Lincoln Electric SVM207-A User Manual

RANGER®3 Phase

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For use with machine code number: 11079 & 11419

Safety Depends on You

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 INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.

SVM207-A

January, 2011

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER­FORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered 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 engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. 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
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

RANGER® 3 PHASE

ii ii

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

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 require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and ACGIH
TLV limits using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a res­pirator may be required. Additional precautions are also
required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

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5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

RANGER® 3 PHASE

iii iii

SAFETY

WELDING and CUTTING
SPARKS can cause fire or
explosion.

6.a.
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.

6.h. Also see item 1.c.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

If

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

FOR ELECTRICALLY
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 with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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RANGER® 3 PHASE

iv iv

SAFETY

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 suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

RANGER® 3 PHASE

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

v v

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com­plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national

codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip­ment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

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h) the time of day that welding or other activities are to be carried out.

RANGER® 3 PHASE

vi vi

SAFETY

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 may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con­nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-

1

tions.

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_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

RANGER® 3 PHASE

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-496

RANGER® 3 PHASE

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications.............................................................................................................................A-2

Safety Precautions.....................................................................................................................................A-3

Machine Grounding ...................................................................................................................................A-3

Spark Arrestor............................................................................................................................................A-3

Towing .......................................................................................................................................................A-3

Vehicle Mounting .......................................................................................................................................A-4

Pre-Operation Service ...............................................................................................................................A-4

Welding Output Cables..............................................................................................................................A-5

Angle of Operation.....................................................................................................................................A-5

Lifting .........................................................................................................................................................A-5

TABLE OF CONTENTS - INSTALLATION SECTION

Fuel ... ..................................................................................................................................................A-4

Oil .........................................................................................................................................................A-4

Battery Connections .............................................................................................................................A-4

High Altitude Operation..............................................................................................................................A-5

Muffler Relocation......................................................................................................................................A-5

Location/Ventilation....................................................................................................................................A-6

Connection of Wire Feeders......................................................................................................................A-6

Additional Safety Precautions....................................................................................................................A-6

Welder Operation.......................................................................................................................................A-6

Auxiliary Power ..........................................................................................................................................A-7

Motor Starting ............................................................................................................................................A-8

Stand-by Power Connections ....................................................................................................................A-8

Auxiliary Power While Welding..................................................................................................................A-8

Connection of RANGER® 3PHASE to Premises Wiring (Drawing) ..........................................................A-9

Extension Cord Recommendations .........................................................................................................A-10

Electrical Devices used w/RANGER® 3 PHASE ....................................................................................A-10

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RANGER® 3 PHASE

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER® 3 PHASE (K2337-1 & K2337-2)

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Operating

Speed (RPM)

Displacement

cu. in.

(cu.cm.)

Starting

System

Capacities

K2337-1

Kohler

CH20S

K2337-2

Kohler

CH23S

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic

Ignition

RATED OUTPUT @ 104°F (40°C)- WELDER

RATED OUTPUT @ 104°F (40°C)- GENERATOR

20 HP @

3600 RPM

23 HP @

3600 RPM

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

High Idle 3700

Full Load 3500

Low Idle 2200

Welding Output

Auxiliary Power

38(624)

Kohler

CH20S

41(674)

Kohler

CH23S

1

12VDC
Battery

Electric Start

Group 58

Battery

(435 cold

cranking

amps)

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

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11,500 Watts Peak,10,500 Watts Continuous, 3 Phase 60 Hz AC,480V

10,500 Watts Peak, 9500 Watts Continuous, Single Phase 60 Hz AC,120V/240V

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.1 in. 42.3 in. 538 lbs.
770 mm 485 mm 1074 mm (244kg)

1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.
When welding available auxiliary power will be reduced.

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RANGER® 3 PHASE

A-3 A-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, it’s
frame must be electrically bonded to the metal frame of
the vehicle. Use a #8 or larger copper wire connected
between the machine grounding stud and the frame of
the vehicle.

Where this engine driven welder is connected to
premises wiring such as that in your home or shop, it’s
frame must be connected to the system earth ground.
See further connection instructions in the section enti­tled “Standby Power Connections”, as well as the arti­cle on grounding in the latest National Electrical Code
and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The National Electrical
Code lists a number of alternate means of grounding
electrical equipment. A machine grounding stud
marked with the symbol is provided on the front of
the welder.

SPARK ARRESTER

See additional warning information at the

front of this operator’s manual.

-----------------------------------------------------------

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.).

WARNING

To prevent dangerous electric shock, other equip­ment to which this engine driven welder supplies
power must:

• be grounded to the frame of the welder using a

grounded type plug, or be double insulated.

Do not ground the machine to a pipe that carries
explosive or combustible material.

------------------------------------------------------------------------

Some federal, state, or local laws may require that
gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this welder does not
qualify as a spark arrester. When required by local reg­ulations, the K894-1 spark arrester must be installed
and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

------------------------------------------------------------------------

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincoln’s K957-1. If the user adapts a non-Lincoln trail­er, he must assume responsibility that the method of
attachment and usage does not result in a safety haz­ard nor damage the welding equipment. Some of the
factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equip­ment and likely additional attachments.

(1)

is

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2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue
stress to the framework.

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RANGER® 3 PHASE

A-4 A-4

3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.

4. Typical conditions of use, i.e., travel speed; rough­ness of surface on which the trailer will be operated;
environmental conditions.

5. Conformance with federal, state and local laws

(1) Consult applicable federal, state and local laws regarding specif-

ic requirements for use on public highways.

VEHICLE MOUNTING

INSTALLATION

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.

(1)

-----------------------------------------------------------------------

WARNING

• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in or weld to the RANGER®®
10,000 or the RANGER®® 10,000
PLUS base.

WARNING

Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.

• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.

• Distribute, balance and secure loads so vehicle
is stable under conditions of use.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufacture’s instructions.

------------------------------------------------------------------------

OIL

LUBRICATION  SYSTEM  CAPACITY

(INCLUDING  FILTER)

Kohler CH20S / CH23S - 2.0 Quarts (1.9 Liters)

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, add oil as required. Make cer­tain that the oil filler cap is tightened securely. Refer to
the engine Owner’s Manual for specific oil recommen­dations.

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance
instructions supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from
tank.

• Do not leave unattended while fuel­ing.

• Wipe up spilled fuel and allow fumes
to clear before starting engine.

GASOLINE

can cause fire
or explosion.

• Do not overfill tank, fuel expansion
may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

CAUTION

BATTERY CONNECTIONS

Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.

-----------------------------------------------------------------------

This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is dis­charged and does not have enough power to start the
engine, see the battery charging instructions in the
Battery section.

NOTE: This machine is furnished with a wet charged

battery; if unused for several months, the bat­tery may require a booster charge. Be careful
to charge the battery with the correct polarity.

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RANGER® 3 PHASE

A-5 A-5

INSTALLATION

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 neces­sary. Loose connections will result in overheating of the
output studs.

When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated are
the distance from the welder to work and back to the
welder again. Cable sizes are increased for greater
lengths primarily for the purpose of minimizing cable
voltage drop.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

225 Amps

100% Duty Cycle

0-100 Ft.

100-200 Ft.

200-250 Ft.

1 AWG

1 AWG

1/0 AWG

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when
lifting.

• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer
or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, elder output de-rating may be necessary.

For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above 3000ft. (914m).

If operation will consistently be at altitudes above 5,000 ft.
(1525m), a carburetor jet designed for high altitudes should
be installed. This will result in better fuel economy, cleaner
exhaust and longer spark plug life. It will not give increased
power. Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine manu­facturer.

ANGLE OF OPERATION

Internal combustion engines are designed to run in a
level condition which is where the optimum perfor­mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintaining
the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.

When operating at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.

LIFTING

The RANGER® 3 PHASE weighs approximately 575
lbs. with a full tank of gasoline. A lift bail is mounted to
the machine and should always be used when lifting
the machine.

CAUTION

Do not operate with a high altitude jet installed at alti­tudes below 5000 ft. This will result in the engine running
too lean and result in higher engine operating tempera­tures which can shorten engine life.

--------------------------------------------------------------------------------

Muffler Relocation

WARNING

Shut off welder and allow muffler to cool before touch-

•

ing muffler.

--------------------------------------------------------------------------------

The RANGER® 3 PHASE is shipped with the exhaust com­ing out on the left side. The exhaust can be changed to the
opposite side by removing the two screws that hold the
exhaust port cover in place and installing the cover on the
opposite side. (Operating the RANGER® 3 Phase machine
without the covers in place will result in a higher noise level
and no increase in machine output.)

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RANGER® 3 PHASE

A-6 A-6

INSTALLATION

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LOCATION / VENTILATION

The welder should be located to provide an unrestrict­ed 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
outside area.

STACKING

RANGER® 3 PHASE machines cannot be stacked.

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off welder before making any electrical
connections.

------------------------------------------------------------------------

WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER

The LN-15 has an internal contactor and the electrode
is not energized until the gun trigger is closed. When
the gun trigger is closed the wire will begin to feed and
the welding process is started.
Note: LN-15 Control Cable model will not work with

the RANGER® 3PHASE.

a. Shut the welder off.

Connect the electrode cable from the LN-15 to

b.

the

“ELECTRODE” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.

c. Set the Polarity switch to the desired polarity, either

DC (-) or DC (+).

d. Attach the single lead from the front of the LN-15

to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.

e. Set the “RANGE” switch to the “WIRE FEED-CV”

position

f. Place the Engine switch in the “High Idle” position.
g. Adjust the wire feed speed at the LN-15 and adjust

the welding voltage with the output “CONTROL” at
the welder.

CONNECTION OF THE LN-25 / LN25PRO / LN-25
PRO DUAL

Note: LN-25PRO Dual Control Cable model will not

work with the RANGER® 3 PHASEe.

a. Shut the welder off.

Connect the electrode cable from the LN-25 to

b.

the

“ELECTRODE” terminal of the welder. Connect
the work cable to the “TO WORK” terminal of the
welder.

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Output “CONTROL” must be set above 3.

c. Position the welder “Polarity” switch to the desired

polarity, either DC (-) or DC (+).

d. Position the “RANGE” switch to the “WIRE FEED”

position.

e. Attach the single lead from the LN-25 control box

to the work using the spring clip on the end of the

lead - it carries no welding current.
f. Place the engine switch in the “AUTO” position.
g. Adjust wire feed speed at the LN-25 and adjust the

welding voltage with the output “CONTROL” at the

welder.
NOTE: The welding electrode is energized at all times,

unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the
LN-25 contactor may not pull in.

CONNECTION OF K930-2 TIG MODULE TO THE
RANGER® 3 PHASE.

The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.

NOTE: The TIG Module does not require the use of a

high frequency bypass capacitor. However, if
any other high frequency equipment is used, a
Bypass Capacitor Kit (T12246) must be
installed in the RANGER® 3 PHASE.

INSTRUCTIONS

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case sides
in place as this provides maximum protection from
moving parts and assures proper cooling air flow.

Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Owner’s Manual.

WELDER OPERATION

WELDER OUTPUT

• Maximum Open Circuit Voltage at 3700 RPM is

80 Volts RMS.

• Duty Cycle is the percentage of time the load is

being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty Cycle
for the RANGER® 3 PHASE is 100%.

RANGER® 3 PHASE

Constant Current 225 Amps AC @ 25 Volts

210 Amps DC @ 25 Volts

Constant Voltage 200 Amps DC @ 20 Volts

RANGER® 3 PHASE

A-7 A-7

GND

120 V

120 V*

240 V

*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)

GND

480 V

Y

(FOR ALL SINGLE AND

X

Z

THREE PHASE LOADS)

INSTALLATION

AUXILIARY POWER

CAUTION

Do not connect any plugs that connect to the
power receptacles in parallel.

------------------------------------------------------------------------

Start the engine and set the “IDLER” control switch to
the “High Idle” mode. Set the “CONTROL” to 10.
Voltage is now correct at the receptacles for auxiliary
power. This must be done before a tripped GFCI
receptacle can be reset properly. See the MAINTE­NANCE section for more detailed information on test­ing and resetting the GFCI receptacle.

