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Lincoln Electric RANGER 3PHASE SVM207-A manual

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Table of contents for the manual

  • Page 1

    S VM207 -A Jan uar y , 20 1 1 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFET[...]

  • Page 2

    RANGER® 3 PHASE SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________[...]

  • Page 3

    SAFETY ii ii RANGER® 3 PHASE FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which re[...]

  • Page 4

    RANGER® 3 PHASE SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance wi[...]

  • Page 5

    SAFETY iv iv RANGER® 3 PHASE PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique:[...]

  • Page 6

    S AFETY Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformity with European Community Council Directiv e of 1 5 Dec 2004 on the appro ximation of the laws of the Member States relating to electromagnetic compatibilit y , 2004/1 08/EC . It was manuf actured in conformity with a national standard that imp[...]

  • Page 7

    S AFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area ma y e xtend bey ond the boundar ies of the premises. Methods of Reducing Emissions Mains Supply W elding equipment should be connected to the mai[...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I RANGER® 3 PHASE Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 RANGER® 3 PHASE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications ...................................................................................[...]

  • Page 10

    INST ALLA TION A-2 A-2 RANGER® 3 PHASE TECHNICAL SPECIFICA TIONS - RANGER® 3 PHASE (K2337-1 & K2337-2) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.3 in. 538 lbs. 770 mm 485 mm 1074 mm (244kg) RA TED OUTPUT @ 104°F (40°C)- GENERA TOR Welding Output AC Constant Current 225A / 2[...]

  • Page 11

    INST ALLA TION A-3 A-3 RANGER® 3 PHASE SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder / generator creates it’s own power , it is not necessary to connect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). T o prevent dangerous electric shock, other equip- [...]

  • Page 12

    INST ALLA TION A-4 A-4 RANGER® 3 PHASE FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL The RANGER® 3 PHASE is shipped with the engine crankcase filled with SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, a[...]

  • Page 13

    INST ALLA TION A-5 A-5 RANGER® 3 PHASE WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary . Loose connections will result in overheating of the output studs. When welding at a considerable distance from the welder , be[...]

  • Page 14

    INST ALLA TION A-6 A-6 RANGER® 3 PHASE LOCA TION / VENTILA TION The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid heated air coming out of the welder recirculating back to the cooling air inlet. Also, locate the welder so that engine exhaust fumes are properly vented to an outs[...]

  • Page 15

    INST ALLA TION A-7 A-7 RANGER® 3 PHASE 120 V GFCI DUPLEX RECEPT ACLES A GFCI (Ground Fault Circuit Interrupter) electrical receptacle is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault. If this situation should occur , the GFCI will trip, removing voltage from the output of th[...]

  • Page 16

    INST ALLA TION A-8 A-8 RANGER® 3 PHASE All auxiliary power is protected by circuit breakers with the following values: The 120V has 20 amp circuit breakers for each duplex receptacle. The 240V has 50 amp circuit breakers for each hot lead going the 240V receptacle. The 480V 3 phase circuit breaker / switch is a 3 phase, 15 amp circuit breaker . Gr[...]

  • Page 17

    INST ALLA TION A-9 A-9 RANGER® 3 PHASE 240 Volt 60 Hz. 3-Wire Service POWER  COMPANY  METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS.[...]

  • Page 18

    INST ALLA TION A-10 A-10 RANGER® 3 PHASE RANGER® 3 PHASE Extension Cord Length Recommendations (Use the shortest length extension cord possible sized per the following table.) Maximum Allowable Cord Length in ft. (m) for Conductor Size Conductor size is based on maximum 2.0% voltage drop. 14 A WG 12 A WG 10 A WG 8 A WG 6 A WG 4 A WG Current (Amps[...]

  • Page 19

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 RANGER® 3 PHASE Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 20

    OPERA TION B-2 B-2 RANGER® 3 PHASE WELDER CONTROLS - FUNCTION AND OPERA TION ENGINE SWITCH The engine switch is used to Start the Engine, Select High Idle or Auto Idle while the engine is running, and stop the Engine. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine. When held in the “ST ART” [...]

