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Lincoln Electric
SVM207-A
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NOTES
D-6 D-6
RANGERĀ® 3 PHASE
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Contents
Main
SVM207-A
January, 2011
SERVICE MANUAL
RANGER3 Phase
i i
FOR ENGINE powered equipment.
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ii ii
RANGER 3 PHASE
FUMES AND GASES can be dangerous.
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
iii iii
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
WELDING and CUTTING SPARKS can cause fire or explosion.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
iv iv
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
Page
Electromagnetic Compatibility (EMC)
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
TABLE OF CONTENTS - INSTALLATION SECTION
TECHNICAL SPECIFICATIONS - RANGER 3 PHASE (K2337-1 & K2337-2)
INPUT - GASOLINE ENGINE
PHYSICAL DIMENSIONS
RATED OUTPUT @ 104F (40C)- GENERATOR
RATED OUTPUT @ 104F (40C)- WELDER
SAFETY PRECAUTIONS
MACHINE GROUNDING
SPARK ARRESTER
TOWING
PRE-OPERATION SERVICE
GASOLINE FUEL ONLY
GASOLINE
WELDING OUTPUT CABLES
ANGLE OF OPERATION
LIFTING
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
HIGH ALTITUDE OPERATION
INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
WELDER OPERATION
AUXILIARY POWER
* **
***
A-9 A-9
Figure A.3 CONNECTION OF RANGER 3 PHASE TO PREMISES WIRING
Page
TABLE OF CONTENTS - OPERATION SECTION
WELDER CONTROLS - FUNCTION AND OPERATION
ENGINE SWITCH
SAFETY PRECAUTIONS
GENERALDESCRIPTION
POLARITY SWITCH
RANGER 3 PHASE APPROXIMATE FUEL CONSUMPTION
WELDING PROCESS
Page
STARTING/SHUTDOWN INSTRUCTIONS
BREAK-IN PERIOD
Page
ACCESSORIES
OPTIONAL EQUIPMENT
ACCESSORIES
RECOMMENDEDEQUIPMENT
Page
TABLE OF CONTENTS - MAINTENANCE SECTION
ENGINE OIL CHANGE
ENGINE OIL REFILL CAPACITIES
SAFETY PRECAUTIONS
ROUTINE MAINTENANCE
Kohler CH23S Oil 100 Hrs. Oil Filter 200 Hrs.
OIL FILTER CHANGE
AIR CLEANER AND OTHER MAINTENANCE
GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE
SLIP RINGS
Page
Page
Page
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1 E-1
STATOR
+-
FIGURE E.1 BLOCK DIAGRAM
GENERAL DESCRIPTION
ENGINE COMPONENTS AND OPERATION
ROTOR, STATOR & CONTROL CIRCUITS
WELD CIRCUITRY
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
Page
Page
Page
Page
Page
Page
Page
ROTOR VOLTAGE TEST PROCEDURE
Slip Rings
Brushes
Lead 200A
Lead 219
+ -
ROTOR VOLTAGE TEST (continued)
ROTOR RESISTANCE TEST
+ -
ROTOR RESISTANCE TEST (continued)
TESTPROCEDURE
AUXILIARY AND FIELD WINDING TEST
AUXILIARY AND FIELD WINDING TEST (continued)
PROBES READING X to Y 480 to 520 VAC Y to Z 480 to 520 VAC X to Z 480 to 520 VAC
FIGURE F.4 CONTROL PC BOARD
AUXILIARY AND FIELD WINDING TEST (continued)
FTP1
C36
A
F-17 F-17
Page
OUTPUT RECTIFIER BRIDGE TEST
()
TO POLARITY SWITCH (S2)
AC2
TO RANGE SWITCH (S1)
OUTPUT RECTIFIER BRIDGE TEST (continued)
TOROID TEST
B
A
D C
CONTROL L12198-1
TOROID TEST (continued)
TESTPROCEDURE
F-22 F-22
CHARGING CIRCUIT TEST
Voltage Regulator
AC Lead
DC Lead
AC Lead
CHARGINGCIRCUITTEST (continued)
ENGINE THROTTLE ADJUSTMENT TEST
Blower Paddle
Solenoid Housing
3/8" Low Idle Adjustment Nut
Page
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM
TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE)
TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
MACHINE LOADED TO 200 AMPS AT 26 VDC
TYPICAL AC WELD OUTPUT WAVEFORM
MACHINE LOADED TO 225 AMPS AT 25 VDC
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
ONE OUTPUT DIODE NOT FUNCTIONING
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
ONE OUTPUT DIODE NOT FUNCTIONING
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
Page
BRUSH REMOVAL AND REPLACEMENT PROCEDURE
BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued)
SLIP RINGS
Page
Page
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT PROCEDURE
PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued)
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE
()
(+)
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued)
ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE
Page
Page
ROTOR REMOVAL PROCEDURE
REASSEMBLY PROCEDURE
RETEST AFTER REPAIR
ENGINE OUTPUT
WELDER DC OUTPUT
WELDER AC OUTPUT
WELDER CV OUTPUT
TABLE OF CONTENTS - DIAGRAM SECTION
* NOTE:
ElEcTrical DiaGramS
RANGER
EAD
TI
NSAMEDIREC
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ElEcTrical DiaGramS
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