Brush Removal and Replacement Procedure | Lincoln Electric SVM207-A

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F-39	TROUBLESHOOTING AND REPAIR	F-39

BRUSH 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 accessing the generator brushes for maintenance or replacement.

MATERIALS NEEDED

Misc. Hand Tools

RANGER® 3 PHASE

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

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 Devices Without Addi Tional Resistive Type Loads Electrical Device USE with the Ranger 3 PhaseUSE These Devices with a Ranger 3 Phase 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 Engine Components and Operation Theory of OperationGeneral Description 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 Materials Needed Rotor Voltage Test ProcedureTest Description 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 High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply 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