  • Page 21

    OPERA TION B-3 B-3 RANGER® 3 PHASE “ RANGE” SWITCH The “Range” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Never change the “RANGE” Switch setting while welding. This will damage the switch. -----------------------------------------------------------[...]

  • Page 22

    OPERA TION B-4 B-4 RANGER® 3 PHASE WELDING PROCESS For any electrodes the procedures should be kept with- in the rating of the machine. For electrode information see the appropriate Lincoln publication. STICK (CONST ANT CURRENT) WELDING Connect welding cables to the "T O WORK” and "ELECTRODE” studs. Start the engine. Set the "[...]

  • Page 23

    OPERA TION B-5 B-5 RANGER® 3 PHASE SUMMAR Y OF WELDING PROCESSES C O N T RO L E LE CT R O D E C A B L E I DL E W HE N N OT T O S T AR T P R O C ES S U SE D M OD E W EL DI NG WE LD IN G STICK No AUTO Hot T ouch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger , LN-25 [...]

  • Page 24

    OPERA TION B-6 B-6 RANGER® 3 PHASE ST ARTING/SHUTDOWN INSTRUCTIONS ST ARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’s Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER ENGINE - Always pull the c[...]

  • Page 25

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 RANGER® 3 PHASE Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 26

    ACCESSORIES C-2 C-2 RANGER® 3 PHASE OPTIONAL EQUIPMENT (Field Installed) K957-1 HEA VY DUTY , TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 Trailer K958-1 Ball Hitch K958[...]

  • Page 27

    ACCESSORIES C-3 C-3 RANGER® 3 PHASE RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield WIRE FEED LN-25 K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “cold” elec- trode until gun trigger is pressed. Inc[...]

  • Page 28

    NOTES C-4 C-4 RANGER® 3 PHASE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 RANGER® 3 PHASE Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 30

    MAINTENANCE D-2 D-2 RANGER® 3 PHASE Have qualified personnel do the maintenance work. T urn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their removal is complete. Alwa[...]

  • Page 31

    MAINTENANCE D-3 D-3 RANGER® 3 PHASE Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tempera- ture use, -5 F to 104 F (-20 C to 40 C). See Engine Own[...]

  • Page 32

    MAINTENANCE D-4 D-4 RANGER® 3 PHASE BA TTER Y 1. When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to the charging circuit. The positive (+) battery cable has a red terminal cover . 2. If the battery requires chargi[...]

  • Page 33

    MAINTENANCE D-5 D-5 RANGER® 3 PHASE FIGURE D.1 - MAJOR COMPONENT LOCA TION 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBL Y 3. BASE/UNDERCARRIAGE ASSEMBL Y 4. ENGINE/ROTOR/ST A T OR ASSEMBL Y 5. CASE TOP & SIDES 2 2 1 1 3 3 4 4 5 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to [...]

  • Page 34

    NOTES D-6 D-6 RANGER® 3 PHASE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 35

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 RANGER® 3 PHASE Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 36

    THEOR Y OF OPERA TION E-2 E-2 RANGER® 3 PHASE FIGURE E.2 - ENGINE COMPONENTS AND OPERA TION NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion GENERAL DESCRIPTION The RANGER® 3 PHASE is a twin cylinder , gasoline driven, multiprocess arc welder and AC power genera- tor . It is capable of AC or DC Stick (SMA W) or TIG (GT A [...]

  • Page 37

    THEOR Y OF OPERA TION E-3 E-3 RANGER® 3 PHASE FIGURE E.2 - ROTOR, ST A TOR AND CONTROL CIRCUITS NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion IDLER SOL ENO ID OUTPUT CONTROL MECHANICAL RO T A T ION FIELD CA PA C I T OR SLIP RINGS RANGE SWITCH OUTPUT BRIDGE CHOKE AC AC WORK TERMINAL PRINTED CIRCUIT BOARD TOROID T OROID *[...]

