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Lincoln Electric RANGER 3PHASE SVM207-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM207-A
®
RANGER
3 Phase
11079 & 11419
For use with machine code number:
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

Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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

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Summary of Contents for Lincoln Electric RANGER 3PHASE SVM207-A

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM207-A ® RANGER 3 Phase 11079 & 11419 For use with machine code number: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation .

  • Page 2: California Proposition 65 Warnings

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area.If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjcent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 Electromagnetic Compatibility (EMC) Conformance Introduction Installation and Use Assessment of Area RANGER® 3 PHASE...
  • Page 7 Electromagnetic Compatibility (EMC) Methods of Reducing Emissions Mains Supply Maintenance of the Welding Equipment Welding Cables Equipotential Bonding Earthing of the Workpiece Screening and Shielding RANGER® 3 PHASE...
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-iv Installation .

  • Page 9: Table Of Contents

    High Altitude Operation...A-5 Muffler Relocation ...A-5 Location/Ventilation...A-6 Connection of Wire Feeders ...A-6 Additional Safety Precautions...A-6 Welder Operation...A-6 Auxiliary Power ...A-7 Motor Starting ...A-8 Stand-by Power Connections ...A-8 Auxiliary Power While Welding ...A-8 Connection of RANGER® 3PHASE to Premises Wiring (Drawing) ...A-9 Extension Cord Recommendations ...A-10...
  • Page 10 CH23S Liners, Electronic Ignition RATED OUTPUT @ 104°F (40°C)- WELDER AC Constant Current 225A / 25V / 100% DC Constant Current 210A / 25V / 100% DC Constant Voltage 200A / 20V / 100% RATED OUTPUT @ 104°F (40°C)- GENERATOR 11,500 Watts Peak,10,500 Watts Continuous, 3 Phase 60 Hz AC,480V...

  • Page 11: Installation

    To prevent dangerous electric shock, other equip- ment to which this engine driven welder supplies power must: • be grounded to the frame of the welder using a grounded type plug, or be double insulated. Do not ground the machine to a pipe that carries explosive or combustible material.

  • Page 12: Vehicle Mounting

    Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. ----------------------------------------------------------------------- This welder is shipped with the negative battery cable disconnected. Make sure that the Engine Switch is in the “STOP” position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine.

  • Page 13: Welding Output Cables

    Listed below are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

  • Page 14: Location/Ventilation

    Also, locate the welder so that engine exhaust fumes are properly vented to an outside area.

  • Page 15: Auxiliary Power

    AUXILIARY POWER CAUTION Do not connect any plugs that connect to the power receptacles in parallel. ------------------------------------------------------------------------ Start the engine and set the “IDLER” control switch to the “High Idle” mode. Set the “CONTROL” to 10. Voltage is now correct at the receptacles for auxiliary power.

  • Page 16: Motor Starting

    All auxiliary power is protected by circuit breakers with the following values: The 120V has 20 amp circuit breakers for each duplex receptacle. The 240V has 50 amp circuit breakers for each hot lead going the 240V receptacle. The 480V 3 phase circuit breaker / switch is a 3 phase, 15 amp circuit breaker.
  • Page 17 CONNECTION OF RANGER® 3 PHASE TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT...
  • Page 18 Capacitive/Inductive Computers, high resolution TV sets, The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER® 3 PHASE machine RANGER® 3 PHASE Extension Cord Length Recommendations (Use the shortest length extension cord possible sized per the following table.)
  • Page 19 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 20: Engine Switch

    • Insulate yourself from work and ground • Always wear dry insulating gloves. • Always operate the welder with the hinged door closed and the side panels in place. • Read carefully the Safety Precautions page before operating this machine. Always follow...

  • Page 21: Polarity Switch

    “ The “Range” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Process STICK/TIG (constant current) (3 range settings) WIRE FEED (constant voltage) (one range setting) Never change the “RANGE” Switch setting while welding.

