Lincoln Electric SVM207-A service manual Brush Removal and Replacement Procedure

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F-40

TROUBLESHOOTING AND REPAIR

F-40

 

BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued)

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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.

4.Remove the fuel cap. The rubber gasket for the fill tube with come off with the case top.

5.Remove the case top, then reinstall the fuel cap.

6.WIth the 5/16” nut driver, remove the 5 screws holding the right case side.

7.Remove the right case side by lifting up and out.

8.With the needle nose pliers, gently remove the blue and the red wires from the brushes. See

Figure F.9.

9.With a 7/16” wrench or socket, remove the brush holder assembly bracket from the stator frame.

10.With a 5/16” open end wrench, remove the two screws that secure the brush holder assembly to the bracket. Slide the brush holder assembly out of the bracket.

11.To change the brushes, use a flat head screw dri- ver to pop off the plastic retainer on the back of the brush holder assembly.

12.Remove the old brushes and insert the new ones. One corner of the terminal clip is beveled so that the brush can go in only one way.

13.Snap the plastic retainer back onto the brush hold- er. The brushes may need some repositioning; wiggle them slightly to help them seat properly on the slip rings.

14.To reinstall the brush holder, depress the spring- loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder. A cable tie works well, and will hold the brushes up so that you can easily install the holder.

15.Slide the brush holder assembly back into the bracket and, with the 5/16” open end wrench, install the two screws that hold it in place.

16.With the 7/16” wrench, install the brush holder assembly bracket to the stator frame.

17.Slowly remove the non-metallic retainer from the brush holder and let the brushes snap back against the slip rings.

18.With the needle nose pliers, connect the red and the black wires to the appropriate terminals on the brushes. The red wire is inboard.

19.Check the wire connections for clearance and tightness.

20.Reinstall the case side, fuel cap, lift bail gasket, case top, and spark plug wires.

SLIP RINGS

A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary. If brushes are to be replaced, clean slip rings with a fine emery paper.

CAUTION

Do not attempt to polish slip rings while engine is run- ning.

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 Auxiliary Power InstallationTechnical Specifications Ranger 3 Phase K2337-1 & K2337-2 Height Width Depth WeightSpark Arrester Safety PrecautionsMachine Grounding TowingVehicle Mounting PRE-OPERATION ServiceGasoline Can cause fire or explosionHigh Altitude Operation Welding Output CablesTotal Combined Length of Electrode and Work Cables Angle of OperationInstructions Gfci Duplex Receptacles Auxiliary PowerVolt 3 Phase Receptacle with Ground 120/240 Volt Dual Voltage ReceptacleAuxiliary Power While Welding Ground WireStandby Power Connections 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 GENERAL DESCRIPTION Engine SwitchOperation Welder Controls Function and OperationRange Switch Polarity SwitchRanger 3 Phase Approximate Fuel Consumption Control DialStick Constant Current Welding Wire Feed Welding Processes Constant VoltageWelding Process TIG Constant Current WeldingStick Auto Starting the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Stopping the EngineTable of Contents Accessories Section Accessories K1745-1 Welding GAS Cylinder LPG Tank HolderStick WIRE FEEDRECOMMENDED EQUIPMENT TIGRanger 3 Phase Table of Contents Maintenance Section Maintenance Safety PrecautionsOIL Filter Change Gfci Receptacle Testing and RESET- Ting ProcedureAIR Cleaner and Other Maintenance Slip Rings Do not attempt to polish slip rings while engine is runningFram CA79 BatteryEngine Maintenance Parts KOHLER C23S 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 Auxiliary Windings To test the 480 VAC 3 Phase windingProbes Reading 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
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