  • Page 38

    THEOR Y OF OPERA TION E-4 E-4 RANGER® 3 PHASE FIGURE E.2 - WELD CIRCUITR Y NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion WELD CIRCUITR Y One end of the Weld Winding is connected to the Output Rectifier and at the other end to the Reactor . There are taps (C1) for constant voltage (CV) welding and (W AC) for AC welding. [...]

  • Page 39

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 RANGER® 3 PHASE T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    TROUBLESHOOTING AND REP AIR F-2 F-2 RANGER® 3 PHASE This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that th[...]

  • Page 41

    TROUBLESHOOTING AND REP AIR F-3 F-3 RANGER® 3 PHASE Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that t[...]

  • Page 42

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 43

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 44

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 45

    ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 46

    ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 47

    ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 48

    WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical trouble[...]

  • Page 49

    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 thr[...]

  • Page 50

    Slip Rings Brushes Lead 219 + - Lead 200A FIGURE F .1 – SLIP RINGS AND BRUSHES ROT OR VOL T AGE TEST (continued) TEST PROCEDURE 1. Using a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. Remove the fuel cap. The rubber gasket for the fill tube will co[...]

  • Page 51

    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 thr[...]

  • Page 52

    Lead 219 Lead 200A + - FIGURE F .2 – SLIP RINGS ROTOR RESIST ANCE TEST (continued) TEST PROCEDURE 1. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bail. 3. Remove the fuel cap. The rubber gasket for the fill tube will come off with the case top. 4. [...]

  • Page 53

    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 thr[...]

  • Page 54

    120 V AC GFCI RECEPT ACLE 120/240 V AC 1 PHASE RECEPT ACLE 480 V AC 3 PHASE RECEPT ACLE TEST RESET Lead #3 Lead #5 Lead #6 Lead #3 Z YX GND FIGURE F .3 – RECEPT ACLES AND LEADS AUXILIAR Y AND FIELD WINDING TEST (continued) TEST PROCEDURE AUXILIAR Y WINDINGS NOTE: The following tests can be made by carefully inserting the meter probes into the rec[...]

  • Page 55

    FIGURE F .4 – CONTROL PC BOARD AUXILIAR Y AND FIELD WINDING TEST (continued) FIELD WINDING 1. Remove the fuel cap and lift bail rubber gasket. With a 5/16” nut driver or socket, remove the case top and left side; then reinstall the fuel cap. 2. Connect the volt/ohmmeter probes to leads #7 and #9 where they connect to the Control P .C. Board. 3.[...]

  • Page 56

    NOTES F-18 F-18 RANGER® 3 PHASE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 57

    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 thr[...]

  • Page 58

    (—) (+) TO POLARITY SWITCH (S2) LEAD 8 TO CHOKE (L1) LEAD 254 TO ST A TOR (LEAD W1) TO ST A TOR (LEAD S2) TO RANGE SWITCH (S1) AC2 AC1 FIGURE F .5 – OUTPUT RECTIFIER OUTPUT RECTIFIER BRIDGE TEST (continued) TEST PROCEDURE 1. Remove the spark plug wires to prevent accidental engine kickback or starting. 2. WIth a 5/16” nut driver or socket, [...]

  • Page 59

    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 thr[...]

  • Page 60

    B A D C CONTROL L1219 8-1 X4 DZ5 D1 C24 C39 R4 D2 X3 C31 R33 R76 R95 R82 R39 Q3 R47 C12 R 72 R 67 C37 R88 R45 J2 R48 D3 C30 C32 DZ8 D11 D 10 C2 R5 TP2 D21 R73 D9 DZ2 DZ10 R11 Q1 R 16 DZ9 R10 Q5 R52 R83 R 57 D19 R12 C40 C41 R79 C36 R81 R29 R89 R41 DZ4 R84 R80 Q4 R21 R 32 R96 C14 R91 R40 C26 R20 R 85 R69 C10 C13 R17 R23 C1 R44 D16 X1 R58 R42 R75 R49 [...]

