Page 2 - RANGER® 3 PHASE; SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
RANGER® 3 PHASE SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn 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 engi...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii RANGER® 3 PHASE FUMES AND GASEScan be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep fumes and gases away from the breathin...
Page 4 - iii
RANGER® 3 PHASE SAFETY iii iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv RANGER® 3 PHASE PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous c...
Page 6 - Conformance; b) radio and television transmitters and receivers
SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It was manufactured in conform...
Page 7 - uct standard for arc welding equipment.”
SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Weldi...
Page 8 - - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -; Page
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I I RANGER® 3 PHASE Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 9 - TABLE OF CONTENTS - INSTALLATION SECTION
TABLE OF CONTENTS - INSTALLATION SECTION A-1 A-1 RANGER® 3 PHASE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications .........................................
Page 10 - INSTALLATION; INPUT - GASOLINE ENGINE
INSTALLATION A-2 A-2 RANGER® 3 PHASE TECHNICAL SPECIFICATIONS - RANGER® 3 PHASE (K2337-1 & K2337-2) INPUT - GASOLINE ENGINE RATED 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) RATED OUTPUT @ 104°F (40°C)- GENERATOR Weldi...
Page 11 - is; CAUTION
INSTALLATION A-3 A-3 RANGER® 3 PHASE SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder / generatorcreates it’s own power, it is not necessary to connectit’s frame to an earth ground, unless the machine isconnected to premises wiring (your home, shop, etc.). To prevent d...
Page 12 - PRE-OPERATION SERVICE; GASOLINE FUEL ONLY; GASOLINE
INSTALLATION 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 enginecrankcase filled with SAE 10W-30 oil. Check the oillevel before starting the engine. If it is ...
Page 13 - At higher altitudes, elder output de-rating may be necessary.
INSTALLATION A-5 A-5 RANGER® 3 PHASE WELDING OUTPUT CABLES With the engine off, connect the electrode and workcables to the studs provided. These connectionsshould be checked periodically and tightened if neces-sary. Loose connections will result in overheating of theoutput studs. When welding at a ...
Page 14 - LOCATION / VENTILATION; INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS; WELDER OUTPUT
INSTALLATION A-6 A-6 RANGER® 3 PHASE LOCATION / VENTILATION The welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid heated air coming out of the welder recirculating back to the cooling air inlet. Also, locate the welder sothat engine ex...
Page 15 - AUXILIARY POWER
INSTALLATION A-7 A-7 RANGER® 3 PHASE 120 V GFCI DUPLEX RECEPTACLES A GFCI (Ground Fault Circuit Interrupter) electricalreceptacle is a device to protect against electric shockshould a piece of defective equipment connected to itdevelop a ground fault. If this situation should occur,the GFCI will tri...
Page 16 - AUXILIARY POWER WHILE WELDING
INSTALLATION A-8 A-8 RANGER® 3 PHASE All auxiliary power is protected by circuit breakers withthe following values: The 120V has 20 amp circuit breakers for each duplexreceptacle. The 240V has 50 amp circuit breakers foreach hot lead going the 240V receptacle.The 480V 3 phase circuit breaker / switc...
Page 17 - CONNECTION OF RANGER® 3 PHASE TO PREMISES WIRING
INSTALLATION 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 NEUTRALBUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDAT...
Page 19 - TABLE OF CONTENTS - OPERATION SECTION
TABLE OF CONTENTS - OPERATION SECTION B-1 B-1 RANGER® 3 PHASE Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 20 - OPERATION; W E L D E R C O N T R O L S - F U N C T I O N A N D; ENGINE SWITCH; Welding; SAFETY PRECAUTIONS; GENERAL DESCRIPTION
OPERATION B-2 B-2 RANGER® 3 PHASE W E L D E R C O N T R O L S - F U N C T I O N A N D OPERATION ENGINE SWITCH The engine switch is used to Start the Engine, SelectHigh Idle or Auto Idle while the engine is running, andstop the Engine. When placed in the “OFF” position, the ignitioncircuit is de-ener...
Page 21 - POLARITY SWITCH; Provides three selectable welding polarities:; RANGER® 3 PHASE APPROXIMATE FUEL CONSUMPTION
OPERATION B-3 B-3 RANGER® 3 PHASE “ RANGE” SWITCH The “Range” switch is used to select one of threeamperage ranges with generous overlap for Stick/TIGwelding, or one Wire Feed welding range. Never change the “RANGE” Switch setting whilewelding. This will damage the switch. --------------------------...