The RANGER® 3 PHASE can provide both three
phase and single phase power, up to 11,500 watts of
480 volts AC, three phase 60Hz power for peak use,
and up to 10,500 watts of 480 volts AC, three phase
60Hz power for continuous use, up to 10,500 watts of
120/240 volts AC, single phase 60Hz power for peak
use, and up to 9,500 watts of 120/240 volt AC, single
phase 60Hz power for continuous use. The front of the
machine includes four receptacles for connecting the
AC power plugs; one 20 amp 480 volt 3 phase NEMA
receptacle, one 50 amp 120/240 volt NEMA 14-50R
receptacle and two 20 amp 120 volt NEMA 5-20R
receptacles. Output voltage is within +/-10% at all
loads up to rated capacity. Do not use 3 phase power
and single phase power simultaneously. All auxiliary
power is protected by cuircuit breakers.

120/240 VOLT DUAL VOLTAGE RECEPTACLE

The 120/240 volt receptacle can supply up to 40 amps
of 240 volt power to a two wire circuit, up to 40 amps
of 120 volts power from each side of a three wire cir­cuit (up to 80 amps total). Do not connect the 120 volt
circuits in parallel. Current sensing for the automatic
idle feature is only in one leg of the three wire circuit as
shown in Figure A.1.

120 V GFCI DUPLEX RECEPTACLES

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
the receptacle. If a GFCI receptacle is tripped see the
MAINTENANCE section for detailed information on
testing and resetting it. A GFCI receptacle should be
properly tested at least once every month.

The 120V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.

The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle.

480 VOLT 3 PHASE RECEPTACLE WITH GROUND

The 480 volt receptacle can supply 12.6 amps of 3
phase power, or up to 15 amps of single phase power.
A NEMA L16-20P plug is required to use this recepta­cle. The ground (GND) connection is connected to the
machine frame, it is NOT the neutral of the three phase
connection, and should under no circumstances be
connected to the neutral of any 3 phase load. Do not
connect 480V 3 phase to single phase premises
wiring.

If 480 volt single phase load is to be run, the X lead
must be one of the leads in the circuit in order for the
automatic idle to function. Using a NEMA plug L16­20P, connect either X and Y or X and Z to the recepta­cle, as well as the machine ground. See Figure A.2.

NOTE: Use of 3-Phase AC power is not recommend-

ed while welding.

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FIGURE A.1

FIGURE A.2

RANGER® 3 PHASE

A-8 A-8

INSTALLATION

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.

Ground Wire

Periodically check the ground wire at plugs, power
cords and auxiliary loads to ensure that the grounding
circuit is intact and connected.

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a

1.5 hp motor is approximately 20 amperes (10
amperes for 240 volt motors). The motor may be run at
full load when plugged into only one side of the duplex
receptacle. Larger motors through 2 hp can be run pro­vided the receptacle rating as previously stated is not
exceeded. This may necessitate 240V operation only.

The 480 volt 3 phase output of the RANGER® 3
PHASE is capable of running most 480VAC 3 phase
motors up to 10HP. A 10HP motor must be started with
no load on the motor and no other load connected to
the machine, since the full load current of a 10HP
480VAC 3 phase motor is approximately 12.5 amps.
Refer to the reconnect phase output to any load, the
ground at the 3 phase receptacle is NOT the neutral of
3 phase connection, and should under no circum­stance be connected to the neutral of any 3 phase
load.

1. Install a double pole, double throw switch between

the power company meter and the premises dis­connect.

Switch rating must be the same or greater than the
customer’s premises disconnect and service over­current protection.

2. Take necessary steps to assure load is limited to

the capacity of the RANGER® 3 PHASE by
installing a 40 amp 240V double pole circuit break­er. Maximum rated load for the 240V auxiliary is 40
amperes. Loading above 40 amperes will reduce
output voltage below the allowable -10% of rated
voltage which may damage appliances or other
motor-driven equipment.

3. Install a 50 amp 120/240V plug (NEMA type 14-50)

to the Double Pole Circuit Breaker using No. 8, 4
conductor cable of the desired length. (The 50 amp
120/240V plug is available in the optional plug kit.)

4. Plug this cable into the 50 amp 120/240V recepta-

cle on the RANGER® 3 PHASE case front.

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time). Also,
the “Output Control” is set at “10” for maximum auxil­iary power.

TABLE A.1

SIMULTANEOUS WELDING AND POWER***

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STANDBY POWER CONNECTIONS

The RANGER® 3 PHASE is suitable for temporary,
standby, or emergency power using the engine manu­facturer’s recommended maintenance schedule.

The RANGER® 3 PHASE can be permanently
installed as a standby power unit for 240V-3 wire, sin­gle phase 40 ampere service.

WARNING

(Connections must be made by a licensed electrician
who can determine how the 120/240V power can be
adapted to the particular installation and comply with
all applicable electrical codes.) The following informa­tion can be used as a guide by the electrician for most
applications (refer also to the connection diagram
shown in Figure A.1).

------------------------------------------------------------------------

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Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Max. Stick or Wire

Feed Setting None 00

145 Stick Setting 4500 38 23

90 Stick Setting 6500 54

NO WELDING 9500 80

* Each duplex receptacle is limited to 20 amps.

** Not to exceed 40A per 120VAC branch circuit

when splitting the 240 VAC output.

*** Use of 3-Phase AC power is not recommended

while welding.

RANGER® 3 PHASE

Factor) @ 120V

** 27

** 40

*-or- @ 240V

A-9 A-9

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.

240 VOLT

GROUNDED CONDUCTOR

40 AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

INSTALLATION

Figure A.3

CONNECTION OF RANGER® 3 PHASE TO PREMISES WIRING

WARNING

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Connection of RANGER® 3 PHASE to premises wiring
must be done by a licensed electrician and must com­ply with the National Electrical Code and all other
applicable electrical codes. See the Installation Section
for important information about not using the 480V 3
Phase Receptacle for connection to Single Phase
Premises Wiring.

RANGER® 3 PHASE

A-10 A-10

INSTALLATION

ELECTRICAL DEVICE USE WITH THE RANGER® 3 PHASE

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capaci-

tative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe oper­ation. DO NOT RUN THESE

DEVICES WITHOUT ADDI­TIONAL RESISTIVE TYPE
LOADS.

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain

maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required, and
liabilities still exist. DO NOT

USE THESE DEVICES WITH A
RANGER® 3 PHASE

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected
to the RANGER® 3 PHASE machine

RANGER® 3 PHASE Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Current

(Amps)

15
20
15
20
40

Voltage

Volts

120
120
240
240
240

Load

(Watts)

1800
2400
3600
4800
9500

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

30

60

Maximum Allowable Cord Length in ft. (m) for Conductor Size

(9)

(18)

40
30
75
60

Conductor size is based on maximum 2.0% voltage drop.

(12)

(9)
(23)
(18)

150
100

75
50

50

(23)
(15)
(46)
(30)
(15)

125

88
225
175

90

(38)
(27)
(69)
(53)
(27)

175
138
350
275
150

(53)
(42)

(107)

(84)
(46)

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

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RANGER® 3 PHASE

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Starting/Shutdown Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

TABLE OF CONTENTS - OPERATION SECTION

Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

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RANGER® 3 PHASE

B-2 B-2

OPERATION

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door
closed and the side panels in place.

• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The RANGER® 3 PHASE is a twin-cylinder, gasoline
driven, multiprocess arc welder and AC power genera­tor. It is built in a heavy gauge steel case for durability
on the job site.

WELDER CONTROLS - FUNCTION AND
OPERATION

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 “START” position, the engine
starter motor is energized.

When in “HIGH IDLE” ( ) position, the engine will
run continuously at high idle.

When in “AUTO IDLE” ( / ) position, the engine
will run continuously and the idler operates as follows:

• Welding

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.

• Auxiliary Power

With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles,
the engine will accelerate to high speed.  If no
power is being drawn from the receptacles (and
not welding) for 10-14 seconds, the idler reduces
the engine speed to low idle.

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RANGER® 3 PHASE

B-3 B-3

OPERATION

“ 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.

Process Range Setting Current Range

STICK/TIG
(constant current)
(3 range settings)

WIRE FEED

(constant voltage)

(one range setting)

90 Max.

145 Max.

210DC/225AC Max.

15 to 25V

50 to 90 Amps

70 to 145 Amps

120 to 210 (DC) 225(AC)

Up to 200 Amps

CAUTION

Never change the “RANGE” Switch setting while
welding. This will damage the switch.

------------------------------------------------------------------------

“ CONTROL” DIAL

Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and welding
voltage control with the Range switch set in the wire
feed mode.

POLARITY SWITCH

Provides three selectable welding polarities:

AC, DC+ & DC-

CAUTION

Never change the Polarity switch setting while welding.

This will damage the switch.

------------------------------------------------------------------------------------------------

RANGER® 3 PHASE APPROXIMATE FUEL CONSUMPTION

KOHLER

CH20S or CH23S

Low Idle - No Load

2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
225 Amps @ 25 Volts
DC CC Weld Output
210 Amps @ 25 Volts
DC CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power Single Phase
9,500 Watts
Auxiliary Power 3 Phase
10,500 Watts

.35 Gallons/Hour

(1.34 Liters/Hour)

.76 Gallons/Hour

(2.86 Liters/Hour)

1.23 Gallons/Hour
(4.64 Liters/Hour)

1.38 Gallons/Hour
(5.21 Liters/Hour)

1.22 Gallons/Hour
(4.60 Liters/Hour)

1.52 Gallons/Hour)
(5.77 Liters/Hour)

1.64Gallons/Hour)
(6.23 Liters/Hour)

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RANGER® 3 PHASE

B-4 B-4

OPERATION

WELDING PROCESS

For any electrodes the procedures should be kept with­in the rating of the machine. For electrode information

see the appropriate Lincoln publication.

STICK (CONSTANT CURRENT) WELDING

Connect welding cables to the "TO WORK” and
"ELECTRODE” studs. Start the engine. Set the
"Polarity” switch to the desired polarity. The “RANGE”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The “OUTPUT” Control provides fine adjust­ment of the welding current within the select range. For
maximum output within a selected range set the “OUT­PUT” Control at 10. For minimum output within a
selected range set the “OUTPUT” Control at 5. (“OUT­PUT” Control settings below 5 may reduce arc stabili­ty) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUT­PUT” Control near the maximum to achieve the
desired welding current.

RANGE SETTING TYPICAL CURRENT RANGE

ELECTRODE SIZE

90 MAX.

125 MAX.

3/32

1/8

50 TO 90 AMPS

70 TO 145 AMPS

SETTINGS FOR  1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps

The K930-[ ] TIG Module should be used with the
RANGER® 3 PHASE on high idle to maintain satisfac­tory operation. It can be used in the AUTO position but
the delay going to flow idle after welding is ceased will
be increased if the AFTER FLOW CONTROL is set
above 10 seconds.

WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)

®

The Innershield

electrode recommended for use with
the RANGER 3 PHASE is NR®-212-MP. The electrode
sizes and welding ranges that can be used with the
RANGER®3 PHASE are shown in the following table:

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A

210(DC)/225(AC)

MAX.

5/32

120 TO 210(DC),

225(AC) AMPS

The RANGER® 3 PHASE can be used with a broad
range of AC and DC stick electrodes. See “Welding
Tips 1” included with the RANGER 3 PHASE for elec­trodes within the rating of this unit and recommended
welding currents of each.

TIG (CONSTANT CURRENT) WELDING

The K930-[ ] TIG Module installed on a RANGER 3
PHASE provides high frequency and shielding gas
control for AC and DC GTAW (TIG) welding processes.
The TIG Module allows full range output control. After
flow time is adjustable from 0 to 55 seconds.

When using the RANGER® 3 PHASE for AC TIG weld­ing of aluminum, the following settings and electrodes
are recommended:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/16 90 40 - 80 Amps

The RANGER® 3 PHASE is recommended for limited
“MIG” welding (GMAW - gas metal arc welding). The
recommended electrodes are.030” and .035”SuperArc
L-50 and L-56. They must be used with a blended
shielding gas such as C25 (75% Argon - 25% CO

2

The welding ranges that can be used with the
RANGER 3 PHASE are shown in the following table:

Diameter Wire Speed Approximate

(in.) Range In./Min. Current Range

.030 80 - 110 75A to 120A
.035 70 - 130 120A to 170A

ARC GOUGING

The RANGER® 3 PHASE can be used for limited arc
gouging.

Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:

CARBON DIAMETER (in) CURRENT RANGE (DC, electrode positive)

1/8 30 - 60 Amps
5/32 90 - 150 Amps
3/16 200 - 250 Amps

).

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RANGER® 3 PHASE

B-5 B-5

SUMMARY OF WELDING PROCESSES

CONTROL ELECTRODE

CABLE IDLE WHEN NOT TO START

PROCESS USED MODE WELDING WELDING

STICK No AUTO Hot Touch electrode to work.

WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding

TIG, TIG MODULE WITH Yes High Cold Press Arc Start Switch
WITH CONTACTOR KIT contactor closes,
CONTROL CABLE, & ARC welding starts immediately.
START SWITCH

OPERATION

Welding starts immediately
and engine goes to high
idle.

starts immediately and
engine goes to high idle.
NOTE: Output Control
must be set above “3”

WIRE FEED, LN-15 No Auto Cold Press gun trigger.
ACROSS the ARC LN-15 contactor closes,
(has internal contactor) Welding starts immediately

NOTE: Output Control must be

set above “3” on the dial.

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RANGER® 3 PHASE

B-6 B-6

OPERATION

STARTING/SHUTDOWN INSTRUCTIONS

STARTING THE ENGINE

WARNING

• Do not touch electrically live parts
of electrode with skin or wet
clothing.

• Keep flammable material away.

• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.

• Keep your head out of the fumes.

• Use ventilation or exhaust to
remove fumes from breathing zone.

Be sure all Pre-Operation Maintenance has been per­formed. Also, read the Engine Owner’s Manual before
starting for the first time.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.

Stop the engine by placing the Engine switch in the

“OFF” position.

A fuel shut off valve is not required on the RANGER®
3 PHASE because the fuel tank is mounted below the
engine.

BREAK-IN PERIOD

It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi­mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS-

BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.

Remove all loads connected to the AC power recepta­cles. Use the choke control as follows:

KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.

Turn the engine switch to the “start” position and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
and turn the switch to the Auto Idle( / )
position. Do not turn the switch to the “start” position
while the engine is running because this will cause
damage to the ring gear and/or starter motor

After running at high engine speed for 10-14 seconds,
the engine will go to low idle. Allow the engine to warm
up by letting it run at low idle for a few minutes.

The engine manufacturer’s recommendation for the
running time until the first oil change is 5 Hours

The oil filter is to be changed at the second oil change.
Refer to the Engine Owner’s Manual for more informa­tion.

.

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RANGER® 3 PHASE

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

TABLE OF CONTENTS - ACCESSORIES SECTION

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RANGER® 3 PHASE

C-2 C-2

ACCESSORIES

OPTIONAL EQUIPMENT (Field Installed)

K957-1 HEAVY 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
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack

K889-2 & -3 TWO-WHEEL UNDERCARRIAGE - For
moving by hand. Overall Width 29 in (.74m) Both have
pneumatic tires. Puncture proof tires included with
K889-3.

K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR­RIAGE - For moving by hand at construction sites.

Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY) - For mov­ing by hand on a smooth surface. One or two gas cylin­ders can be mounted on the rear of the undercarriage
with the installation of K1745-1 Cylinder Holder(s).
Heavy duty puncture resistant pneumatic tires and
front caster.

K704 ACCESSORY KIT - Includes 35 ft (10.7m) 2/0 AWG
electrode cable, 30 ft. (9.1m) 2/0 AWG work cable, head­shield Filterplate, work clamp and electrode holder. 400 Amp.
Capacity.

K875 ACCESSORY KIT - Includes 20 ft (6.1m) #6 electrode
cable, headshield, filter plate, work clamp , electrode holder
and sample pack of mild steel electrodes 150 Amp. Capacity.
lug, 15ft. (4.6) #6 work cable

K894-1 SPARK ARRESTER KIT - Includes a heavy gauge
steel, approved spark arrester and clamp for easy mounting
to muffler exhaust pipe.

K1816-1 FULL KVA ADAPTER KIT - Plugs into the
120/240V NEMA 14-50R receptacle on the case front (which
accepts 4-prong plugs) and converts it to a NEMA 6-50R
receptacle, (which accepts 3-prong plugs.)

T12153-9 FULL-KVA POWER PLUG - One dual voltage
plug rated at 120/240V, 50 amps.

K930-2 TIG MODULE - Provides high frequency and shield­ing gas control.for AC and DC GTAW (TIG) welding applica­tions. Its compact case is designed foe easy carrying, com­plete with a handle. High frequency bypass is built in
Requires K938-1 Contactor Kit, K936-4 Control Cable, and
K814 Arc Start Switch.

K1745-1 WELDING GAS CYLINDER LPG TANK
HOLDER

Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.

K1788-1 ROLL CAGE - Gives added damage protection.
Attaches to K1737-1, K1770-1, and K957-1.

K886-1 CANVAS COVER -To protect the RANGER 3
PHASE when not in use. Made from attractive red can­vas material which is flame retardant, mildew resistant,
and water repellent.

K802R POWER PLUG KIT- provides four 120V plugs
rated at 15 amps each and one dual voltage, Full KVA
plug rated at 120/240V, 50 amps.

K802N POWER PLUG KIT - Provides four 120V plugs
rated at 20 amps each and one dual voltage, full KVA
plug rated at 120/240V, 50 amps.

K938-1 CONTACTOR KIT - For use with TIG Module,
Provides a “cold” electrode until the triggering device (Arc
Start Switch) is pressed.

K936-4 CONTROL CABLE - Connects TIG Module to
RANGER 3 PHASE. (9 Pin to 115V Plug)

K814 ARC START SWITCH - Attaches to the TIG torch for
convenient finger control.

K937-45 CONTROL CABLE EXTENSION - Allows TIG
Module to be operated at distances up to 200ft. from the
power source. Available in 45ft. (13.7m) Sections.

K939-1 DOCKING KIT - For Mounting the K930-2 TIG
Module on top of the RANGER 3 PHASE.

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RANGER® 3 PHASE

C-3 C-3

ACCESSORIES

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” elec­trode until gun trigger is pressed. Includes gas sole­noid. Requires Drive Roll Kit and Weld Power Cable.

Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.

LN-15

K449 LN-15 - Includes internal contactor for across the

arc operation (no control cable). Provides “cold” elec­trode until gun trigger is pressed. Includes gas sole­noid. Requires Drive Roll Kit and Weld Power Cable.

TIG

PRO TORCH®TIG Torch

• K1783-9 PTA 26V TIG Torch

Magnum Parts Kit and Argon Gas

• KP509 Parts Kit

K930-2 TIG Module (Requires)

• Requires K938-1 Contactor Kit,

• K936-4 Control Cable, and

• K814 Arc Start Switch

Optional TIG Module Accessory:

• K939-1 Docking Kit

• K937-45 Control Cable Extensions (45ft.)

Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Magnum Innershield
Gun and wire bushing is required for gasless welding.

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RANGER® 3 PHASE

C-4 C-4

NOTES

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RANGER® 3 PHASE

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

TABLE OF CONTENTS - MAINTENANCE SECTION

Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Air Cleaner/General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

GFCI Test & Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Engine Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

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RANGER® 3 PHASE

D-2 D-2

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
main t en ance. R em ov e g uards o nl y w he n
necessary and replace them when the mainte­nance re q u iring their removal is co m p lete.
Always use the greatest care when working near
moving parts.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
or el e ct ro de w it h s ki n o r w et
clothing.

• Insulate yourself from wo rk and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

CAUTION

iMake certain that the oil filler cap is securely tight­ened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.

------------------------------------------------------------------------

• OIL - Maintenance schedule for changing the oil and
oil filter after break-in :

Kohler
CH23S

Oil 100 Hrs.

Oil Filter 200 Hrs.

The above schedule is for normal operating conditions.
More frequent oil changes are required with dusty, high
temperature and other severe operating conditions.
Refer to the maintenance section of the Engine
Owner's Manual for more information.

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ENGINE EXHAUST can kill.

• Use in open, well ventilated areas
or vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See addi tio nal w arn ing i nfo rma tio n

throughout this operator’s manual and
the Engine manual as well.

------------------------------------------------------------

Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.

Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, cloth­ing, and tools away from gears, fans, and all other mov­ing parts when starting, operating, or repairing the
equipment.

ROUTINE MAINTENANCE

• At the end of each day’s use, refill the fuel tank to
minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and
add oil if indicated.

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: Engine life will be reduced if the oil and oil fil-

NOTE

ENGINE OIL CHANGE

Drain the oil while the engine is warm to assure rapid
and complete draining.

• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable con­tainer.

• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

• 1.7qt. (1.6 liter)-Kohler

With oil filter replacement:

• 2.0qt. (1.9 liter)-Kohler

RANGER® 3 PHASE

ter are not changed according to the manufac­turer’s recommendation.

D-3 D-3

MAINTENANCE

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 con­tainer to be sure it includes the letters SG or SH.

SAE 10W-30 is recommended for general, all-tempera­ture use, -5 F to 104 F (-20 C to 40 C).

See Engine Owner’s Manual for more specific informa­tion on oil viscosity recommendations.

Wash your hands with soap and water after handling
used oil.

Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.

Do not throw it in the trash, pour it on the ground or
down a drain.

OIL FILTER CHANGE

1. Drain the engine oil.

2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.

3. Clean the filter mounting base, and coat the gasket of
the new oil filter with clean engine oil.

4. Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil fil­ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.

5. Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.

6. Start the engine and check for oil filter leaks.

7. Stop the engine, and check the oil level. If necessary,
add oil to the upper limit mark on the dipstick.

• Blow out the machine with low pressure air peri­odically. In particularly dirty locations, this may be
required once a week.

• Output Ranger Selector and Polarity Switches:

Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the handle
from maximum to minimum setting twice each
morning before starting to weld.

GFCI RECEPTACLE TESTING AND RESET­TING PROCEDURE

The GFCI receptacle should be properly tested at least
once every month or whenever it is tripped. To proper­ly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully remove

any load and check it for damage.

• If the equipment has been shut down, it must be

restarted.

• The equipment needs to be operating at high idle

speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be

tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI recep-

tacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other

product (such as a lamp) into the GFCI receptacle
and turn the product "ON".

• Push the "Test" button located on the GFCI recepta-

cle. The night-light or other product should go "OFF".

• Push the "Reset" button, again. The light or other

product should go "ON" again.

If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI is not working prop­erly or has been incorrectly installed (miswired). If your
GFCI is not working properly, contact a qualified, certi­fied electrician who can assess the situation, rewire the
GFCI if necessary or replace the device.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

AIR CLEANER AND OTHER MAINTENANCE

• Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling the
foam pre-filter is every 25 hours and replacement of
the air cleaner filter every 100 hours. More frequent
servicing is required with dusty operating conditions.
Refer to the maintenance section of the Engine
Owner’s Manual for more information.

• Refer to the maintenance section of the Engine
Owner’s Manual for other scheduled maintenance ,

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary.If brushes are to
be replaced, clean slip rings with a fine emery paper.

CAUTION

Do not attempt to polish slip rings while engine is
running.

------------------------------------------------------------------------

RANGER® 3 PHASE

D-4 D-4

MAINTENANCE

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect to new battery
last.

• CONNECTING A BATTERY CHARGER - Remove bat­tery from welder by disconnecting negative cable first,
then positive cable and battery clamp. When rein­stalling, connect negative cable last. Keep well venti­lated.

• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.

BATTERY

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 charging from an external
charger, disconnect the negative battery cable
first and then the positive battery cable before
attaching the charger leads. Failure to do so
can result in damage to the internal charger
components. When reconnecting the cables,
connect the positive cable first and the negative
cable last.