  • Page 61

    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 thr[...]

  • Page 62

    V oltage Regulator AC Lead DC Lead AC Lead FIGURE F .1 – DOOR REMOV AL CHARGING CIRCUIT TEST (continued) TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. Set the voltmeter for AC volts and place one meter probe on each of the two outside leads that attach to the engine voltage regulator . See Figure F .5 for locatio[...]

  • Page 63

    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 thr[...]

  • Page 64

    Blower Paddle FIGURE F .6 – BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD ENGINE THROTTLE ADJUSTMENT TEST (continued) TEST PROCEDURE This test can be conducted by any one of four meth- ods. Strobe-tach Method: 1. With the 5/16” nut driver , remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift[...]

  • Page 65

    Throttle linkage Choke Cable 3/8" High Idle Adjustment Nut FIGURE F .7 HIGH IDLE ADJUSTMENT NUT ENGINE THROTTLE ADJUSTMENT TEST (continued) Frequency Counter Method 1. Plug the frequency counter into one of the 1 15 V AC auxiliary receptacles. 2. Start the engine and check the frequency counter . At HIGH IDLE (3700 RPM), the counter should r[...]

  • Page 66

    FIGURE F .9 - 1 15V AC SUPPL Y W A VEFORM (HIGH IDLE- NO LOAD) ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 1 15 V AC recepta- cle, according to the manufacturer ’s instructions. At 3700 RPM, the waveform should exhibit a peri- od of 16.2 milliseconds. At 2400 RPM, the wave- form should exhib[...]

  • Page 67

    TROUBLESHOOTING AND REP AIR F-29 F-29 RANGER® 3 PHASE CH1 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep .....5 ms/Div . Coupling .............................DC T rigger .........................Internal This is the typical AC output voltage generated from a properly operating machine. Note that ea[...]

  • Page 68

    TROUBLESHOOTING AND REP AIR F-30 F-30 RANGER® 3 PHASE This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected at ma[...]

  • Page 69

    TROUBLESHOOTING AND REP AIR F-31 F-31 RANGER® 3 PHASE This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected at ma[...]

  • Page 70

    TROUBLESHOOTING AND REP AIR F-32 F-32 RANGER® 3 PHASE This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected at ma[...]

  • Page 71

    TROUBLESHOOTING AND REP AIR F-33 F-33 RANGER® 3 PHASE This is NOT the typical CV output volt- age waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was dis- connected to simulate an open or non- functioning output diode. Each vertical division represents 20 volts and each horizontal division re[...]

  • Page 72

    TROUBLESHOOTING AND REP AIR F-34 F-34 RANGER® 3 PHASE This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was disconnected to simulate an open or nonfunctioning output diode. Each vertical division represents 50 volts and each horizontal division repr[...]

  • Page 73

    TROUBLESHOOTING AND REP AIR F-35 F-35 RANGER® 3 PHASE This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/D[...]

  • Page 74

    TROUBLESHOOTING AND REP AIR F-36 F-36 RANGER® 3 PHASE This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 mil- liseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/D[...]

  • Page 75

    TROUBLESHOOTING AND REP AIR F-37 F-37 RANGER® 3 PHASE This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V o[...]

  • Page 76

    NOTES F-38 F-38 RANGER® 3 PHASE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 77

    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 thr[...]

  • Page 78

    BRUSH REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove the spark plug wires. 2. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. Remove the fuel cap. The rubber gasket for the fill tube with come off with the case top. 5. Remove [...]

  • Page 79

    7/16" Brush Assembly Bracket Bolts FIGURE F .9 – BRUSH HOLDER MOUNTING BOL TS BRUSH REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-41 F-41 RANGER® 3 PHASE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return[...]

  • Page 80

    NOTES F-42 F-42 RANGER® 3 PHASE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 81

    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 thr[...]

