Lincoln Electric 3PHASE Instrukcja Użytkownika

SVM207-AJanuary, 2011Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,you

INSTALLATIONA-2 A-2RANGER® 3 PHASETECHNICAL SPECIFICATIONS - RANGER® 3 PHASE (K2337-1 & K2337-2)INPUT - GASOLINE ENGINERATED OUTPUT @ 104°F (40°C)

INSTALLATIONA-3 A-3RANGER® 3 PHASESAFETY PRECAUTIONSMACHINE GROUNDINGBecause this portable engine driven welder / generatorcreates it’s own power, it

INSTALLATIONA-4 A-4RANGER® 3 PHASEFUELFill the fuel tank with clean, fresh, lead-free gasoline.Observe fuel gauge while filling to prevent overfilling

INSTALLATIONA-5 A-5RANGER® 3 PHASEWELDING OUTPUT CABLESWith the engine off, connect the electrode and workcables to the studs provided. T

INSTALLATIONA-6 A-6RANGER® 3 PHASELOCATION / VENTILATIONThe welder should be located to provide an unrestrict-ed flow of clean, cool air to the coolin

INSTALLATIONA-7 A-7RANGER® 3 PHASE120 V GFCI DUPLEX RECEPTACLESA GFCI (Ground Fault Circuit Interrupter) electricalreceptacle is a device to pro

INSTALLATIONA-8 A-8RANGER® 3 PHASEAll auxiliary power is protected by circuit breakers withthe following values:The 120V has 20 amp circuit breakers f

INSTALLATIONA-9 A-9RANGER® 3 PHASE240 Volt60 Hz.3-WireServicePOWERCOMPANYMETER240 VOLT120 VOLT120 VOLTLOADNNEUTRALBUSGROUNDPREMISESDISCONNECT

INSTALLATIONA-10 A-10RANGER® 3 PHASE RANGER® 3 PHASE Extension Cord Length Recommendations(Use the shortest length extension cor

TABLE OF CONTENTS - OPERATION SECTIONB-1 B-1RANGER® 3 PHASEOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RANGER® 3 PHASESAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work re

OPERATIONB-2 B-2RANGER® 3 PHASEWELDER CONTROLS - FUNCTION ANDOPERATIONENGINE SWITCHThe engine switch is used to Start the Engine, SelectHigh Idle

OPERATIONB-3 B-3RANGER® 3 PHASE“ RANGE” SWITCHThe “Range” switch is used to select one of threeamperage ranges with generous overlap f

OPERATIONB-4 B-4RANGER® 3 PHASEWELDING PROCESSFor any electrodes the procedures should be kept with-in the rating of the machine. For electrode inform

OPERATIONB-5 B-5RANGER® 3 PHASESUMMARY OF WELDING PROCESSESCONTROL ELECTRODECABLE IDLE WHEN NOT

OPERATIONB-6 B-6RANGER® 3 PHASESTARTING/SHUTDOWN INSTRUCTIONSSTARTING THE ENGINEBe sure all Pre-Operation Maintenance has been per-formed. Also, read

TABLE OF CONTENTS - ACCESSORIES SECTIONC-1 C-1RANGER® 3 PHASEAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC-2 C-2RANGER® 3 PHASEOPTIONAL EQUIPMENT (Field Installed)K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS - For road, off-roa

ACCESSORIESC-3 C-3RANGER® 3 PHASERECOMMENDED EQUIPMENTSTICKK704 Accessory Kit which includes:• Electrode Holder & Cable• Work Clamp & Cable•

NOTESC-4 C-4RANGER® 3 PHASEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

TABLE OF CONTENTS - MAINTENANCE SECTIOND-1 D-1RANGER® 3 PHASEMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETYii iiRANGER® 3 PHASEFUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes

MAINTENANCED-2 D-2RANGER® 3 PHASEHave qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In

MAINTENANCED-3 D-3RANGER® 3 PHASEUse 4-stroke motor oil that meets or exceeds therequirements for API service classification SG or SH.Al

MAINTENANCED-4 D-4RANGER® 3 PHASEBATTERY1. When replacing, jumping, or otherwise connectingthe battery to the battery cables, the properpolarity mu