ENGINE MAINTENANCE PARTS

KOHLER C23S

KOHLER 12 050 01

Oil Filter FRAM PH8172*

Air Filter KOHLER 47 083 03
Element FRAM CA79

Air Filter KOHLER 24 083 02
Pre-Cleaner

Fuel Filter KOHLER 24 050 10

Spark Plugs CHAMPION RC12YC
(Resistor (.030” GAP)

Type)

* Oil capacity increases from 2.0 Qts. to 2.1

Qts. when using this filter.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

HARDWARE

Both English and Metric fasteners are used in this
welder.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

D-5 D-5

22

11

33

44

55

FIGURE D.1 - MAJOR COMPONENT LOCATION

MAINTENANCE

1. CASEFRONT

2. OUTPUT RECTIFIER ASSEMBLY

3. BASE/UNDERCARRIAGE ASSEMBLY

4. ENGINE/ROTOR/STATOR ASSEMBLY

5. CASE TOP & SIDES

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

RANGER® 3 PHASE

D-6 D-6

NOTES

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

RANGER® 3 PHASE

E-1 E-1

IDLER

SOLENOID

OUTPUT

CONTROL

MECHANICAL

ROTATION

FIELD
CAPAC ITOR

SLIP

RINGS

RANGE

SWITCH

OUTPUT

BRIDGE

CHOKE

AC

AC

WORK

TERMINAL

PRINTED CIRCUIT
BOARD

TOROIDTOROID**

ENGINE

FLYWHEEL ALTERNATOR/

VOLTAGE REGULATOR

BATTERY

HOUR
METER

OIL

PRESSURE

SWITCH

+

-

STARTER

FUEL

SHUTOFF

SOLENOID

STARTER

SOLENOID

ENGINE

CONTROL

SWITCH*

4

3

2

1

ZY

3

5

6

X

120 & 230 VOLT

BREAKERS AND

RECEPTACLES

EXCITER

WINDING

AUXILIARY
WINDINGS

WELD WINDINGS

Z X Y

480 VOLT 3 PHASE

BREA KE R AND

RECEPTACLE

W2

C1

W1

TOROIDTOROID**

254

3 6 X

*

Lead 254 - 1 turn through the toroid
Leads 3 & 6 - two turns through the toroid in opposite directions.
Lead X passes though the toroid in the same direction as lead 6

STATOR

+

--

ELECTRODE

TERMINAL

POLARITY

SWITCH

ROTOR

FLASHING

DIODE

E

S2

WAC

REACTOR

7 9

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Engine Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Rotor, Stator and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Weld Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIGURE E.1 BLOCK DIAGRAM

RANGER® 3 PHASE

E-2 E-2

IDLER

SOLENOID

OUTPUT

CONTROL

MECHANICAL

ROTATION

FIELD
CAPAC ITOR

SLIP

RINGS

RANGE

SWITCH

OUTPUT

BRIDGE

CHOKE

AC

AC

WORK

TERMINAL

PRINTED CIRCUIT
BOARD

TOROIDTOROID**

ENGINE

FLYWHEEL ALTERNATOR/

VOLTAGE REGULATOR

BATTERY

HOUR
METER

OIL

PRESSURE

SWITCH

+

-

STARTER

FUEL

SHUTOFF

SOLENOID

STARTER

SOLENOID

ENGINE

CONTROL

SWITCH*

4

3

2

1

Z Y

3

5

6

X

120 & 230 VOLT

BREAKERS AND

RECEPTACLES

EXCITER
WINDING

AUXILIARY
WINDINGS

WELD WINDINGS

Z X Y

480 VOLT 3 PHASE

BREA KE R AND

RECEPTACLE

W2

C1

W1

TOROIDTOROID**

254

3 6 X

*

Lead 254 - 1 turn through the toroid
Leads 3 & 6 - two turns through the toroid in opposite directions.
Lead X passes though the toroid in the same direction as lead 6

STATOR

+

--

ELECTRODE

TERMINAL

POLARITY

SWITCH

ROTOR

FLASHING

DIODE

E

S2

WAC

REACTOR

7 9

THEORY OF OPERATION

FIGURE E.2 - ENGINE COMPONENTS AND OPERATION

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

GENERAL DESCRIPTION

The RANGER® 3 PHASE is a twin cylinder, gasoline
driven, multiprocess arc welder and AC power genera­tor. It is capable of AC or DC Stick (SMAW) or TIG
(GTAW) welding and CV Wire welding, either
Innershield® or MIG (GMAW). The AC power genera­tor is capable of providing 10,500 Watts continuous, 3
Phase 60 Hz. AC 480 volt power or 9500 Watts contin­uous, Single Phase 60 Hz. AC 120/240 volt power.

ENGINE COMPONENTS AND OPERATION

The Engine Control Switch is used to start and stop the
engine and to select the idle mode (High Idle or Auto
Idle). The Fuel Shutoff Solenoid is activated at first by
the Engine Control Switch. Then, as oil pressure builds
up it is held in by the output of the voltage regulator
through the oil pressure switch. If the oil pressure
switch opens for any reason, the Fuel Solenoid will
release and the engine will shut down.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

When the Engine control Switch is released it returns to
the High Idle position.

a delay of approximately 10 seconds, the Idler Solenoid
will energize and the engine will drop to low speed.

When the switch is placed in the Auto Idle position, after

Upon striking an arc or drawing of current from any of
the Auxiliary Power receptcles, the solenoid will release
and the engine will go to the high idle speed. Once the
load is removed, and after a 10 second delay, it will
return to the low idle condition.

The Hour Meter runs whenever the oil pressure switch
is closed to help keep track of running time for mainte­nance concerns.

Turning the Engine Control Switch to the ‘OFF’ Position
will shut down the machine.

RANGER® 3 PHASE

E-3 E-3

IDLER

SOLENOID

OUTPUT

CONTROL

MECHANICAL

ROTATION

FIELD
CAPAC ITOR

SLIP

RINGS

RANGE
SWITCH

OUTPUT

BRIDGE

CHOKE

AC

AC

WORK

TERMINAL

PRINTED CIRCUIT
BOARD

TOROIDTOROID**

ENGINE

FLYWHEEL ALTERNATOR/

VOLTAGE REGULATOR

BATTERY

HOUR
METER

OIL

PRESSURE

SWITCH

+

-

STARTER

FUEL

SHUTOFF

SOLENOID

STARTER

SOLENOID

ENGINE

CONTROL

SWITCH*

4

3

2

1

ZY

3

5

6

X

120 & 230 VOLT

BREAKERS AND

RECEPTACLES

EXCITER
WINDING

AUXILIARY

WINDINGS

WELD WINDINGS

Z X Y

480 VOLT 3 PHASE

BREA KE R AND

RECEPTACLE

W2

C1

W1

TOROIDTOROID**

254

3 6 X

*

Lead 254 - 1 turn through the toroid
Leads 3 & 6 - two turns through the toroid in opposite directions.
Lead X passes though the toroid in the same direction as lead 6

STATOR

+

--

ELECTRODE

TERMINAL

POLARITY

SWITCH

ROTOR

FLASHING

DIODE

E

S2

WAC

REACTOR

7 9

THEORY OF OPERATION

FIGURE E.2 - ROTOR, STATOR AND CONTROL CIRCUITS

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

ROTOR, STATOR & CONTROL CIRCUITS

Once the Engine is running and the oil pressure switch
closes, 12 VDC is fed to the rotor slip rings by way of
the Control PC Board. This “flashing” voltage energizes
the rotor and the resulting spinning magnetic field
induces power into the windings of the stator. The
exciter winding voltage is routed to the Control Board
where it is rectified and regulated and fed back to the
rotor slip rings. . This regulated supply is used to control
the voltage output of the welder. A diode on the PC
Board is used to isolate the exciter voltage from the
engine 12 VDC supply. The Output Control is used to
adjust the weld voltage.

The Idler Circuit is also controlled by the Control PC
Board. A Toroid is used to sense current draw through
either the weld circuit or any of the auxiliary receptacles.
When current is sensed, a signal from the Toroid caus­es the PC Board to release the Idler Solenoid and the
engine goes to high speed.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

RANGER® 3 PHASE

Approximately 10 seconds after the current stops, the
board will re-energize the solenoid and pull the engine
down to the low idle speed. If the Control Power Switch
is in the High Idle position, the signal from the Toroid is
ignored.

The Weld Winding provides the power for welding.
Different portions are used depending on the weld
mode selected. The full winding is used for DC welding
while a tapped off portion (WAC) is used for AC welding.
There is also a tap (C1) used for constant voltage (CV)
welding. The Auxiliary Winding is a 3 phase ‘wye’ con­nected 480 VAC supply. Tapped off of one leg are the
230 VAC single phase and the 120VAC single phase
supplies for the various receptacles. Each of the recep­tacles including the 3 phase receptacle is protected by
an appropriately sized Circuit Breaker.

E-4 E-4

IDLER

SOLENOID

OUTPUT

CONTROL

MECHANICAL

ROTATION

FIELD
CAPAC ITOR

SLIP

RINGS

RANGE
SWITCH

OUTPUT
BRIDGE

CHOKE

AC

AC

WORK

TERMINAL

PRINTED CIRCUIT
BOARD

TOROIDTOROID**

ENGINE

FLYWHEEL ALTERNATOR/

VOLTAGE REGULATOR

BATTERY

HOUR
METER

OIL

PRESSURE

SWITCH

+

-

STARTER

FUEL

SHUTOFF

SOLENOID

STARTER

SOLENOID

ENGINE

CONTROL

SWITCH*

4

3

2

1

ZY

3

5

6

X

120 & 230 VOLT

BREAKERS AND

RECEPTACLES

EXCITER

WINDING

AUXILIARY
WINDINGS

WELD WINDINGS

Z X Y

480 VOLT 3 PHASE

BREA KE R AND

RECEPTACLE

W2

C1

W1

TOROIDTOROID**

254

3 6 X

*

Lead 254 - 1 turn through the toroid
Leads 3 & 6 - two turns through the toroid in opposite directions.
Lead X passes though the toroid in the same direction as lead 6

STATOR

+

--

ELECTRODE

TERMINAL

POLARITY

SWITCH

ROTOR

FLASHING

DIODE

E

S2

WAC

REACTOR

7 9

THEORY OF OPERATION

FIGURE E.2 - WELD CIRCUITRY

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

WELD CIRCUITRY

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 (WAC) for AC welding.

The Reactor Winding is tapped winding to provide the
three constant current (CC) welding ranges. As current
is drawn through the reactor it causes the voltage out­put of the machine to drop off. This action creates the
“drooping” output characteristic that is required for stick
and TIG welding. The C1 tap does not go through the
reactor so there is very little “droop” as the weld current
is increased. It is used to provide the constant voltage
(CV) output that is required for wire welding.

The Polarity Switch is used to select the desired weld
mode — DC+, DC- or AC. It connects either the AC out­put or the proper side of the rectified output to the
WORK and ELECTRODE terminals.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

In AC weld mode, the weld current is routed through
another winding in the Reactor (S2 to E) in order to
improve weld characteristics.

When DC output is selected, the AC weld current is fed
to the Output Rectifier to be converted to DC. The
positve output of the rectifier is then routed through the
Choke to smooth out the ripple and provide good weld­ing characteristics.

Lead #254 is a sense lead that is connected in parallel
to the lead from the Range Switch to the AC side of the
rectifier and as a result shares a portion of the weld cur­rent. It is routed through the toroid to activate the Idler
Circuit when weld current is present.

RANGER® 3 PHASE

F-1 F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Rotor Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Rotor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Auxiliary and Field Winding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15

Output Rectifier Bridge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19

Toroid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21

Charging Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23

Engine Throttle Adjustment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25

Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Normal Open Circuit Voltage Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Typical DC Weld Output Waveform (CV Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-30

Typical DC Weld Output Waveform (CC Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31

Typical AC Weld Output Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-32

Abnormal Open Circuit Weld Voltage Waveform (CV Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

Abnormal Open Circuit DC Weld Voltage Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-34

Normal Open Circuit Weld Voltage Waveform (CV Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35

Normal Open Circuit DC Weld Voltage Waveform (CC Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-36

Normal Open Circuit AC Weld Voltage Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37

Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39

Brush Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39

Printed Circuit Board Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43

Output Rectifier Bridge Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Engine/Rotor Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52

RANGER® 3 PHASE

F-2 F-2

TROUBLESHOOTING AND REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
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.

---------------------------------------------------------------------------------------------------------------------------

This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob­lems, wire feeding problems, and welding
problems.

Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely com­ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com­ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

to eliminate

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAUTION

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 troubleshooting
assistance before you proceed. Call 1-888-935-3877.

