Lincoln Electric SVM207-A

ElEcTrical DiaGramS G-4

raNGEr® 3 phaSE

SchEmaTic - cONTrOl pc bOarD - l12197-1

G-4

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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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 T ElEcTrical DiaGramS SchEmaTic - cOmplETE machiNE - l12259 bly assem r stato