  • Page 22: Welding Process

    WELDING PROCESS For any electrodes the procedures should be kept with- in the rating of the machine. For electrode information see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity”...
  • Page 23 CONTROL CABLE PROCESS USED STICK WIRE FEED, LN-25 WITH INTERNAL CONTACTOR TIG, TIG MODULE WITH WITH CONTACTOR KIT CONTROL CABLE, & ARC START SWITCH WIRE FEED, LN-15 ACROSS the ARC (has internal contactor) OPERATION SUMMARY OF WELDING PROCESSES ELECTRODE IDLE WHEN NOT MODE WELDING AUTO AUTO Cold High...
  • Page 24 STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. • Keep flammable material away. • Insulate yourself from work and ground. Wear eye, ear, and body protection. • Keep your head out of the fumes. •...
  • Page 25 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Optional Equipment .
  • Page 26 OPTIONAL EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-2 Fender &...
  • Page 27 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield WIRE FEED LN-25 K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “cold” elec- trode until gun trigger is pressed. Includes gas sole- noid.
  • Page 28 NOTES RANGER® 3 PHASE...
  • Page 29 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 30: Maintenance

    SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their removal is complete.

  • Page 31: Slip Rings

    Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tempera- ture use, -5 F to 104 F (-20 C to 40 C).

  • Page 32: Battery

    • CONNECTING A BATTERY CHARGER - Remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated.
  • Page 33 MAINTENANCE FIGURE D.1 - MAJOR COMPONENT LOCATION 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY 3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 5. CASE TOP & SIDES RANGER® 3 PHASE...
  • Page 34 NOTES RANGER® 3 PHASE...
  • Page 35 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 36: General Description

    CONTROL GENERAL DESCRIPTION The RANGER® 3 PHASE is a twin cylinder, gasoline driven, multiprocess arc welder and AC power genera- tor. It is capable of AC or DC Stick (SMAW) or TIG (GTAW) welding and CV Wire welding, either Innershield® or MIG (GMAW). The AC power genera- tor is capable of providing 10,500 Watts continuous, 3 Phase 60 Hz.

  • Page 37: Theory Of Operation

    . This regulated supply is used to control the voltage output of the welder. A diode on the PC Board is used to isolate the exciter voltage from the engine 12 VDC supply.
  • Page 38 THEORY OF OPERATION FUEL STARTER SHUTOFF SOLENOID SOLENOID STARTER MECHANICAL ROTAT ION ENGINE FLYWHEEL ALTERNATOR/ VOLTAGE REGULATOR IDLER SOLENOID PRESSURE SWITCH ENGINE CONTROL SWITCH* HOUR METER OUTPUT BATTERY CONTROL WELD CIRCUITRY One end of the Weld Winding is connected to the Output Rectifier and at the other end to the Reactor.
  • Page 39 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ..............F-1 How to Use Troubleshooting Guide .

  • Page 40: How To Use Troubleshooting Guide

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 41: Pc Board Troubleshooting Procedures

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.
  • Page 42 Engine runs normally. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 43 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 44 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 45 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 46 Engine will not crank or cranks very slow. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 47 S3 is switched to “RUN” position. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 48 Auxiliary output is also low. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 49 F-11 ROTOR VOLTAGE TEST PROCEDURE Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 50: Rotor Voltage Test

    TROUBLESHOOTING AND REPAIR F-12 ROTOR VOLTAGE TEST (continued) FIGURE F.1 – SLIP RINGS AND BRUSHES Brushes TEST PROCEDURE 1. Using a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail.

  • Page 51: Rotor Resistance Test

    F-13 ROTOR RESISTANCE TEST Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 52 TROUBLESHOOTING AND REPAIR F-14 ROTOR RESISTANCE TEST (continued) TEST PROCEDURE 1. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. Remove the fuel cap. The rubber gasket for the fill tube will come off with the case top.