-----------------------------------------------------------------------------------------------------------------------------------

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-3 F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK
can kill.

•

Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

2. Check for loose connections at the PC board
to a ss ur e tha t the PC b oa rd is p ro pe rly
connected.

3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:

PC board can be damaged by static electricity.

- Remov e y ou r b od y’s st at ic
charge before opening the static­shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

to a grounded p ar t of the
equipment frame.

- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touch in g the frame to prev en t
stati c buil d- up . Be sure not to
touch any electrically live parts at
the same time.

- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield­ing bag.

- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop­er failure analysis.

4. Test the machine to determine if the failure

sympt om has b een co rrecte d by t he
replacement PC board.

NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.

5. Remo ve the r eplace me nt PC b oa rd and

subst it ute it wit h the orig in al PC boar d to
recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
board was the pro bl em . Rein st al l the
replacement PC board and test the machine.

6. Alwa ys indicat e that this proc edure was

follo we d when warran ty repor ts are to be
submitted.

NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

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RANGER® 3 PHASE

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is Evident.

No weld output and no auxiliary power. Engine runs normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check the brushes for wear and
proper contact to the rotor slip
rings.

RECOMMENDED

COURSE OF ACTION

1. Contact The Lincoln Electric
Service Dept. 1-888-935-3877.

1. Check for the presence of 12
VDC (at the pc board) from lead
#224 to frame ground. This is
the supply voltage to the board
and is present when the engine
is running and the S3 switch is
in the “HIGH” or “AUTO” posi­tion. If the 12VDC is missing
check the leads, switches and
connections associated with the
lead #224. See the Wiring
Diagram.

2. Perform the Rotor Voltage

Test.

3. If Rotor Voltage Test is normal,
then preform the Rotor

Resistance Test.

4. If the Rotor Voltage Test is NOT
normal, perform the Auxiliary

and Field Winding Voltage
Test. The Printed Circuit Board

may be faulty. Replace

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAUTION

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

No weld output in AC or DC Modes. The auxiliary power (480, 23 & 115VAC) is normal. Engine runs normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check the welding cables,
clamps and electrode holder for
loose or broken connections.

2. Check the open circuit voltage
(OCV) at the welder output termi­nals, engine at high idle (3650
RPM). Normal maximum is 73 to
80VAC. Normal DC maximum is
67 to 72VDC. If the OCV is OK
then proceed to Step #2.

RECOMMENDED

COURSE OF ACTION

1. Disconnect lead W1 from the
Output Bridge (D1) and check
for the presence of 80VAC from
lead W1 to lead W2 on the main
stator winding. See the Wiring
Diagram. If the AC voltage is
NOT present, the winding in the
stator may be faulty. Check the
winding for continuity and test to
be sure it is NOT grounded to
the stator iron. Replace the
Sstator if necessary. If the cor­rect AC voltage is present, pro­ceed to step #2.

2. Check the Reactor, Range
Switch (S1) and associated
wires for loose or faulty connec­tions. Check the reactor wind­ing for continuity and test to be
sure it is NOT grounded to the
reactor iron.

No DC welding output. AC welding
output and auxiliary power is nor­mal.

1. Make sure the Polarity Switch is
in the proper position and is
“seated” correctly.

2. Make sure the electrode and
polarity are correct for the
process being used.

3. Check the Choke (L1), Polarity
Switch (S2) and associated
wires for loose or faulty connec­tions. Check the choke winding
for continuity and test to be sure
it is NOT grounded to the choke
iron.

4. Check the weld output terminals
and associated wires for loose
or faulty connections.

5. Perform the Output Bridge
Test.

1. Perform the Output Bridge Test.

2. Check the Choke (L1), the
Polarity Switch (S2) and associ­ated wires for loose or faulty
connections. Check the choke
winding for continuity and test to
be sure it is NOT grounded the
choke iron.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAUTION

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

No AC welding output. DC welding
output and auxiliary power is nor­mal.

No constant voltage (CV) welding output. Constant current (CC) and the auxiliary power are operating normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the Polarity Switch is
in the proper position and is
“seated” correctly.

2. Make sure the electrode is cor­rect for the process being used.

3. Make sure the welding cables are
not coiled or too long.

1. Make sure the Range Switch
(S1) is in the proper position (CV)
and “seated” correctly.

2. Make sure the wire feeder is con­nected correctly.

RECOMMENDED

COURSE OF ACTION

1. Check the operation of the
Polarity Switch (S2). Also check
the associated wires for loose or
faulty connections. See Wiring
Diagram.

2. Check for continuity from lead
“S2” to lead “E” located in the
main stator. See

gram

.

1. Check the operation of the
Range Switch (S1) and check
the associated wires for loose or
faulty connections. See Wiring
Diagram.

2. Check for continuity from lead
C1 to lead W1 located in the
main stator. See Wiring Dia -

gram.

Wiring Dia -

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CAUTION

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Engine will not go to high idle when
attempting to weld or when the aux­iliary power is loaded. Welding out­put and auxiliary power output is
normal when Idler Switch is in the
“HIGH” position.

Engine will not go to high idle when attempting to weld. Welding output is normal when Idler Switch is in “HIGH” position. Automatic idle function works properly when the auxiliary power is loaded.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Automatic idler may not function
if the auxiliary power is loaded to
less than 100 Watts.

1. Make sure the welding cables
and connections are tight.

RECOMMENDED

COURSE OF ACTION

1. Check that the leads are cor­rectly wrapped through the
Toroid. See Wiring Diagram.

2. Perform the Toroid Test.

3. The Printed Circuit Board may
be faulty. Replace.

1. Check for broken or faulty con­nections in the sensing lead
(#254). Make sure the connec­tions are tight at the Output
Rectifier and the Polarity
Switch. See the Wiring
Diagram.

2. Make sure the #254 lead is
wrapped properly through the
Toroid. See the Wiring
Diagram.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAUTION

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Engine will not idle down to low speed. Machine has normal weld output and auxiliary power.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure the Engine Control
Switch (S3) is in the “AUTO”
position.

2. Make sure there is NOT an exter­nal load on the weld terminals or
the auxiliary power receptacles.

RECOMMENDED

COURSE OF ACTION

1. With the Engine Control Switch
in the “AUTO” position, check
for the presence of 12VDC at
leads #213 to #215 located at
the Idler Solenoid. If 12VDC is
present and the Idler Solenoid is
not activating, then the solenoid
may be faulty or there is a
mechanical restriction prevent­ing it from functioning.

2. If there is NOT 12VDC at leads
#213 to #215, then test for
12VDC from lead #213 to
ground (lead #5). See Wiring
Diagram. If 12VDC is present,
then check lead #215 for conti­nuity (zero ohms) from the Idler
Solenoid to the Printed Circuit
Board plug 3J1. If lead #215 is
OK, then the Printed Circuit
Board may be faulty. Replace

Engine will not crank or cranks very slow.

1. Check for loose or faulty battery
cable connections.

2. The battery may be faulty.

3. Check the ammeter to see if the
battery is charging. If not, the
charging circuit may be defec­tive.

3. If there is NOT 12VDC from lead
#213 to ground (lead #5), then
check the Engine Control
Switch (S3) for proper operation
and as sociated wires for loose
or faulty connections. See the
Wiring Diagram.

1. If the battery is replaced or tests
good, then the charging circuit
may be faulty. Perform the
Charging Circuit Test.

2. The starter motor or starter
solenoid may be faulty.

3. The Engine may be hard to
crank due to a mechanical fail­ure in the engine.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAUTION

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-9 F-9

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The Engine shuts off.

Engine does not develop full power.

Engine tries to start when S3 is in start position, then shuts off when switched to run.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ENGINE PROBLEMS

1. The Engine may be low on or out
of fuel.

2. The Oil level may be low. Check
and fill to proper level.

3. The fuel filter may be clogged.

1. The fuel filter may be clogged.
Replace if necessary.

2. The air filter may be clogged.
Replace if necessary.

3. The spark plug(s) may be faulty.
Replace if necessary.

1. O il pressure switc h may be

faulty.

2. Fuel Shutoff Solenoid Diodes

may be open.

RECOMMENDED

COURSE OF ACTION

1. The oil pressure switch may be
faulty. Replace if necessary.

2. The fuel shut off solenoid may
be faulty (Kohler Engines only).

1. Due to wear, the engine may be
in need of repair.

1. Check Oil Switch should show

continuity when running/open
when off Switch. Replace oil
pressure switch if necessary.

2. Check engine diodes in engine

wirin g ha rn es s. Replace if
necessary (Engine Mfg. Part).

Engine will not start with S3 in start position, but then tries to start or does start when S3 is switched to run position.

Engine will not shut off when S3 is placed “OFF” position.

Engine continues to crank when S3 is switched to “RUN” position.

1. E ng in e shutdo wn solenoi d
diodes may be open.

2. Start switch (S3) may be faulty.

1. Fuel shutoff solenoid may be
faulty or stuck open.

2. Start switch (S3) may be faulty.

1. E ng in e s hu td ow n solenoi d
diodes may be shorted.

CAUTION

1. Check Engine diodes in engine
wirin g har ne ss . Replace if
necessary (Engine Mfg. Part).

2. C he ck start switch (S3).
Replace if necessary.

1. Feel solenoid for clicking open
or c lo se d. Re pl ac e if
necessary.

2. C he ck start swit ch (S3 ).
Replace if necessary.

1. Check diodes. Replace Engine

Diodes (Engine Mfg. Part) if
necessary.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-10 F-10

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The welding arc is “cold.” Engine
runs normally (3700 RPM no load).
Auxiliary power is functioning nor­mally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1. Check for loose or faulty connec­tions at the weld output terminals
and welding cable connections.

2. The welding cable may be too
long or coiled, causing an exces­sive voltage drop.

RECOMMENDED

COURSE OF ACTION

1. Check for the correct open cir­cuit voltage (OCV) at the welder
output terminals See the
Machine Diagram. If the cor­rect voltage is present at the
output terminals, then check for
loose connections on the heavy
current carrying leads inside the
RANGER® 8. See Wiring
Diagram.

2. If the OCV is low at the welder
output terminals, perform The

Engine Throttle Adjustment
Test.

3. Perform the Output Rectifier
Bridge Test.

4. Check for shorted or grounded
windings in the reactor and also
in the main stator. See Wiring
Diagram.

Welding output is low with little or no control. Auxiliary output is also low.

1. Check the brushes for wear and
proper contact to the rotor slip
rings.

1. Make up a jumper to connect
the Field Test Point (FTP1) on
the PC Board to lead 219. The
connection can be made at the
board (J1,Pin5), or at the
Negative Exciter Brush. See

Figure F.4 and/or the Wiring
Diagram. If the output comes

up to full strength, the Control
Board is probably defective.
Replace.

2. Perform the Rotor Voltage

Test.

3. If Rotor Voltage Test is normal,
then preform the Rotor

Resistance Test.

4. If the Rotor Voltage Test is NOT
normal, perform the Auxiliary

and Field Winding Voltage
Test. The Printed Circuit Board

may be faulty. Replace

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CAUTION

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 troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-11 F-11

TROUBLESHOOTING AND REPAIR

ROTOR VOLTAGE TEST 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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct DC voltage is being applied to the rotor at maximum
engine speed (3700 RPM). This information will aid the technician in determining if the
generator field is operating properly.

MATERIALS NEEDED

Volt/Ohmmeter
Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

Slip Rings

Brushes

Lead 219

+

-

Lead 200A

F-12 F-12

TROUBLESHOOTING AND REPAIR

ROTOR VOLTAGE TEST (continued)

FIGURE F.1 – SLIP RINGS AND BRUSHES

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 come off with the case top.

4. Remove the case top, then reinstall the fuel cap.

5. With the 5/16” nut driver or socket, remove the 5
screws holding the right case side.

6. Remove the right case side by lifting up and

out.

7. Set the volt/ohmmeter to the DC volts position.

8. Connect the positive meter probe to the brush near­est the rotor lamination (lead 200A). See Figure F.1
for location.

9. Connect the negative meter probe to the other
brush (lead 219).

10. Start the engine and run it at high idle. Set the out­put control to the MAXIMUM position (position

10).]

