUTPUT CAPACITOR REMOVAL; FIGURE F.16 – OUTPUT CONTACTOR LOCATION
  • Page 118 – TROUBLESHOOTING & REPAIRs; FIGURE F.17 – CONTACTOR COIL LEAD PLACEMENT
  • Page 120 – STATOR AND/OR REMOVAL AND
  • Page 121 – STATOR AND/OR ROTOR REMOVAL
  • Page 122 – ROTOR REMOVAL PROCEDURE; FIGURE F.19- ENGINE AND ROTOR REMOVED FROM STATOR
  • Page 124 – RETEST AFTER REPAIR
  • Page 126 – NOTES
  • Page 127 – ELECTRICAL DIAGRAMS
  • Page 131 – DIAGRAMS; RF BYPASS BOARD SCHEMATIC
  • Page 132 – DIMENSION PRINT
  • Page 133 – SVM ERROR REPORTING FORM; Please give detailed description below:; Return to Section TOC
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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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RETURN TO MAIN INDEX

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Premier Manufacturer of Industrial Motors

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Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ________________________________________________...

Page 3 - ii; ELECTRIC SHOCK can kill.

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter l...

Page 4 - iii

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National ...

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