Page 22 - WELDING PROCESS; The Innershield; ARC GOUGING; Diameter Wire Speed Approximate
OPERATION 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 informationsee the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK” and"ELECTRODE” stud...
Page 24 - STARTING/SHUTDOWN INSTRUCTIONS; pull the choke control out
OPERATION B-6 B-6 RANGER® 3 PHASE STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per-formed. Also, read the Engine Owner’s Manual beforestarting for the first time. Remove all loads connected to the AC power recepta-cles. Use the choke control as fo...
Page 25 - TABLE OF CONTENTS - ACCESSORIES SECTION
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 RANGER® 3 PHASE Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 26 - ACCESSORIES; OPTIONAL EQUIPMENT; K802R POWER PLUG KIT
ACCESSORIES C-2 C-2 RANGER® 3 PHASE OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicablefederal, state and local laws regarding requirements forbrakes, lights, fenders, etc.)...
Page 27 - RECOMMENDED EQUIPMENT; - Includes internal contactor for across the
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 u...
Page 28 - NOTES
NOTES C-4 C-4 RANGER® 3 PHASE Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC
Page 29 - TABLE OF CONTENTS - MAINTENANCE SECTION
TABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 RANGER® 3 PHASE Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 30 - MAINTENANCE; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n; ROUTINE MAINTENANCE; Oil
MAINTENANCE D-2 D-2 RANGER® 3 PHASE Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be necessaryto remove safety guards to perform requiredm a i n t e n a n c e . R e m o v e g u a r d s o n l y w h e nnecessary and replace...
Page 31 - OIL FILTER CHANGE
MAINTENANCE D-3 D-3 RANGER® 3 PHASE Use 4-stroke motor oil that meets or exceeds therequirements 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, ...
Page 32 - CHAMPION RC12YC
MAINTENANCE D-4 D-4 RANGER® 3 PHASE BATTERY 1. When replacing, jumping, or otherwise connecting the battery to the battery cables, the properpolarity must be observed. Failure to observethe proper polarity could result in damage to thecharging circuit. The positive (+) battery cablehas a red termina...
Page 35 - TABLE OF CONTENTS-THEORY OF OPERATION SECTION
TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 RANGER® 3 PHASE Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . . . . . . . . . . . . . . . . . ....
Page 36 - THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic
THEORY OF OPERATION E-2 E-2 RANGER® 3 PHASE FIGURE E.2 - ENGINE COMPONENTS AND OPERATION NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion GENERAL DESCRIPTION The RANGER® 3 PHASE is a twin cylinder, gasolinedriven, multiprocess arc welder and AC power genera-tor. It is capabl...
Page 38 - WELD CIRCUITRY
THEORY OF OPERATION E-4 E-4 RANGER® 3 PHASE FIGURE E.2 - WELD CIRCUITRY NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion WELD CIRCUITRY One end of the Weld Winding is connected to theOutput Rectifier and at the other end to the Reactor.There are taps (C1) for constant voltag...
Page 39 - TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 F-1 RANGER® 3 PHASE Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . ...
Page 40 - TROUBLESHOOTING AND REPAIR; HOW TO USE TROUBLESHOOTING GUIDE
TROUBLESHOOTING AND REPAIR F-2 F-2 RANGER® 3 PHASE This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMPTOMS)”. This column de...
Page 41 - PC BOARD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING AND REPAIR F-3 F-3 RANGER® 3 PHASE Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connections. To avoid prob-lems when troubleshooting and replacing PC boards,please use the following procedure: 1. Determine t...
Page 42 - OUTPUT PROBLEMS; Wiring
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 El...
Page 43 - Output Bridge Test
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 El...
Page 45 - ENGINE PROBLEMS
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 El...
Page 48 - WELDING PROBLEMS
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 E...
Page 49 - ROTOR VOLTAGE TEST PROCEDURE
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 50 - TEST PROCEDURE; then reinstall the fuel cap.; Rotor Resis tance Test
Slip Rings Brushes Lead 219 + - Lead 200A FIGURE F.1 – SLIP RINGS AND BRUSHES ROTOR VOLTAGE 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. T...
Page 51 - ROTOR RESISTANCE TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 52 - FIGURE F.2 – SLIP RINGS; then replace the fuel cap.
Lead 219 Lead 200A + - FIGURE F.2 – SLIP RINGS ROTOR RESISTANCE 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...