11. Check the voltage reading on the voltmeter. It
should read between 32 and 45 VDC.

12. If the voltage reading is low or not present, the
generator field is not functioning properly. Perform

the Rotor Resis tance Test.

13. If the voltage reading is normal, the field circuit is
functioning properly. Install the right case side
with the 5 sheet metal screws. Remove the fuel
cap; install the case top and tighten the 6 sheet
metal screws. Install the rubber gasket over the lift
bail and reinstall the fuel cap.

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

RANGER® 3 PHASE

F-13 F-13

TROUBLESHOOTING AND REPAIR

ROTOR RESISTANCE TEST

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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.

MATERIALS NEEDED

Volt/Ohmmeter
Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

Lead 219

Lead 200A

+

-

F-14 F-14

TROUBLESHOOTING AND REPAIR

ROTOR RESISTANCE TEST (continued)

FIGURE F.2 – SLIP RINGS

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. Remove the case top, then replace the fuel cap.

5. Remove the 5 screws holding the right case side.

6. Remove the right case side by lifting up and out.

7. Conduct the test with the gasoline engine OFF.

8. Remove the spark plug wires to prevent accidental
engine kickback or starting.

9. Isolate the rotor electrically by removing the gener­ator brush leads (#219 & #200). Refer to Figure F.2
as you perform the remaining steps.

12. Measure the resistance across the rotor slip rings.

A. Set the ohmmeter on the low scale (X1).

13. Measure the resistance to ground.
A. Set the ohmmeter on the high scale

(X100,000).

B. Place one probe on either of the slip rings.

Place the other probe on any good, unpainted
ground.  The machine ground stud works well.

C. Check the resistance. It should read very high,

at least 0.5 megohm (500,000 ohms).

If the test does not meet the resistance specifica­tions, then the rotor may be faulty. Replace the
rotor.

If the test does meet the resistance specifications,
the rotor is okay.

14. Connect lead 200A to the positive brush, which is
the one nearest the rotor lamination. Connect lead
219 to the negative brush.

15. Reinstall the case side, case top, fuel cap, lift bail
gasket and spark plug wires.

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

B. Check the resistance across the slip rings. It

should read approximately 5 ohms.

RANGER® 3 PHASE

F-15 F-15

TROUBLESHOOTING AND REPAIR

AUXILIARY AND FIELD WINDING TEST

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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct AC voltages are being generated from the stator
windings.

MATERIALS NEEDED

Volt/Ohmmeter
Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

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

YX

GND

F-16 F-16

TROUBLESHOOTING AND REPAIR

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.3 – RECEPTACLES AND LEADS

TEST PROCEDURE

WARNING

ELECTRIC SHOCK
can kill.

•

Turn the machine OFF before
working on equipment or making
the meter connections. Do not

touc h elec t ri ca ll y ho t pa rt s.

AUXILIARY WINDINGS
NOTE: The following tests can be made by carefully

inserting the meter probes into the receptacles
as indicated. If the probes do not make or
maintain contact, the measurements can be
made on the back of the receptacles or on the
appropriate Circuit Breaker. See the Wiring
Diagram.

To test the 120 VAC winding:

1. With the Voltmeter set to read AC Volts (use proper
scale), place the probes in one of the 120VAC
receptacles as shown in Figure F.3.

2. With the Output Control set at ‘10’, Start the engine
and let it run in the HIGH idle mode.

3. The voltmeter should read 120 to 132 volts from
lead #3 to lead #5.

To test the 240 VAC winding:

1. With the Voltmeter set to read AC Volts (use proper
scale), place the probes in the 240VAC receptacle
where shown in Figure F.3.

2. With the Output Control set at ‘10’, Start the engine
and let it run in the HIGH idle mode.

3. The voltmeter should read 240 to 264 volts from
lead #3 to lead #6.

4. Turn the engine OFF.

To test the 480 VAC 3 Phase winding:

1. With the Output Control set at ‘10’, Start the engine
and let it run in the HIGH idle mode.

2. Set the voltmeter to the proper scale and check the
voltage readings per the following table:

PROBES READING

X to Y 480 to 520 VAC

Y to Z 480 to 520 VAC

X to Z 480 to 520 VAC

3. Turn the engine OFF

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

4. Turn the engine OFF.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-17 F-17

B

A

D

C

CONTROL

L12198-1

X4

DZ5

D1

C24

C39

R4

D2

X3

C31

R33

R76

R95

R82

R39

Q3

R47

C12

R72

R67

C37

R88

R45

J2

R48

D3

C30

C32

DZ8

D11

D10

C2

R5

TP2

D21

R73

D9

DZ2

DZ10

R11

Q1

R16

DZ9

R10

Q5

R52

R83

R57

D19

R12

C40

C41

R79

C36

R81

R29

R89

R41

DZ4

R84

R80

Q4

R21

R32

R96

C14

R91R40

C26

R20

R85

R69

C10

C13

R17

R23

C1

R44

D16

X1

R58

R42

R75

R49

D14

C29

R43

DZ7

C38

TP1

D15

R7

R94

DZ1

J1

C23

X5

DZ3

R31

C3

R66

R51

C35

R62

R70

D28

R100

DZ11

R19

B1

C43

R13

C27

R34

D18

R14

C28

R15

R56

R102

R97

R18

C4

C42

R46

R101

R74

R65

B2

R87

D4

R98

Q6

C22

R53

R99

R77

R68

R78

C19

R71

C7

FTP1

FIELD VOLTAGE

(Leads #7 & #9)

16

7 12

Lead #219 (J1, Pin 5)

TROUBLESHOOTING AND REPAIR

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.4 – CONTROL PC BOARD

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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. Start the engine and run it at high idle (3700 RPM).

4. Set the output control to the maximum position
(position 10).

5. Check the AC voltage reading. It should be
between 41 and 45 VAC.

If any one or more of the readings are missing or not
within specifications, then check for loose or broken
wires between the test points and the stator windings.
See the Wiring Diagram. Make sure the windings are
NOT grounded internally to the stator iron. If the leads
are intact, then the stator may be faulty. Replace the
stator.

If the voltage readings are within specifications, then
the windings are good and functioning properly.

6. Reinstall the case side, case top, fuel cap, and lift
bail gasket

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-18 F-18

NOTES

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

RANGER® 3 PHASE

F-19 F-19

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER BRIDGE TEST

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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if there are faulty diodes in the Output Rectifier Bridge.

MATERIALS NEEDED

Volt/Ohmmeter (Analog Meter Preferred)
Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

(—)

(+)

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

F-20 F-20

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER BRIDGE TEST (continued)

FIGURE F.5 – OUTPUT RECTIFIER

TEST PROCEDURE

1. Remove the spark plug wires to prevent accidental
engine kickback or starting.

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 will come off with the case top.

5 Remove the case top, then replace the fuel cap.

6. Rremove the 5 screws holding the right case side.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

7. Remove the right case side by lifting up and out.

8. Conduct the test with the gasoline engine OFF.

9. Locate the Output Rectifier Bridge behind the

machine case front.

10. Put the Polarity Switch in the AC Mode.

11. Unplug the 12 pin connector (J1) from the Control
Board.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

12. Use an Ohmter (analog meter preferred) to test the
Output Rectifier per the following chart:

+ Meter Lead — Meter Lead Meter Reading

AC 1 + LOW < 100Ω

AC 2 + LOW < 100Ω

AC 1 — HIGH >1MΩ

AC 2 — HIGH >1MΩ

NOTE: Meter readings may vary depending on the

If any of the readings are not correct, disconnect the
leads at those terminals and re-test. If still not correct,
replace the Output Rectifier.

If the readings are now correct, check the leads that
were disconnected for shorts or grounds.

RANGER® 3 PHASE

+ AC 1 HIGH >1MΩ

+ AC 2 HIGH >1MΩ

— AC 1 LOW < 100Ω

— AC 2 LOW < 100Ω

type of meter. Typically, all “LOW” readings and
all “HIGH” readings should be similar.

F-21 F-21

TROUBLESHOOTING AND REPAIR

TOROID TEST

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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will aid the technician in determining whether the current sensing toroid is
functioning properly

MATERIALS NEEDED

Volt/Ohmmeter
Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

B

A

D

C

CONTROL

L12198-1

X4

DZ5

D1

C24

C39

R4

D2

X3

C31

R33

R76

R95

R82

R39

Q3

R47

C12

R72

R67

C37

R88

R45

J2

R48

D3

C30

C32

DZ8

D11

D10

C2

R5

TP2

D21

R73

D9

DZ2

DZ10

R11

Q1

R16

DZ9

R10

Q5

R52

R83

R57

D19

R12

C40

C41

R79

C36

R81

R29

R89

R41

DZ4

R84

R80

Q4

R21

R32

R96

C14

R91R40

C26

R20

R85

R69

C10

C13

R17

R23

C1

R44

D16

X1

R58

R42

R75

R49

D14

C29

R43

DZ7

C38

TP1

D15

R7

R94

DZ1

J1

C23

X5

DZ3

R31

C3

R66

R51

C35

R62

R70

D28

R100

DZ11

R19

B1

C43

R13

C27

R34

D18

R14

C28

R15

R56

R102

R97

R18

C4

C42

R46

R101

R74

R65

B2

R87

D4

R98

Q6

C22

R53

R99

R77

R68

R78

C19

R71

C7

FTP1

16

7 12

1

2

3

4

LEAD ‘X’

LEAD 254

LEAD 6

LEAD 3

LEAD 213A

F-22 F-22

TROUBLESHOOTING AND REPAIR

TOROID TEST (continued)

FIGURE F.6 – TOROID ASSEMBLY

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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. Remove the case top, then replace the fuel cap.

5. Remove the screws holding the right case side.

6. Remove the right case side by lifting up and out.

7. Start the engine and set it to AUTO and wait for it to
drop to low idle (2400 rpm).

8. Plug a trouble light with a 100 watt bulb into one of
the 120VAC receptacles.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

The machine should go to High Idle.

9. Shut the engine OFF.

NOTE: If the Toroid needs to be replaced, pay close

RANGER® 3 PHASE

If it does not, measure the voltage across the toroid
leads (260 and 261) at pins 3 and 4 of J2. See
Figure F.6. It should be approximately 2.8VAC.

If the voltage is correct, the Control Board may be
defective.

If the voltage is not correct, the toroid may be
defective.

attention to the direction that the various leads
are routed through it. See the Wiring Diagram
for exact instructions.

F-23 F-23

TROUBLESHOOTING AND REPAIR

CHARGING CIRCUIT TEST

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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the Flywheel Alternator, Regulator, and associated circuitry are
functioning properly.

MATERIALS NEEDED

Volt/Ohmmeter
Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

Voltage
Regulator

AC Lead

DC Lead

AC Lead

F-24 F-24

TROUBLESHOOTING AND REPAIR

CHARGING CIRCUIT TEST (continued)

FIGURE F.1 – DOOR REMOVAL

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
location. Check for 42-52 VAC at the voltage reg­ulator.

3. If the AC voltage is low or not present, the engine
flywheel alternator may be faulty. This is an engine
problem; consult your local engine repair facility.

4. If the voltage reading is correct, then check the out­put of the voltage regulator to determine the charg­ing voltage for the battery. Run the engine at high
idle (3650 RPM). Set the voltmeter for DC volts
and place the Positive meter probe on the middle
lead and the Negative probe on the green ground
wire connected to the voltage regulator. See
Figure F.5.. The meter should read 13-15 VDC.

5. If the DC voltage reading is incorrect or not pre­sent, the voltage regulator may be faulty. Replace
the entire voltage regulator module.

6. If the DC voltage reading is correct, check the
associated wiring and circuitry. See the Wiring
Diagram.

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-25 F-25

TROUBLESHOOTING AND REPAIR

ENGINE THROTTLE ADJUSTMENT TEST

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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

If the machine output is low, this test will determine whether the gasoline engine is oper­ating at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions
for adjusting the throttle to the correct RPM are given.

MATERIALS NEEDED

Misc. Hand Tools
Strobe-tach, frequency counter, oscilloscope, or vibratach
Black or red marking pencil

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RANGER® 3 PHASE

Blower Paddle

F-26 F-26

TROUBLESHOOTING AND REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.6 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD

TEST PROCEDURE

This test can be conducted by any one of four meth­ods.

