Ranger 3 Phase | Lincoln Electric SVM207-A instruction

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SVM207-A

January, 2011

RANGER® 3 Phase

For use with machine code number: 11079 & 11419

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

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• 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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Lincoln Electric SVM207-A service manual Ranger 3 Phase

Contents

Ranger 3 Phase Ranger 3 Phase Safety Fumes 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 Weight Machine Grounding Safety PrecautionsSpark Arrester Towing Gasoline PRE-OPERATION ServiceVehicle Mounting Can cause fire or explosion Total Combined Length of Electrode and Work Cables Welding Output CablesHigh Altitude Operation Angle of Operation Instructions Volt 3 Phase Receptacle with Ground Auxiliary PowerGfci Duplex Receptacles 120/240 Volt Dual Voltage Receptacle Standby Power Connections Ground WireAuxiliary Power While Welding TABLE A.1 Simultaneous Welding and Power Figure A.3 Connection of Ranger 3 Phase to Premises Wiring USE 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 Operation Ranger 3 Phase Approximate Fuel Consumption Polarity SwitchRange Switch Control Dial Welding Process Wire Feed Welding Processes Constant VoltageStick Constant Current Welding TIG Constant Current Welding Stick Auto BREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the Engine Table of Contents Accessories Section K1745-1 Welding GAS Cylinder LPG Tank Holder Accessories RECOMMENDED EQUIPMENT WIRE FEEDStick TIG Ranger 3 Phase Table of Contents Maintenance Section Safety Precautions Maintenance AIR 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 running Engine Maintenance Parts KOHLER C23S BatteryFram CA79 CHAMPION RC12YC Figure D.1 Major Component Location MAINTENANCED-5 Ranger 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 Circuits Figure E.2 Weld Circuitry Weld Circuitry 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and Repair Return to Section PC Board Troubleshooting Procedures Diagram 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 Procedure Rotor Resistance Test Figure F.2 Slip Rings TEST PROCEDURE Auxiliary and Field Winding Test Probes Reading To test the 480 VAC 3 Phase windingAuxiliary Windings To test the 120 VAC winding Field Winding Figure F.4 Control PC Board Ranger 3 Phase Output Rectifier Bridge Test + Meter Lead Meter Reading Figure F.5 OUTPUT RECTIFIER Toroid 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 Mode Machine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC Mode Machine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output Waveform Abnormal 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 Procedure Brush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Figure F.10 Door Removal Printed Circuit Board Removal Output Rectifier Bridge Removal Replacement Procedure Figure F.11 OUTPUT RECTIFIER Output Rectifier Bridge Removal ENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Figure F.13 Engine and Rotor Removed from Stator Rotor Removal Procedure Reassembly Procedure Retest After Repair Table of Contents Diagram Section RaNGEr 3 phaSE Ranger 3-PHASE L12259 SchEmaTic cOmplETE machiNE l12259 ElEcTrical DiaGramS