Page 53 - AUXILIARY AND FIELD WINDING TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 54 - PROBES; X to Y
120 VAC GFCI RECEPTACLE 120/240 VAC 1 PHASE RECEPTACLE 480 VAC 3 PHASE RECEPTACLE TEST RESET Lead #3 Lead #5 Lead #6 Lead #3 Z Y X GND FIGURE F.3 – RECEPTACLES AND LEADS AUXILIARY AND FIELD WINDING TEST (continued) TEST PROCEDURE AUXILIARY WINDINGS NOTE: The following tests can be made by carefullyi...
Page 55 - FIGURE F.4 – CONTROL PC BOARD; FIELD WINDING; Remove the fuel cap and lift bail rubber gasket.; Set the output control to the maximum position
FIGURE F.4 – CONTROL PC BOARD AUXILIARY 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 casetop and left side; then reinstall the fuel cap. 2. Connect the volt/ohmmeter probes to leads #7 and #9 where ...
Page 57 - OUTPUT RECTIFIER BRIDGE TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 59 - TOROID TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 60 - FIGURE F.6 – TOROID ASSEMBLY; Wiring Diagram
B A D C CONTROL L12198-1 X4 DZ 5 D1 C2 4 C3 9 R4 D2 X3 C3 1 R3 3 R7 6 R95 R8 2 R3 9 Q3 R47 C1 2 R72 R67 C3 7 R88 R4 5 J2 R4 8 D3 C3 0 C3 2 DZ 8 D1 1 D10 C2 R5 TP2 D2 1 R73 D9 DZ 2 DZ 10 R1 1 Q1 R16 DZ 9 R1 0 Q 5 R5 2 R83 R57 D1 9 R1 2 C4 0 C4 1 R7 9 C36 R8 1 R2 9 R8 9 R41 DZ 4 R84 R8 0 Q4 R2 1 R32 R...
Page 61 - CHARGING CIRCUIT TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 62 - FIGURE F.1 – DOOR REMOVAL; Set the voltmeter for AC volts and place one meter
Voltage Regulator AC Lead DC Lead AC Lead FIGURE F.1 – DOOR REMOVAL 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 attachto the engine voltage r...
Page 63 - ENGINE THROTTLE ADJUSTMENT TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 64 - Blower Paddle; FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD
Blower Paddle FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH 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...
Page 65 - HIGH IDLE ADJUSTMENT NUT; Frequency Counter Method; Plug the frequency counter into one of the 115 VAC; Solenoid
Throttle linkage Choke Cable 3/8" High IdleAdjustment 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 115 VAC auxiliary receptacles. 2. Start the engine and check the frequency counter. At ...
Page 67 - volts; SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY); HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM
TROUBLESHOOTING AND REPAIR F-29 F-29 RANGER® 3 PHASE CH1 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div .....................50V/Div.Horizontal Sweep .....5 ms/Div.Coupling .............................DCTrigger .........................Internal This is the typical AC output voltagegenerated from a ...
Page 68 - TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE); MACHINE LOADED; MACHINE LOADED TO 200 AMPS AT 20 VDC
TROUBLESHOOTING AND REPAIR F-30 F-30 RANGER® 3 PHASE This is the typical CV output voltagegenerated from a properly operatingmachine. Note that each vertical divi-sion represents 20 volts and that eachhorizontal division represents 5 mil-liseconds in time. The machine wasloaded with a resistance gri...
Page 69 - TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)
TROUBLESHOOTING AND REPAIR F-31 F-31 RANGER® 3 PHASE This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each vertical divi-sion represents 20 volts and that eachhorizontal division represents 5 mil-liseconds in time. The machine wasloaded with a resistance gri...
Page 70 - TYPICAL AC WELD OUTPUT WAVEFORM
TROUBLESHOOTING AND REPAIR F-32 F-32 RANGER® 3 PHASE This is the typical AC output voltagegenerated from a properly operatingmachine. Note that each vertical divi-sion represents 20 volts and that eachhorizontal division represents 5 mil-liseconds in time. The machine wasloaded with a resistance gri...
Page 71 - ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE); HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM
TROUBLESHOOTING AND REPAIR F-33 F-33 RANGER® 3 PHASE This is NOT the typical CV output volt-age waveform. One output diode isnot functioning. Note the “gap” in thewaveform. One output diode was dis-connected to simulate an open or non-functioning output diode. Each verticaldivision represents 20 vol...
Page 72 - ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
TROUBLESHOOTING AND REPAIR F-34 F-34 RANGER® 3 PHASE This is NOT the typical DC (+) outputvoltage waveform. One output diodeis not functioning. Note the “gap” inthe waveform. One output diode wasdisconnected to simulate an open ornonfunctioning output diode. Eachvertical division represents 50 volts...