Strobe-tach Method:

1. With the 5/16” nut driver, remove the 6 sheet metal

2. Remove the rubber gasket (cover seal) from the lift

3. Remove the fuel cap. The rubber gasket for the fill

4. Remove the case top, then replace the fuel cap.

5. Conduct this marking procedure with the gasoline

6. Remove the spark plug wires to prevent accidental

7. With the black or red marking pencil, place a mark

8. Connect the strobe-tach according the manufactur-

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

screws from the case top.

bail.

tube will come off with the case top.

engine OFF.

engine kickback or starting.

on one of the blower paddles. See Figure F.6 for
location.

er’s instructions.

RANGER® 3 PHASE

9. Reconnect the spark plug wires and start the
engine. Direct the strobe-tach light on the blower
paddle and synchronize it to the rotating mark.

10. With the machine at HIGH IDLE the tach should
read between 3700 and 3750 RPM.

With the machine at LOW IDLE the tach should
read between 2150 and 2400 RPM.

11. If either of the readings is incorrect, adjust the
throttle as follows:

Adjust HIGH IDLE: Use the 3/8” wrench to turn the
spring-loaded adjustment nut. See Figure F.8 for
location of the adjustment nut. Turn the nut clock­wise to increase HIGH IDLE speed. Adjust the
speed until the tach reads between 3700 and 3750
RPM.

Adjust LOW IDLE: First make sure there is no load
on the machine. Set the IDLE switch to AUTO and
wait for the engine to change to low idle speed.
Use the 3/8” wrench to adjust the solenoid nut,
which changes the amount of throw in the throttle
lever arm. See Figure F.8 for location of the adjust­ment nut. Adjust the nut until the tach reads
between 2150 and 2400 RPM.

Throttle

linkage

Choke

Cable

3/8" High Idle
Adjustment Nut

F-27 F-27

Solenoid

Housing

3/8" Low Idle

Adjustment

Nut

TROUBLESHOOTING AND REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.7

HIGH IDLE ADJUSTMENT NUT

FIGURE F.8

LOW IDLE ADJUSTMENT NUT

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 HIGH IDLE (3700 RPM), the counter should
read 60.8 to 62.5 Hz. At LOW IDLE (2200 RPM),
the counter should read 38.3 to 41.6 Hz. Note that
these are median measurements; hertz readings
may vary slightly above or below.

3. If either of the readings is incorrect, adjust the
throttle as follows:

Adjust HIGH IDLE: Use the 3/8” wrench to turn the
spring-loaded adjustment nut. See Figure F.7 for
location of the adjustment nut. Turn the nut clock­wise to in crease HIGH IDLE speed. Adjust the
speed until the frequency reads between 60.8 and

62.5 Hz.

Adjust LOW IDLE: First make sure there is no load
on the machine. Set the IDLER switch to AUTO
and wait for the engine to change to low idle speed.
Use the 3/8” wrench to adjust the solenoid nut,
which changes the amount of throw in the throttle
lever arm. See Figure F.8 for location of the adjust­ment nut. Adjust the nut until the frequency reads
between 38.3 and 41.6 Hz.

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-28 F-28

TROUBLESHOOTING AND REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.9 - 115VAC SUPPLY WAVEFORM (HIGH IDLE- NO LOAD)

16.2 ms
CH1

0 volts

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Oscilloscope Method:

1. Connect the oscilloscope to the 115 VAC recepta­cle, according to the manufacturer’s instructions.
At 3700 RPM, the waveform should exhibit a peri­od of 16.2 milliseconds. At 2400 RPM, the wave­form should exhibit a period of 25.0 milliseconds.
Refer to NORMAL OPEN CIRCUIT VOLTAGE
WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO
LOAD in this section of the manual.

2. If either waveform periods is incorrect, adjust the
throttle as follows:

Adjust HIGH IDLE: Use the 3/8” wrench to turn the
spring-loaded adjustment nut. See Figure F.8 for

location of the adjustment nut. Adjust the speed
until the period is 16.2 milliseconds.

Adjust LOW IDLE: First make sure there is no load
on the machine. Set the IDLER switch to AUTO
and wait for the engine to change to low idle speed.
Use the 3/8” wrench to adjust the solenoid nut,
which changes the amount of throw in the throttle

lever arm. See Figure F.8 for location of the
adjustment nut. Adjust the speed until the period is

27.3 milliseconds.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

50 volts

RANGER® 3 PHASE

5 ms

Vibratach Method:

1. Place the vibratach as close to the engine as pos­sible. With the machine case top removed, the top
of the air cleaner is the best location.

2. Start the engine and observe the whip handle of
the vibratach. At HIGH IDLE (3700 RPM), the whip
handle should exhibit maximum oscillation. At
LOW IDLE (2400 RPM), the whip handle should
exhibit minimum oscillation.

Note that these are median measurements; vibrat­ach readings may vary slightly above or below:

3. If either of the vibratach indications is incorrect,
adjust the throttle as follows:

Adjust HIGH IDLE: Use the 3/8” wrench to turn the
spring-loaded adjustment nut. See Figure F.8 for

location of the adjustment nut. Turn the nut clock­wise to increase HIGH IDLE speed. Adjust the
speed until the vibratach whip handle exhibits max­imum oscillation at 3700 to 3750 RPM.

Adjust LOW IDLE: First make sure that there is no
load on the machine. Set the IDLER switch to
AUTO and wait for the engine to change to low idle
speed. Use the 3/8” wrench to adjust the solenoid
nut, which changes the amount of throw in the

throttle lever arm. See Figure F.8 for location of
the adjustment nut. Adjust the speed until the
vibratach whip handle exhibits minimum oscillation
at 2150 to 2400 RPM.

F-29 F-29

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

16.2 ms
CH1

0 volts

50 volts

This is the typical AC output voltage
generated from a properly operating
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 115 VAC receptacle.

5 ms

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-30 F-30

TROUBLESHOOTING AND REPAIR

TYPICAL DC WELD OUTPUT WAVEFORM (CV MODE)

MACHINE LOADED

CH1

0 volts

20 volts

MACHINE LOADED TO 200 AMPS AT 20 VDC

This is the typical CV output voltage
generated from a properly operating
machine. Note that each vertical divi­sion represents 20 volts and that each
horizontal division represents 5 mil­liseconds in time. The machine was
loaded with a resistance grid bank.

Note: Scope probes connected at

machine 115VAC receptacle.

5 ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-31 F-31

TROUBLESHOOTING AND REPAIR

TYPICAL DC WELD OUTPUT WAVEFORM (CC MODE)

MACHINE LOADED

CH1

0 volts

20 volts

5 ms

MACHINE LOADED TO 200 AMPS AT 26 VDC

This is the typical DC output voltage
generated from a properly operating
machine. Note that each vertical divi­sion represents 20 volts and that each
horizontal division represents 5 mil­liseconds in time. The machine was
loaded with a resistance grid bank.

Note: Scope probes connected at

machine 115VAC receptacle.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-32 F-32

TROUBLESHOOTING AND REPAIR

TYPICAL AC WELD OUTPUT WAVEFORM

MACHINE LOADED

CH1

0 volts

20 volts

5 ms

MACHINE LOADED TO 225 AMPS AT 25 VDC

This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical divi­sion represents 20 volts and that each
horizontal division represents 5 mil­liseconds in time. The machine was
loaded with a resistance grid bank.

Note: Scope probes connected at

machine 115VAC receptacle.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-33 F-33

TROUBLESHOOTING AND REPAIR

ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)

HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM

ONE OUTPUT DIODE NOT FUNCTIONING

CH1

0 volts

20 volts

This is NOT the typical CV 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 20 volts and each
horizontal division represents 5 mil­liseconds in time.

Note: Scope probes connected at

machine 115VAC receptacle.

SCOPE SETTINGS

5 ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-34 F-34

TROUBLESHOOTING AND REPAIR

ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM

HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM

ONE OUTPUT DIODE NOT FUNCTIONING

CH1

0 volts

50 volts

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 repre­sents 5 milliseconds in time.

Note: Scope probes connected at

machine 115VAC receptacle.

SCOPE SETTINGS

5 ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Volts/Div.....................50V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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RANGER® 3 PHASE

F-35 F-35

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (CV MODE)

HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM

CH1

20 volts

This is the typical CV output voltage
generated from a properly operating
machine. Note that each vertical divi­sion represents 20 volts and that each
horizontal division represents 5 mil­liseconds in time.

Note: Scope probes connected at

machine 115VAC receptacle.

SCOPE SETTINGS

5 ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-36 F-36

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM (CC MODE)

HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM

CH1

50 volts

This is the typical DC output voltage
generated from a properly operating
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 115VAC receptacle.

SCOPE SETTINGS

5 ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Volts/Div.....................50V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-37 F-37

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM

HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM

CH1

0 volts

50 volts

This is the typical auxiliary output volt­age generated from a properly operat­ing 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 115VAC receptacle.

SCOPE SETTINGS

5 ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Volts/Div.....................50V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-38 F-38

NOTES

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

RANGER® 3 PHASE

F-39 F-39

TROUBLESHOOTING AND REPAIR

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 trou­bleshooting 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

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

RANGER® 3 PHASE

F-40 F-40

TROUBLESHOOTING AND REPAIR

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
tube with come off with the case top.

5. Remove the case top, then reinstall the fuel cap.

6. WIth the 5/16” nut driver, remove the 5 screws
holding the right case side.

7. Remove the right case side by lifting up and out.

8. With the needle nose pliers, gently remove the
blue and the red wires from the brushes. See

Figure F.9.

9. With a 7/16” wrench or socket, remove the brush
holder assembly bracket from the stator frame.

10. With a 5/16” open end wrench, remove the two
screws that secure the brush holder assembly to
the bracket. Slide the brush holder assembly out
of the bracket.

14. To reinstall the brush holder, depress the spring­loaded brushes into the holder and slip a suitable
non-metallic, fairly stiff retainer through the slots at
the top and bottom of the holder. A cable tie works
well, and will hold the brushes up so that you can
easily install the holder.

15. Slide the brush holder assembly back into the
bracket and, with the 5/16” open end wrench,
install the two screws that hold it in place.

16. With the 7/16” wrench, install the brush holder
assembly bracket to the stator frame.

17. Slowly remove the non-metallic retainer from the
brush holder and let the brushes snap back
against the slip rings.

18. With the needle nose pliers, connect the red and
the black wires to the appropriate terminals on the
brushes. The red wire is inboard.

19. Check the wire connections for clearance and
tightness.

20. Reinstall the case side, fuel cap, lift bail gasket,
case top, and spark plug wires.

11. To change the brushes, use a flat head screw dri­ver to pop off the plastic retainer on the back of the
brush holder assembly.

12. Remove the old brushes and insert the new ones.

One corner of the terminal clip is beveled so that
the brush can go in only one way.

13. Snap the plastic retainer back onto the brush hold-

er. The brushes may need some repositioning;
wiggle them slightly to help them seat properly on
the slip rings.

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary. If brushes are
to be replaced, clean slip rings with a fine emery paper.

CAUTION

Do not attempt to polish slip rings while engine is run­ning.

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

RANGER® 3 PHASE

7/16" Brush

Assembly

Bracket Bolts

F-41 F-41

TROUBLESHOOTING AND REPAIR

BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.9 – BRUSH HOLDER MOUNTING BOLTS

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

RANGER® 3 PHASE

F-42 F-42

NOTES

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

RANGER® 3 PHASE

F-43 F-43

TROUBLESHOOTING AND REPAIR

PRINTED CIRCUIT BOARD 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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the printed circuit board for
maintenance or replacement.

MATERIALS NEEDED

Misc. Hand Tools
Wiring Diagram

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

RANGER® 3 PHASE

12 Pin Plug

4 Pin Plug

4 Self Tapping Screws (at corners)

1/4" Q.C. Tabs

F-44 F-44

TROUBLESHOOTING AND REPAIR

PRINTED CIRCUIT BOARD REMOVAL

AND REPLACEMENT PROCEDURE (continued)

FIGURE F.10 – DOOR REMOVAL

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 fuel cap. The rubber gasket for the fill
tube will come off with the case top.