MAINTENANCED-5 D-5RANGER® 3 PHASEFIGURE D.1 - MAJOR COMPONENT LOCATION1. CASEFRONT2. OUTPUT RECTIFIER ASSEMBLY3. BASE/UNDERCARRIAGE ASSEMBLY4. ENG

NOTESD-6 D-6RANGER® 3 PHASEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Maste

TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1RANGER® 3 PHASETheory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATIONE-2 E-2RANGER® 3 PHASEFIGURE E.2 - ENGINE COMPONENTS AND OPERATIONNOTE: Unshaded areas of Block LogicDiagram are the subject of dis

THEORY OF OPERATIONE-3 E-3RANGER® 3 PHASEFIGURE E.2 - ROTOR, STATOR AND CONTROL CIRCUITSNOTE: Unshaded areas of Block LogicDiagram are the subject of

THEORY OF OPERATIONE-4 E-4RANGER® 3 PHASEFIGURE E.2 - WELD CIRCUITRYNOTE: Unshaded areas of Block LogicDiagram are the subject of discussionWELD CIRCU

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIRF-1 F-1RANGER® 3 PHASETroubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .

RANGER® 3 PHASESAFETYiii iiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onth

TROUBLESHOOTING AND REPAIRF-2 F-2RANGER® 3 PHASEThis Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions.

TROUBLESHOOTING AND REPAIRF-3 F-3RANGER® 3 PHASESometimes machine failures appear to be due to PCboard failures. These problems can sometimes be

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

ENGINE PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

ENGINE PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

ENGINE PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

WELDING PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURS

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

SAFETYiv ivRANGER® 3 PHASEPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté sp

Slip RingsBrushesLead 219+-Lead 200AFIGURE F.1 – SLIP RINGS AND BRUSHESROTOR VOLTAGE TEST (continued)TEST PROCEDURE1. Using a 5/16” nut driver o

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

Lead 219Lead 200A+-FIGURE F.2 – SLIP RINGSROTOR RESISTANCE TEST (continued)TEST PROCEDURE1. With a 5/16” nut driver or socket, remove the 6s

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

120 VAC GFCI RECEPTACLE120/240 VAC 1 PHASERECEPTACLE480 VAC 3 PHASERECEPTACLETESTRESETLead #3Lead #5Lead #6Lead #3ZYXGNDFIGURE F.3 – RECEPTACLES AND L

FIGURE F.4 – CONTROL PC BOARDAUXILIARY AND FIELD WINDING TEST (continued)FIELD WINDING1. Remove the fuel cap and lift bail rubber gasket.With

NOTESF-18 F-18RANGER® 3 PHASEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

(—)(+)TO POLARITY SWITCH (S2)LEAD 8 TO CHOKE(L1)LEAD 254TO STATOR (LEAD W1)TO STATOR (LEAD S2)TO RANGE SWITCH (S1)AC2AC1FIGURE F.5 – OUTPUT RECTIFIERO

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

SAFETYElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 15

BADCCONTROLL12198-1X4DZ5D1C24C39R4D2X3C31R33R76R95R82R39Q3R47C12R72R67C37R88R45J2R48D3C30C32DZ8D11D10C2R5TP2D21R73D9DZ2DZ10R11Q1R16DZ9R10Q5R52R83R57D1

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

VoltageRegulatorAC LeadDC LeadAC LeadFIGURE F.1 – DOOR REMOVALCHARGING CIRCUIT TEST (continued)TEST PROCEDURE1. Start the engine and run it at high i

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

Blower PaddleFIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHODENGINE THROTTLE ADJUSTMENT TEST (continued)TEST PROCEDUREThis test can be conduct

ThrottlelinkageChokeCable3/8" High IdleAdjustment NutFIGURE F.7HIGH IDLE ADJUSTMENT NUTENGINE THROTTLE ADJUSTMENT TEST (continued)Frequency Count

FIGURE F.9 - 115VAC SUPPLY WAVEFORM (HIGH IDLE- NO LOAD)ENGINE THROTTLE ADJUSTMENT TEST (continued)Oscilloscope Method:1. Connect the oscilloscope to