  • Page 53: Auxiliary And Field Winding Test

    F-15 AUXILIARY AND FIELD WINDING TEST Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 54 TROUBLESHOOTING AND REPAIR F-16 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – RECEPTACLES AND LEADS 120 VAC GFCI RECEPTACLE Lead #3 Lead #5 TEST PROCEDURE WARNING ELECTRIC SHOCK can kill. • Turn the machine OFF before working on equipment or making the meter connections.
  • Page 55 TROUBLESHOOTING AND REPAIR F-17 AUXILIARY AND FIELD WINDING TEST (continued) FIELD WINDING 1. Remove the fuel cap and lift bail rubber gasket. With a 5/16” nut driver or socket, remove the case top and left side; then reinstall the fuel cap. 2.
  • Page 56 NOTES F-18 F-18 RANGER® 3 PHASE...

  • Page 57: Output Rectifier Bridge Test

    F-19 OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 58 TROUBLESHOOTING AND REPAIR F-20 OUTPUT RECTIFIER BRIDGE TEST (continued) LEAD 8 TO POLARITY SWITCH (S2) TO CHOKE (L1) TEST PROCEDURE 1. Remove the spark plug wires to prevent accidental engine kickback or starting. 2. WIth a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top.

  • Page 59: Toroid Test

    TROUBLESHOOTING AND REPAIR F-21 Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 60 TROUBLESHOOTING AND REPAIR F-22 LEAD ‘X’ LEAD 254 LEAD 6 LEAD 3 LEAD 213A TEST PROCEDURE 1. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail.

  • Page 61: Charging Circuit Test

    TROUBLESHOOTING AND REPAIR F-23 Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 62 TROUBLESHOOTING AND REPAIR F-24 CHARGING CIRCUIT TEST (continued) TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. Set the voltmeter for AC volts and place one meter probe on each of the two outside leads that attach to the engine voltage regulator.

  • Page 63: Engine Throttle Adjustment Test

    F-25 ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 64 TROUBLESHOOTING AND REPAIR F-26 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Blower Paddle TEST PROCEDURE This test can be conducted by any one of four meth- ods. Strobe-tach Method: 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top.
  • Page 65 TROUBLESHOOTING AND REPAIR F-27 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 HIGH IDLE ADJUSTMENT NUT Throttle linkage Choke Cable Frequency Counter Method 1. Plug the frequency counter into one of the 115 VAC auxiliary receptacles. 2. Start the engine and check the frequency counter. At HIGH IDLE (3700 RPM), the counter should read 60.8 to 62.5 Hz.
  • Page 66 TROUBLESHOOTING AND REPAIR F-28 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.9 - 115VAC SUPPLY WAVEFORM (HIGH IDLE- NO LOAD) Oscilloscope Method: 1. Connect the oscilloscope to the 115 VAC recepta- cle, according to the manufacturer’s instructions. At 3700 RPM, the waveform should exhibit a peri- od of 16.2 milliseconds.

  • Page 67: Normal Open Circuit Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-29 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 16.2 ms 50 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 mil- liseconds in time.

  • Page 68: Typical Dc Weld Output Waveform (Cv Mode

    TROUBLESHOOTING AND REPAIR F-30 TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE) MACHINE LOADED TO 200 AMPS AT 20 VDC MACHINE LOADED 20 volts This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time.

  • Page 69: Typical Dc Weld Output Waveform (Cc Mode

    TROUBLESHOOTING AND REPAIR F-31 TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE) MACHINE LOADED TO 200 AMPS AT 26 VDC MACHINE LOADED 20 volts This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time.

  • Page 70: Typical Ac Weld Output Waveform

    TROUBLESHOOTING AND REPAIR F-32 TYPICAL AC WELD OUTPUT WAVEFORM MACHINE LOADED TO 225 AMPS AT 25 VDC MACHINE LOADED 20 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time.

  • Page 71: Abnormal Open Circuit Weld Voltage Waveform (Cv Mode

    TROUBLESHOOTING AND REPAIR F-33 ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 20 volts This is NOT the typical CV output volt- age waveform. One output diode is not functioning.

