Lincoln Electric SVM148-B - Manual

Lincoln Electric SVM148-B

Lincoln Electric SVM148-B – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

1 Page 1
2 Page 2
3 Page 3
4 Page 4
5 Page 5
6 Page 6
7 Page 7
8 Page 8
9 Page 9
10 Page 10
11 Page 11
12 Page 12
13 Page 13
14 Page 14
15 Page 15
16 Page 16
17 Page 17
18 Page 18
19 Page 19
20 Page 20
21 Page 21
22 Page 22
23 Page 23
24 Page 24
25 Page 25
26 Page 26
27 Page 27
28 Page 28
29 Page 29
30 Page 30
31 Page 31
32 Page 32
33 Page 33
34 Page 34
35 Page 35
36 Page 36
37 Page 37
38 Page 38
39 Page 39
40 Page 40
41 Page 41
42 Page 42
43 Page 43
44 Page 44
45 Page 45
46 Page 46
47 Page 47
48 Page 48
49 Page 49
50 Page 50
51 Page 51
52 Page 52
53 Page 53
54 Page 54
55 Page 55
56 Page 56
57 Page 57
58 Page 58
59 Page 59
60 Page 60
61 Page 61
62 Page 62
63 Page 63
64 Page 64
65 Page 65
66 Page 66
67 Page 67
68 Page 68
69 Page 69
70 Page 70
71 Page 71
72 Page 72
73 Page 73
74 Page 74
75 Page 75
76 Page 76
77 Page 77
78 Page 78
79 Page 79
80 Page 80
81 Page 81
82 Page 82
83 Page 83
84 Page 84
85 Page 85
86 Page 86
87 Page 87
88 Page 88
89 Page 89
90 Page 90
91 Page 91
92 Page 92
93 Page 93
94 Page 94
95 Page 95
96 Page 96
97 Page 97
98 Page 98
99 Page 99
100 Page 100
101 Page 101
102 Page 102
103 Page 103
104 Page 104
105 Page 105
106 Page 106
107 Page 107
108 Page 108
109 Page 109
110 Page 110
111 Page 111
112 Page 112
113 Page 113
114 Page 114
115 Page 115
116 Page 116
117 Page 117
118 Page 118
119 Page 119
120 Page 120
121 Page 121
122 Page 122
123 Page 123
124 Page 124
125 Page 125
126 Page 126
127 Page 127
128 Page 128
129 Page 129
130 Page 130
131 Page 131
132 Page 132
133 Page 133
134 Page 134
135 Page 135
136 Page 136
137 Page 137
138 Page 138
139 Page 139
140 Page 140
Page: / 140

