Lincoln Electric SVM207-A service manual Figure F.4 and/or the Wiring

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F-10	TROUBLESHOOTING AND REPAIR								F-10
F-10									F-10

Observe Safety Guidelines detailed in the beginning of this manual.

	PROBLEMS		POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENT(S)	COURSE OF ACTION

			WELDING PROBLEMS
The welding arc is “cold.” Engine		1.	Check for loose or faulty connec-	1. Check for the correct open cir-
runs normally (3700 RPM no load).			tions at the weld output terminals	cuit voltage (OCV) at the welder
Auxiliary power is functioning nor-			and welding cable connections.	output	terminals		See		the
mally.		2.	The welding cable may be too	Machine Diagram . If				the	cor-
		2.	The welding cable may be too	rect voltage is present at					the
			long or coiled, causing an exces-	rect voltage is present at					the
			long or coiled, causing an exces-	output terminals, then check for
			sive voltage drop.	output terminals, then check for
			sive voltage drop.	loose connections on the heavy
				loose connections on the heavy
				current carrying leads inside the
				RANGER® 8.		See		Wiring
				Diagram .
				2. If the OCV is low at the welder
				output terminals,		perform			The
				Engine	Throttle	Adjustment
				Test.
				3. Perform the Output Rectifier
				Bridge Test.
				4. Check for shorted or grounded
				windings in the reactor and also
				in the main stator. See Wiring
				Diagram .

Welding output is low with little		1.	Check the brushes for wear and	1. Make up a jumper to connect
or no control. Auxiliary output is			proper contact to the rotor slip	the Field Test Point (FTP1) on
also low.			rings.	the PC Board to lead 219.					The
				connection can be made at the
				board (J1,Pin5), or at the
				Negative Exciter		Brush. See
				Figure F.4 and/or the Wiring
				Diagram. If the output comes
				up to full strength, the Control
				Board	is probably		defective.
				Replace.
				2. Perform the Rotor Voltage
				Test.
				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. 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 tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

RANGER® 3 PHASE

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Contents Ranger 3 Phase Safety Ranger 3 PhaseFumes and Gases Welding Cutting Précautions DE Sûreté Safety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Ranger 3 Phase K2337-1 & K2337-2Auxiliary Power Height Width Depth WeightSafety Precautions Machine GroundingSpark Arrester TowingPRE-OPERATION Service GasolineVehicle Mounting Can cause fire or explosionWelding Output Cables Total Combined Length of Electrode and Work CablesHigh Altitude Operation Angle of OperationInstructions Auxiliary Power Volt 3 Phase Receptacle with GroundGfci Duplex Receptacles 120/240 Volt Dual Voltage ReceptacleGround Wire Standby Power ConnectionsAuxiliary Power While Welding TABLE A.1 Simultaneous Welding and PowerConnection of Ranger 3 Phase to Premises Wiring Figure A.3Electrical Device USE with the Ranger 3 Phase USE These Devices with a Ranger 3 PhaseDevices Without Addi Tional Resistive Type Loads Table of Contents Operation Section Engine Switch OperationGENERAL DESCRIPTION Welder Controls Function and OperationPolarity Switch Ranger 3 Phase Approximate Fuel ConsumptionRange Switch Control DialWire Feed Welding Processes Constant Voltage Welding ProcessStick Constant Current Welding TIG Constant Current WeldingStick Auto STARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine Stopping the EngineTable of Contents Accessories Section Accessories K1745-1 Welding GAS Cylinder LPG Tank HolderWIRE FEED RECOMMENDED EQUIPMENTStick TIGRanger 3 Phase Table of Contents Maintenance Section Maintenance Safety PrecautionsGfci Receptacle Testing and RESET- Ting Procedure AIR Cleaner and Other Maintenance Slip RingsOIL Filter Change Do not attempt to polish slip rings while engine is runningBattery Engine Maintenance Parts KOHLER C23SFram CA79 CHAMPION RC12YCMAINTENANCED-5 Figure D.1 Major Component LocationRanger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation General DescriptionEngine Components and Operation ROTOR, Stator & Control Circuits Figure E.2 ROTOR, Stator and Control CircuitsWeld Circuitry Figure E.2 Weld Circuitry1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Return to SectionDiagram Perform the Output Bridge Test Gram Wiring Wiring Diagram Troubleshooting and Repair Figure F.4 and/or the Wiring Rotor Voltage Test Procedure Test DescriptionMaterials Needed Test Procedure Rotor Voltage TestRotor Resistance Test TEST PROCEDURE Figure F.2 Slip RingsAuxiliary and Field Winding Test To test the 480 VAC 3 Phase winding Probes ReadingAuxiliary Windings To test the 120 VAC windingFigure F.4 Control PC Board Field WindingRanger 3 Phase Output Rectifier Bridge Test Figure F.5 OUTPUT RECTIFIER + Meter Lead Meter ReadingToroid Test Toroid Test Charging Circuit Test Voltage Regulator AC Lead DC Lead Engine Throttle Adjustment Test Engine Throttle Adjustment Test Low Idle Adjustment SolenoidNut Housing Figure F.9 115VAC Supply Waveform High IDLE- no Load Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh Idle no Load Output Control AT Maximum Typical DC Weld Output Waveform CV Mode Machine LoadedTypical DC Weld Output Waveform CC Mode Machine Loaded to 200 Amps AT 26 VDCTypical AC Weld Output Waveform Machine Loaded to 225 Amps AT 25 VDCAbnormal 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 3 Phase Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure ProcedureBrush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Printed Circuit Board Removal Figure F.10 Door RemovalOutput Rectifier Bridge Removal Replacement Procedure Output Rectifier Bridge Removal Figure F.11 OUTPUT RECTIFIERENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from StatorReassembly Procedure Retest After Repair Table of Contents Diagram Section Ranger 3-PHASE RaNGEr 3 phaSESchEmaTic cOmplETE machiNE l12259 L12259ElEcTrical DiaGramS