TROUBLESHOOTING AND REPAIRF-29 F-29RANGER® 3 PHASECH10 volts5 ms50 voltsSCOPE SETTINGSVolts/Div...50V/Div.Horizontal Sweep...5 ms/

TROUBLESHOOTING AND REPAIRF-30 F-30RANGER® 3 PHASEThis is the typical CV output voltagegenerated from a properly operatingmachine. Note tha

TROUBLESHOOTING AND REPAIRF-31 F-31RANGER® 3 PHASEThis is the typical DC output voltagegenerated from a properly operatingmachine. Note tha

SAFETYElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure of the building and otheractiv

TROUBLESHOOTING AND REPAIRF-32 F-32RANGER® 3 PHASEThis is the typical AC output voltagegenerated from a properly operatingmachine. Note that

TROUBLESHOOTING AND REPAIRF-33 F-33RANGER® 3 PHASEThis is NOT the typical CV output volt-age waveform. One output diode isnot functioning. Not

TROUBLESHOOTING AND REPAIRF-34 F-34RANGER® 3 PHASEThis is NOT the typical DC (+) outputvoltage waveform. One output diodeis not functioning. N

TROUBLESHOOTING AND REPAIRF-35 F-35RANGER® 3 PHASEThis is the typical CV output voltagegenerated from a properly operatingmachine. Note that

TROUBLESHOOTING AND REPAIRF-36 F-36RANGER® 3 PHASEThis is the typical DC output voltagegenerated from a properly operatingmachine. Note that

TROUBLESHOOTING AND REPAIRF-37 F-37RANGER® 3 PHASEThis is the typical auxiliary output volt-age generated from a properly operat-ing machine. Note

NOTESF-38 F-38RANGER® 3 PHASEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued)PROCEDURE1. Remove the spark plug wires.2. With a 5/16” nut driver or socket, remove the

7/16" BrushAssemblyBracket BoltsFIGURE F.9 – BRUSH HOLDER MOUNTING BOLTSBRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND RE

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -I IRANGER® 3 PHASEPageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTESF-42 F-42RANGER® 3 PHASEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

PROCEDUREBefore starting the following procedure, refer to thetopic “PC Board Troubleshooting Procedures” at thebeginning of this section

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

(—)(+)TO POLARITY SWITCH (S2)LEAD 8 TO CHOKE(L1)LEAD 254TO STATOR (LEAD W1)TO STATOR (LEAD S2)TO RANGE SWITCH (S1)AC2AC1FIGURE F.11 – OUTPUT RECTIFIER

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

33448810A10A99775B5B1B1B1C1C1A1A10B10B10C10C22665A5AFIGURE F.12 – ENGINE/ROTOR COMPONENT LOCATIONSENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont

ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.)PROCEDURE1. Refer to Figure F.12 for component locations.2. Remove the engine spark plug wires

ROTORTHRU-BOLTFIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATORENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.)ROTOR REMOVAL PROCEDURE1. To re

ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.)REASSEMBLY PROCEDURENOTE: Lincoln Electric recommends that a new bear-ing be installed when you

TABLE OF CONTENTS - INSTALLATION SECTIONA-1 A-1RANGER® 3 PHASEInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RETEST AFTER REPAIRTROUBLESHOOTING AND REPAIRF-52 F-52RANGER® 3 PHASERetest a machine:• If it is rejected under test for any reason that requires you

TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1RANGER® 3 PHASEElectrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ElEcTrical DiaGramSG-2raNGEr® 3 phaSEWiriNG DiaGram - cOmplETE machiNE - m20315STARTERCR1STARTERSOLENOID12 VOLTIDLERSOLENOIDBATTERYAC ACB+SWITCHREGUL

ElEcTrical DiaGramSG-3raNGEr® 3 phaSESchEmaTic - cOmplETE machiNE - l12259L1225 9RANGER 3 PHASE KOHLERMACHINE SCHEMATICNONEL12249BAMBAM-UNLESSOTHERWI

ElEcTrical DiaGramSG-4raNGEr® 3 phaSESchEmaTic - cONTrOl pc bOarD - l12197-1G-4NOTE: This diagram is for reference only. It may not be accurate for a