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 – NOTES
  • Page 7 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page; RETURN TO MAIN INDEX
  • Page 8 – TABLE OF CONTENTS
  • Page 9 – INSTALLATION; TECHNICAL SPECIFICATIONS - RANGER 300 D AND 300 DLX
  • Page 10 – SAFETY PRECAUTIONS; electrode with skin or wet clothing.; LOCATION AND VENTILATION; STORING; Maintenance; STACKING; CANNOT; TILTING
  • Page 11 – PRE-OPERATION ENGINE SERVICE; OIL
  • Page 12 – FUEL; Operation; ENGINE COOLANT; BATTERY CONNECTIONS; Accessories
  • Page 13 – REMOTE CONTROL; Also see the; WELDING TERMINALS; MACHINE GROUNDING; RANGER 300 OUTPUT CONNECTIONS
  • Page 14 – WELDING CABLE CONNECTIONS; CABLE SIZE AND LENGTH; CABLE INSTALLATION; • Loose connections will cause the output terminals to; CIRCUIT BREAKERS; TOTAL COMBINED LENGTH OF; Cable Length; CAUTION
  • Page 15 – PREMISES WIRING; The switch rating must be the same as
  • Page 16 – CONNECTION OF RANGER 300 TO PREMISES WIRING
  • Page 19 – ADDITIONAL SAFETY PRECAUTIONS; OPERATION
  • Page 20 – FOR WELDING
  • Page 21 – RECOMMENDED APPLICATIONS; WELDER; LIMITATIONS; not recommended
  • Page 22 – WELDER/GENERATOR CONTROLS; OUTPUT RANGE SELECTOR: Selects continuous; OUTPUT PANEL CONTROLS; CONTROLS AND SETTINGS
  • Page 23 – GROUND STUD: Provides a connection point for
  • Page 24 – ENGINE CONTROLS; glow plugs to preheat engine for starting.
  • Page 26 – ENGINE OPERATION; BEFORE STARTING THE ENGINE; USE DIESEL FUEL ONLY
  • Page 27 – STOPPING THE ENGINE; TYPICAL RANGER 300 FUEL CONSUMPTION; Ambient Temperature; NOT REQUIRED
  • Page 28 – WELDING OPERATION; GENERAL INFORMATION
  • Page 30 – AFTER YOU FINISH WELDING:
  • Page 32 – SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS; SUMMARY OF WELDING PROCESSES FOR RANGER 300 DLX
  • Page 33 – SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS, continued; SUMMARY OF WELDING PROCESSES FOR RANGER 300 D
  • Page 34 – AUXILIARY POWER; NONE; RANGER 300 SIMULTANEOUS WELDING AND POWER LOADS
  • Page 35 – 20 V DUPLEX RECEPTACLES; MAXIMUM CURRENT DRAW FROM
  • Page 37 – ACCESSORIES
  • Page 38 – RANGER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM –
  • Page 41 – RANGER 300 DLX/LN-7 WITH K584 CONTROL CABLE CONNECTION DIAGRAM
  • Page 42 – RANGER 300 DLX/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM
  • Page 44 – RANGER 300 DLX/K930-1 TIG MODULE CONNECTION DIAGRAM
  • Page 47 – • Do not touch electrically live parts or; MAINTENANCE; FREQUENCY
  • Page 48 – ENGINE MAINTENANCE
  • Page 50 – SPARK ARRESTER SCREEN; BATTERY MAINTENANCE; CLEANING THE BATTERY
  • Page 51 – Store the RANGER 300 in clean, dry protected areas.
  • Page 52 – MAJOR COMPONENT LOCATIONS
  • Page 54 – RANGER 300 BLOCK LOGIC DIAGRAM
  • Page 55 – THEORY OF OPERATION; ROTOR, STATOR AND IDLER SOLENOID
  • Page 56 – ROTOR FIELD FEEDBACK, AUXILIARY AND WIRE FEEDER POWER
  • Page 57 – WELD WINDING, REACTOR AND RANGE SWITCH
  • Page 58 – AND OUTPUT TERMINALS
  • Page 61 – TROUBLESHOOTING & REPAIR; HOW TO USE TROUBLESHOOTING GUIDE; The
  • Page 62 – PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 63 – OBSERVE SAFETY GUIDELINES; TROUBLESHOOTING GUIDE; DETAILED IN THE BEGINNING OF THIS MANUAL.; OUTPUT PROBLEMS; Contact The Lincoln Electric
  • Page 64 – Normal AC open circuit voltage
  • Page 65 – Output Rectifier
  • Page 66 – If the machine is equipped with
  • Page 67 – If a remote control unit is NOT
  • Page 70 – ENGINE PROBLEMS; is in the “Auto” position.
  • Page 71 – Make sure the welding cables
  • Page 72 – High Speed
  • Page 73 – Fuel Shutdown
  • Page 74 – The oil level or pressure may be
  • Page 75 – FUNCTION PROBLEMS; Make sure the REMOTE switch
  • Page 76 – The wire feeder control cable
  • Page 77 – If the output contactor activates
  • Page 78 – The battery does not stay charged.
  • Page 79 – WELDING PROBLEMS; The welding cables may be too
  • Page 80 – ROTOR RESISTANCE TEST; TEST DESCRIPTION; This procedure requires approximately 20 minutes to perform.
  • Page 81 – FIGURE F.1 – ROTOR BRUSH LEADS REMOVED; TEST PROCEDURE; Conduct the test with the engine OFF.
  • Page 82 – This procedure requires approximately 35 minutes to perform.
  • Page 83 – OUTPUT RECTIFIER BRIDGE TEST; FIGURE F.2 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS; Conduct this test with the engine off.; Diode
  • Page 84 – This procedure requires approximately 25 minutes to perform.
  • Page 85 – FUEL SHUTDOWN SOLENOID RESISTANCE TEST; FIGURE F.3 – PLUG J12 LOCATION
  • Page 87 – HIGH SPEED SOLENOID TEST; FIGURE F.5 – SOLENOID LEADS
  • Page 88 – This procedure requires approximately 30 minutes to perform.
  • Page 89 – ENGINE THROTTLE ADJUSTMENT TEST; FIGURE F.6 – STROBE MARK LOCATION; With a white or red marking pencil, place a