Page 73 - NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)
TROUBLESHOOTING AND REPAIR F-35 F-35 RANGER® 3 PHASE This is the typical CV output voltagegenerated from a properly operatingmachine. Note that each vertical divi-sion represents 20 volts and that eachhorizontal division represents 5 mil-liseconds in time. Note: Scope probes connected atmachine 115V...
Page 74 - NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)
TROUBLESHOOTING AND REPAIR F-36 F-36 RANGER® 3 PHASE This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each vertical divi-sion represents 50 volts and that eachhorizontal division represents 5 mil-liseconds in time. Note: Scope probes connected atmachine 115V...
Page 75 - NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM
TROUBLESHOOTING AND REPAIR 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 verticaldivision represents 50 volts and thateach horizontal division represents 5milliseconds in time. Note: Scope probes connected atmachi...
Page 77 - BRUSH REMOVAL AND REPLACEMENT
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 78 - PROCEDURE; See; SLIP RINGS
BRUSH REMOVAL 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 t...
Page 79 - FIGURE F.9 – BRUSH HOLDER MOUNTING BOLTS
7/16" Brush Assembly Bracket Bolts FIGURE F.9 – BRUSH HOLDER MOUNTING BOLTS BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-41 F-41 RANGER® 3 PHASE Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC R...
Page 81 - PRINTED CIRCUIT BOARD REMOVAL
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 82 - FIGURE F.10 – DOOR REMOVAL
PROCEDURE Before starting the following procedure, refer to thetopic “PC Board Troubleshooting Procedures” at thebeginning 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 (cov...
Page 83 - OUTPUT RECTIFIER BRIDGE REMOVAL
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 84 - FIGURE F.11 – OUTPUT RECTIFIER
(—) (+) TO POLARITY SWITCH (S2) LEAD 8 TO CHOKE (L1) LEAD 254 TO STATOR (LEAD W1) TO STATOR (LEAD S2) TO RANGE SWITCH (S1) AC2 AC1 FIGURE F.11 – OUTPUT RECTIFIER OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove the engine spark plug wires. 2. With a 5/16” nut...
Page 85 - Lincoln Electric Rotor Removal Kit (S20788); ENGINE/ROTOR REMOVAL AND REPLACEMENT
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 86 - FIGURE F.12 – ENGINE/ROTOR COMPONENT LOCATIONS; Rotor Shaft Bearing
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 LOCATIONS ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.) TROUBLESHOOTING AND REPAIR F-48 F-48 RANGER® 3 PHASE 1A. Tolerance Ring 1B. Rotor Thru-Bolt 1C. Blower Fan 2. Kohler...
Page 87 - Turn the fan counter-; Reassembly Procedure
ENGINE/ROTOR REMOVAL 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 bai...
Page 88 - FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR; ROTOR REMOVAL PROCEDURE; To remove the rotor, double check that the engine; counterclockwise; If the rotor does not pop off, tighten the rotor
ROTOR THRU-BOLT FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.) ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the engine spark plug wires are disconnected. You will be turn-ing the rotor during this procedure, and this cou...
Page 89 - REASSEMBLY PROCEDURE; Brush Removal and
ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bear-ing be installed when you replace the rotor andblower assembly. 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft. 2. Insert the rotor thru-bolt, and wit...
Page 90 - RETEST AFTER REPAIR
RETEST AFTER REPAIR TROUBLESHOOTING AND REPAIR 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 component...
Page 91 - TABLE OF CONTENTS - DIAGRAM SECTION
TABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 RANGER® 3 PHASE Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram Complete Machine (M20315) . . . . . . . . . . . . . . . . . . . ...
Page 92 - ElEcTrical DiaGramS; raNGEr® 3 phaSE; WiriNG DiaGram - cOmplETE machiNE - m20315; ELECTRICAL SYMBOLS PER E1537; ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM
ElEcTrical DiaGramS G-2 raNGEr® 3 phaSE WiriNG DiaGram - cOmplETE machiNE - m20315 STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENOID BATTERY AC AC B+ SWITCH REGULATOR FLYWHEEL ALTERNATOR B- HOUR METER 5E 5D 224 ENGINE COMPONENTS 224A 1 2 3 CONNECTOR PIN NUMBERS: 7 6 12 1 2 3 4 J1 N.A. B J2 SOLENOI...
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