  • Page 82

    PROCEDURE Before starting the following procedure, refer to the topic “PC Board Troubleshooting Procedures” at the beginning of this section. 1. Remove the engine spark plug wires. 2. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 3. Remove the rubber gasket (cover seal) from the lift bail. 4. Remove the[...]

  • Page 83

    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 thr[...]

  • Page 84

    (—) (+) TO POLARITY SWITCH (S2) LEAD 8 TO CHOKE (L1) LEAD 254 TO ST A TOR (LEAD W1) TO ST A TOR (LEAD S2) TO RANGE SWITCH (S1) AC2 AC1 FIGURE F .1 1 – OUTPUT RECTIFIER OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove the engine spark plug wires. 2. With a 5/16” nut driver or socket, remove the 6 she[...]

  • Page 85

    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 thr[...]

  • Page 86

    3 3 4 4 8 8 10A 10A 9 9 7 7 5B 5B 1B 1B 1C 1C 1A 1A 10B 10B 10C 10C 2 2 6 6 5A 5A FIGURE F .12 – ENGINE/ROTOR COMPONENT LOCA TIONS ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (cont.) TROUBLESHOOTING AND REP AIR F-48 F-48 RANGER® 3 PHASE 1A. T olerance Ring 1B. Rotor Thru-Bolt 1C. Blower Fan 2. Kohler Engine 3. Rotor 4. Rotor Shaft Bearing 5A[...]

  • Page 87

    ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (cont.) PROCEDURE 1. Refer to Figure F .12 for component locations. 2. Remove the engine spark plug wires. 3. With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top. 4. Remove the rubber gasket (cover seal) from the lift bail. 5. Remove the fuel cap. The rubber gasket f[...]

  • Page 88

    ROTOR THRU-BOL T FIGURE F .13 - ENGINE AND ROTOR REMOVED FROM ST A TOR ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (cont.) ROTOR REMOV AL PROCEDURE 1. T o remove the rotor , double check that the engine spark plug wires are disconnected. Y ou will be turn- ing the rotor during this procedure, and this could accidentally cause engine kickback. 2[...]

  • Page 89

    ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (cont.) REASSEMBL Y PROCEDURE NOTE: Lincoln Electric recommends that a new bear- ing be installed when you replace the rotor and blower assembly . 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft. 2. Insert the rotor thru-bolt, and with the torque wrench tighten the bolt to 50 ft[...]

  • Page 90

    RETEST AFTER REP AIR TROUBLESHOOTING AND REP AIR F-52 F-52 RANGER® 3 PHASE Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE OUTPUT Mode No Load RPM Load RP[...]

  • Page 91

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 RANGER® 3 PHASE Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram Complete Machine (M20315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 92

    ElEcTrical DiaGramS G-2 raNGEr® 3 phaSE WiriNG DiaGram - cOmplETE machiNE - m20315 ST ART ER CR1 ST ART ER SOLENOI D 1 2 VO LT IDLER SOLENOID BA TT ERY AC AC B+ SWI TCH REG ULA T OR FL Y WHEEL A LT ER NATOR B- HO UR ME T ER 5E 5D 224 ENGINE CO MPO NE NTS 22 4A 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 J1 N. A. B J2 SOLENOID FUEL SH UTOFF OI[...]

  • Page 93

    ElEcTrical DiaGramS G-3 raNGEr® 3 phaSE SchEma Tic - cOmplETE machiNE - l12259 L12259 RANGER 3 PHASE KOHLER MACHINE SCHEMATIC NONE L12249 BAM BAM - U NLESS OTHERW ISE SPE C IF IE D TOLERA N CE MANUFACTURIN G TOLERANCE PER E2056 ON 2 PLACE DECIMA LS IS ± .02 ON 3 PLAC E D E CI MAL S I S ± .002 ON ALL ANGLE S IS ± .5 OF A DEG REE WITH PUBLISHED S[...]

  • Page 94

    ElEcTrical DiaGramS G-4 raNGEr® 3 phaSE SchEma Tic - 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. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return [...]