  • Page 90 – FIGURE F.7 – HIGH IDLE ADJUSTMENT
  • Page 91 – Frequency Counter Method; NORMAL OPEN
  • Page 92 – This procedure requires approximately 45 minutes to perform.
  • Page 93 – AUXILIARY AND FIELD WINDING TEST; To test the 115 VAC winding:
  • Page 94 – FIGURE F.10 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER; AC; To test the field winding:; Connect the volt/ohmmeter probes to leads
  • Page 95 – FIGURE F.11 – 14-PIN AMPHENOL PIN ASSIGNMENTS
  • Page 97 – ROTOR VOLTAGE TEST; FIGURE F.12 – LOCATION OF LEADS 200A AND 219 FOR ROTOR VOLTAGE TEST; Connect the positive meter probe to the
  • Page 99 – CHARGING CIRCUIT TEST; FIGURE F.13 – VOLTAGE REGULATOR LEADS; CHARGING CIRCUIT TEST CHART; TEST CONDITIONS
  • Page 100 – SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY); HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM; volts
  • Page 101 – TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP); MACHINE LOADED
  • Page 102 – TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM; MACHINE LOADED TO 250 AMPS AT 25 VDC
  • Page 103 – TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM
  • Page 104 – ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM; HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
  • Page 105 – ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM
  • Page 106 – NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)
  • Page 107 – NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
  • Page 108 – NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
  • Page 109 – BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
  • Page 110 – FIGURE F.14 – BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE; PROCEDURE
  • Page 111 – Slowly remove the non-metallic retainer
  • Page 113 – FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL
  • Page 114 – and the Wiring Diagram.
  • Page 116 – CONTROL BOARD REMOVAL AND REPLACEMENT; FIGURE F.16 – PRINTED CIRCUIT BOARD LOCATION; then reinstall the fuel cap.
  • Page 117 – screws holding the control board.
  • Page 118 – This procedure requires approximately 50 minutes to perform.
  • Page 119 – OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT; FIGURE F.17 – OUTPUT RECTIFIER CONNECTIONS; Note insulator placement.; Clear the leads and carefully remove the heat
  • Page 120 – trical connection surfaces.; These must
  • Page 122 – OUTPUT CAPACITOR BANK REMOVAL AND REPLACEMENT; With the voltmeter, check the voltage across
  • Page 124 – OUTPUT CONTACTOR REMOVAL AND REPLACEMENT; FIGURE F.19 – OUTPUT CONTACTOR LOCATION; With the needle nose pliers, remove the three
  • Page 125 – TROUBLESHOOTING & REPAIRs; FIGURE F.20 – CONTACTOR COIL LEAD PLACEMENT
  • Page 127 – STATOR AND/OR REMOVAL AND REPLACEMENT
  • Page 128 – STATOR REMOVAL PROCEDURE; Field Capacitor and Field
  • Page 129 – ROTOR REMOVAL PROCEDURE; MACHINE FRONT COMPONENTS PIVOTED TO SIDE; STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT
  • Page 130 – REASSEMBLY NOTES; Brush Replacement Pro-; ENGINE
  • Page 131 – RETEST AFTER REPAIR
  • Page 132 – ELECTRICAL DIAGRAMS
  • Page 136 – SCHEMATIC - CONTROL PC BOARD
  • Page 137 – PC BOARD ASSEMBLY - CONTROL BOARD
  • Page 138 – SCHEMATIC - BYPASS PC BOARD
  • Page 139 – PC BOARD ASSEMBLY - BYPASS BOARD; BYPASS; X XXX
  • Page 140 – SVM ERROR REPORTING FORM; Please give detailed description below:
Loading the manual

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

V

iew Safety Info

V

iew Safety Info

V

iew Safety Info

V

iew Safety Info

SVM148-B

February, 2004

For use with machine code numbers

10399

thru

10850

RANGER 300 D and 300 DLX

TM

RETURN TO MAIN INDEX

SERVICE MANUAL

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 thought-
ful operation on your part.

DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN-
UAL AND THE SAFETY PRE-
CAUTIONS CONTAINED
THROUGHOUT.

And, most

importantly, think before you act
and be careful.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

Copyright © 2004 Lincoln Global Inc.

"Loading the manual" means you need to wait until the file loads and becomes available for online reading. Some manuals are very large, and the time they take to appear depends on your internet speed.

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 RANGER 300 D AND 300 DLX 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 RANGER 300 D AND 300 DLX 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...

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 RANGER 300 D AND 300 DLX 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 accordanc...

Other Lincoln Electric Models

All Lincoln Electric Other