Lincoln Electric SVM207-A service manual ENGINE/ROTOR Removal and Replacement Procedure

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F-47	TROUBLESHOOTING AND REPAIR	F-47

ENGINE/ROTOR 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.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the engine and/or rotor for maintenance or replacement of either component.

MATERIALS NEEDED

Lincoln Electric Rotor Removal Kit (S20788)

Required to remove rotor from Engine

Misc. Hand Tools

Impact Wrench

Torque Wrench (ft. lbs)

.017 Feeler Gauge

Wiring Diagram

RANGER® 3 PHASE

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Contents Ranger 3 Phase Ranger 3 Phase SafetyFumes 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 Technical Specifications Ranger 3 Phase K2337-1 & K2337-2 InstallationAuxiliary Power Height Width Depth WeightMachine Grounding Safety PrecautionsSpark Arrester TowingGasoline PRE-OPERATION ServiceVehicle Mounting Can cause fire or explosionTotal Combined Length of Electrode and Work Cables Welding Output CablesHigh Altitude Operation Angle of OperationInstructions Volt 3 Phase Receptacle with Ground Auxiliary PowerGfci Duplex Receptacles 120/240 Volt Dual Voltage ReceptacleStandby Power Connections Ground WireAuxiliary Power While Welding TABLE A.1 Simultaneous Welding and PowerFigure A.3 Connection of Ranger 3 Phase to Premises WiringUSE These Devices with a Ranger 3 Phase Electrical Device USE with the Ranger 3 PhaseDevices Without Addi Tional Resistive Type Loads Table of Contents Operation Section Operation Engine SwitchGENERAL DESCRIPTION Welder Controls Function and OperationRanger 3 Phase Approximate Fuel Consumption Polarity SwitchRange Switch Control DialWelding Process Wire Feed Welding Processes Constant VoltageStick Constant Current Welding TIG Constant Current WeldingStick Auto BREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineTable of Contents Accessories Section K1745-1 Welding GAS Cylinder LPG Tank Holder AccessoriesRECOMMENDED EQUIPMENT WIRE FEEDStick TIGRanger 3 Phase Table of Contents Maintenance Section Safety Precautions MaintenanceAIR Cleaner and Other Maintenance Slip Rings Gfci Receptacle Testing and RESET- Ting ProcedureOIL Filter Change Do not attempt to polish slip rings while engine is runningEngine Maintenance Parts KOHLER C23S BatteryFram CA79 CHAMPION RC12YCFigure D.1 Major Component Location MAINTENANCED-5Ranger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationEngine Components and Operation Figure E.2 ROTOR, Stator and Control Circuits ROTOR, Stator & Control CircuitsFigure E.2 Weld Circuitry Weld Circuitry1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairReturn to Section PC Board Troubleshooting ProceduresDiagram Perform the Output Bridge Test Gram Wiring Wiring Diagram Troubleshooting and Repair Figure F.4 and/or the Wiring Test Description Rotor Voltage Test ProcedureMaterials Needed Rotor Voltage Test Test ProcedureRotor Resistance Test Figure F.2 Slip Rings TEST PROCEDUREAuxiliary and Field Winding Test Probes Reading To test the 480 VAC 3 Phase windingAuxiliary Windings To test the 120 VAC windingField Winding Figure F.4 Control PC BoardRanger 3 Phase Output Rectifier Bridge Test + Meter Lead Meter Reading Figure F.5 OUTPUT RECTIFIERToroid 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 Normal Open Circuit Voltage Waveform 115 VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Waveform CV ModeMachine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC ModeMachine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output WaveformAbnormal 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 Procedure Brush Removal and Replacement ProcedureBrush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Figure F.10 Door Removal Printed Circuit Board RemovalOutput Rectifier Bridge Removal Replacement Procedure Figure F.11 OUTPUT RECTIFIER Output Rectifier Bridge RemovalENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Figure F.13 Engine and Rotor Removed from Stator Rotor Removal ProcedureReassembly Procedure Retest After Repair Table of Contents Diagram Section RaNGEr 3 phaSE Ranger 3-PHASEL12259 SchEmaTic cOmplETE machiNE l12259ElEcTrical DiaGramS