  • Page 72: Abnormal Open Circuit Dc Weld Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-34 ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 50 volts This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform.
  • Page 73 TROUBLESHOOTING AND REPAIR F-35 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 20 volts This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time.
  • Page 74 TROUBLESHOOTING AND REPAIR F-36 NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE) HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 50 volts This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 mil- liseconds in time.

  • Page 75: Normal Open Circuit Ac Weld Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-37 NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM 50 volts This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 76 NOTES F-38 F-38 RANGER® 3 PHASE...

  • Page 77: Brush Removal And Replacement Procedure

    BRUSH REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 78 TROUBLESHOOTING AND REPAIR F-40 BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove the spark plug wires. 2. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 3. Remove the rubber gasket (cover seal) from the lift bail.
  • Page 79 TROUBLESHOOTING AND REPAIR F-41 F-41 BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.9 – BRUSH HOLDER MOUNTING BOLTS 7/16" Brush Assembly Bracket Bolts RANGER® 3 PHASE...
  • Page 80 NOTES F-42 F-42 RANGER® 3 PHASE...

  • Page 81: Printed Circuit Board Removal And Replacement Procedure

    PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT PROCEDURE Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 82 TROUBLESHOOTING AND REPAIR F-44 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) 4 Pin Plug PROCEDURE Before starting the following procedure, refer to the topic “PC Board Troubleshooting Procedures” at the beginning of this section. 1. Remove the engine spark plug wires. 2.

  • Page 83: Output Rectifier Bridge Removal And Replacement Procedure

    OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 84 TROUBLESHOOTING AND REPAIR F-46 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) TO POLARITY SWITCH (S2) TO CHOKE PROCEDURE 1. Remove the engine spark plug wires. 2. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 3.

  • Page 85: Engine/Rotor Removal And Replacement Procedure

    F-47 ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 86 TROUBLESHOOTING AND REPAIR F-48 ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.) FIGURE F.12 – ENGINE/ROTOR COMPONENT LOCATIONS RANGER® 3 PHASE F-48 1A. Tolerance Ring 1B. Rotor Thru-Bolt 1C. Blower Fan 2. Kohler Engine 3. Rotor 4. Rotor Shaft Bearing 5A. Brush Bracket 5B.
  • Page 87 TROUBLESHOOTING AND REPAIR F-49 ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.) PROCEDURE 1. Refer to Figure F.12 for component locations. 2. Remove the engine spark plug wires. 3. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 4.
  • Page 88 Pull out the thru-bolt. 3. Install the appropriate long thru-bolt (two are pro- vided) supplied with Lincoln Electric Rotor Removal Kit S20788. The slot head must face out. Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft, about 3/4”.
  • Page 89 TROUBLESHOOTING AND REPAIR F-51 ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bear- ing be installed when you replace the rotor and blower assembly. 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft.

  • Page 90: Retest After Repair

    Output values of each receptacle can vary within the range shown but must be within 2 volts of each other. RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 2200-2400 3700-3750 WELDER DC OUTPUT Open Circuit Load Volts Volts 65 - 72 WELDER AC OUTPUT...
  • Page 91 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram Complete Machine (M20315) .

  • Page 92: Electrical Diagrams

    WiriNG DiaGram - cOmplETE machiNE - m20315 PRESSURE SWITCH ENGINE COMPONENTS N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE. ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM ELECTRICAL SYMBOLS PER E1537 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ElEcTrical DiaGramS RANGER 3-PHASE GROUND SCREW...

  • Page 93: Schematic - Complete Machine (L12259

    Control board common is AT HIGH IDLE GROUND LOW OIL one diode drop above PRESSURE welder frame ground. Resistance of fuel solenoid cannot be If engine oil pressure drops below safe CONNECTOR PIN NUMBERS: accurately operating pressure, the oil pressure...

  • Page 94: Schematic - Control Pc Board (L12197-1

    ElEcTrical DiaGramS SchEmaTic - cONTrOl pc bOarD - l12197-1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. raNGEr® 3 phaSE...

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