5. Remove the case top, then reinstall the fuel cap.

6. With the 5/16” nut driver, remove the 5 screws
holding the right case side.

7. Remove the right case side by lifting up and out.

8. Remove the 12-pin and 4 pin molex plugs from
the Printed circuit board.

9. Remove leads 7 and 9 from two 1/4” Q.C. connec­tors from the board.

CAUTION

Be sure to follow the recommended static-free meth­ods for handling printed circuit boards. Failure to do so
can result in permanent damage to the equipment.

11. Replace the old printed circuit board with a new
one.

12. Replace 4 self tapping screws previously
removed.

13. Connect the two Molex plugs and the 7 and 9
leads to P.C. Board.

14. Replace any cable ties that were cut during the
removal procedure.

15. Reinstall the case side, fuel cap, lift bail gasket,
case top, and spark plug wires.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

10. With a 1/4” phillips head screw driver, remove four
self tapping screws holding the printed circuit

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

board to the panel.

RANGER® 3 PHASE

F-45 F-45

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER BRIDGE 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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the output rectifier bridge for
maintenance or replacement.

MATERIALS NEEDED

Misc. Hand Tools
Dow Corning 340
Wiring Diagram

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

(—)

(+)

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

F-46 F-46

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL

AND REPLACEMENT PROCEDURE (continued)

FIGURE F.11 – OUTPUT RECTIFIER

PROCEDURE

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 fuel cap. The rubber gasket for the fill
tube will come off with the case top.

5. Remove the case top, then reinstall the fuel cap.

6. With the 5/16” nut driver, remove the 5 screws
holding the right case side.

7. Remove the right case side by lifting up and out.

8. Disconnect the leads from the four terminals of the

rectifier. Note the lead placement and hardware
positioning for reassembly.

9. Loosen the three (3) mounting nuts that hold the

rectifier assembly to the mounting bracket.

NOTE: The mounting nuts are metric (M8) hardware.

Use the proper wrench or an adjustable wrench
to avoid damaging the nuts.

Do not loosen the nuts closest to the heat sinks.

They are factory set to a specific torque.

10. Remove the rectifier assembly from the bracket.

11. Install the replacement rectifier assembly.

12. Re-connect the leads removed in Step 8.
Clean rectifier connection areas with a “very fine”

abrasive to provide a shiny surface.
Use a thin film of heat sink compound (Dow

Corning 340) between the leads and the rectifier
connection points.

Place the leads and hardware exactly as found on
original installation and tighten securely.

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

RANGER® 3 PHASE

F-47 F-47

TROUBLESHOOTING AND REPAIR

ENGINE/ROTOR 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 trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the engine and/or rotor for
maintenance or replacement of either component.

MATERIALS NEEDED

Lincoln Electric Rotor Removal Kit (S20788)

Required to remove rotor from Engine

Misc. Hand Tools

Impact Wrench

Torque Wrench (ft. lbs)

.017 Feeler Gauge

Wiring Diagram

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

33

44

88

10A10A

99

77

5B5B

1B1B

1C1C

1A1A

10B10B

10C10C

22

66

5A5A

F-48 F-48

TROUBLESHOOTING AND REPAIR

ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.)

FIGURE F.12 – ENGINE/ROTOR COMPONENT LOCATIONS

1A. Tolerance Ring
1B. Rotor Thru-Bolt
1C. Blower Fan

2. Kohler Engine

3. Rotor

4. Rotor Shaft Bearing
5A. Brush Bracket
5B. Brush Holder

6. Engine/Stator Mtg. Bolts

7. Lift Bale/Stator

8. Idler Plunger

9. Pull Wire
10A. Idle Spring
10B. Idle Washer
10C. Adjustment Nut

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

F-49 F-49

TROUBLESHOOTING AND REPAIR

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 bail.

5. Remove the fuel cap. The rubber gasket for the fill
tube will come off with the case top.

6. Remove the case top, the reinstall the fuel cap.

7. Remove the 5 screws holding the right case side
and the 5 screws holding the left case side.

8. Remove the case sides by lifting up and out.

9. WIth a 3/8” wrench or socket, remove the battery
cover.

10. Disconnect the negative battery cable, then the
positive battery cable. BE SURE TO DISCON­NECT THE NEGATIVE BATTERY CABLE FIRST.
Remove the battery and set it aside.

11. With a diagonal cutters, cut the cable ties around

the leads from the starter solenoid and disconnect
the leads. Remove lead 209A from the harness
bundle.

12. Disconnect the large black plug in front of the fuel
tank spout.

13. With a 3/8” wrench, remove the cowling covers at
the rear on the stator, both sides of the machine.

14. WIth a 3/8” wrench, remove the two screws that
hold the vertical fan baffle in place. Slide the baf­fle forward toward the rectifier bridge heat sink
assembly.

16. With a 1/4” nut driver, disconnect the engine
choke cable from the engine. Mark the location
of the retainer for reassembly. The other end can
remain connected.

17. Disconnect the idle linkage by unsnapping the
plastic clip at the engine end of the idler rod. Snap
the clip back onto the rod to avoid losing it; remove
the rod for reassembly.

18. Disconnect the fuel line from the fuel tank. Plug
the hose and also plug the connection at the fuel
tank to prevent the escape of gasoline fumes.

19. Cut the cable ties and remove leads 224C and 210
from the oil pressure switch.

20. With a 9/16” wrench, remove the ground lead from
the right engine foot mounting bolt.

21. With a 7/16” wrench, remove the brush holder
bracket and leads #219 & 200A from the stator
frame.

22. Support the engine with a chain hoist. Lift bails
are provided on the top of the engine for this pur­pose.

23. With the 9/16” wrench, remove the right and left
engine foot mounting bolts.

24. With the 9/16” wrench, remove the four bolts that
hold the stator to the engine. There is one lock
washer per bolt.

25. With the chain hoist, unweight the engine gently.
Use a pry bar to carefully pry between the engine
and the stator frame in order to unseat the bearing
on the end of the rotor shaft. Separate the engine
and rotor from the stator frame, supporting the
rotor by hand to prevent damage to the rotor core.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

15. Hold the rotor shaft with locking pliers and
unscrew the blower fan. Turn the fan counter-
clockwise. You do not need to remove the fan
from the machine, but be sure it is completely
unscrewed from the rotor shaft

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

26. Move the engine and rotor assembly to a bench.
The engine is off balance with the rotor still
attached; therefore, support the end of the rotor
with a suitably sized block before unhooking the
chain hoist.

NOTE: If the Stator needs to be replaced, it can be dis-

connected and removed/replaced at this point.
Then move on to the Reassembly Procedure.

RANGER® 3 PHASE

ROTOR

THRU-BOLT

F-50 F-50

TROUBLESHOOTING AND REPAIR

ENGINE/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (cont.)

FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR

ROTOR REMOVAL PROCEDURE

1. To remove the rotor, double check that the engine
spark plug wires are disconnected. You will be turn­ing the rotor during this procedure, and this could
accidentally cause engine kickback.

2. With an impact wrench, remove the rotor thru-bolt.
See Figure F.13. If an impact wrench is not avail­able, use a 5/8” box wrench or socket. Hold the
rotor with one hand and shock the wrench with a
mallet to loosen the thru-bolt. The thru-bolt has a
star washer and lock washer, beveled to conform to
the rotor shaft. Pull out the thru-bolt.

3. Install the appropriate long thru-bolt (two are pro­vided) supplied with Lincoln Electric Rotor Removal
Kit S20788. The slot head must face out. Screw in
the bolt with the slot head screw driver until the bolt
bottoms out on the engine crankshaft, about 3/4”.

4. Turning it counterclockwise, screw in the left-hand
thread rotor removal tool from the kit into the rotor
shaft. Support the rotor with one hand and tighten
the tool to approximately 50 ft lbs with the torque or
impact wrench.

5. If the rotor does not pop off, tighten the rotor
removal tool an additional 5 ft lbs. Hold the rotor
with one hand until the rotor pops off the engine
crankshaft.

HINT: If the rotor does not pop off, hit the end of the

rotor removal tool with a hammer.

6. Slide the rotor the rest of the way off the crankshaft.
Be careful not to lose the washer that fits between
the blower fan and the rotor.

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

RANGER® 3 PHASE

F-51 F-51

TROUBLESHOOTING AND REPAIR

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 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 lbs.

3. Support the engine/rotor assembly with the chain
hoist. Fit the rotor into the stator frame, being
careful not to damage the rotor core against the
stator. The bearing will seat into its race about half
way.

4. Insert the four bolts and lock washers that hold the
engine to the stator. With the 9/16” wrench, draw
the bolts up evenly in order to seat the bearing
properly. Tighten to 22 ft-lb. moving diagonally
from bolt to bolt.

5. Check the rotor-stator air gap with the .017 feeler
gauge. The measurement is taken at the blower
end of the rotor before the fan is reinstalled. Turn
the rotor with a pair of locking pliers as necessary
so that the rotor “iron” is up to take the measure­ment. (The rotor has two flat sides, which are not
measured for air gap.) Slide in the gauge. Then
rotate the shaft 180 degrees and measure again.
If the gauge does not clear, loosen the four
engine/stator bolts; retighten the bolts and recheck
the air gap. Repeat until the proper .017 minimum
air gap is achieved.

8. Attach leads to the oil pressure switch refer to
wiring diagram. Replace any cut cable ties.

9. Unplug the fuel tank connection and fuel hose and
connect them.

10. Connect the idle linkage to the idler rod. Snap the
plastic clip back into place.

11. Connect the engine choke cable at the position
marked during disassembly.

12. Screw the blower fan back onto the end of the
rotor shaft. Be sure the washer is in place and
hand tighten the fan only.

13. Reposition the vertical fan baffle and secure it with
the two screws.

14. Install the two cowling covers at the rear of the sta­tor.

15. Connect the black plug in front of the fuel tank fill
spout.

16. Connect the leads to the starter solenoid and
replace any cable ties cut during disassembly.

17. Install the battery. Connect the positive battery
cable, then the negative battery cable. BE SURE
TO CONNECT THE POSITIVE BATTERY CABLE
FIRST.

18. Replace the battery cover.

19. Reinstall the case side, fuel cap, lift bail gasket,
and case top. Connect the spark plug wires.

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

6. Fasten the ground lead to the right engine mount­ing bolt and install both bolts.

7. Install the brush holder bracket back into the sta­tor frame. See the Brush Removal and
Replacement Procedure in this section of the

manual.

RANGER® 3 PHASE

20. See the Retest after Repair Procedure, the fol­lowing topic in this section of the manual.

F-52 F-52

TROUBLESHOOTING AND REPAIR

RETEST AFTER REPAIR

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 RPM

Low Idle 2200-2400 NA

High Idle 3700-3750 3100-3750

WELDER DC OUTPUT

1

Output Control Range Switch Open Circuit Load Volts Load Amps

Volts

Maximum Maximum 65 - 72 21 - 26.5 205 - 240

WELDER AC OUTPUT

1

Output Control Range Switch Open Circuit Load Volts Load Amps

Volts

Maximum Maximum 73 - 80 25 - 32 225 - 275

WELDER CV OUTPUT

1

Output Control Range Switch Open Circuit Load Volts Load Amps

Volts

Maximum Wire Feed CV 29 - 33 19 - 23 200 - 220

AUXILIARY POWER RECEPTACLE OUTPUT

230 Volt Receptacle 115 Volt Receptacle

1

2

Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps

Voltage Voltage

246 - 264 216 - 250 34 - 41.5 123- 132 115 - 130 17.5 - 21

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

FIELD AMPS AND VOLTS

Slip Ring Volts Field Amps

32.0 - 45.0 VDC 6.5 - 7.5 VDC

1

OUTPUT CONTROL set at MAXIMUM (position 10).

2

Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

G-1 G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram Complete Machine (M20315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Schematic – Complete Machine (L12259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3

Schematic – Control PC Board (L12197-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4

TABLE OF CONTENTS - DIAGRAM SECTION

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and/or multi-lay-

ered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER® 3 PHASE

ST

ART

ER

CR1

ST

ART

ER

SOLENOI

D

1

2 VO

LT

IDLER

SOLENOID

BATTERY

AC AC

B+

SWI

TCH

REG

ULATOR

FLYWHEEL ALTER

NATOR

B-

HO

UR

METER

5E

5D

224

ENGINE CO

MPONENTS

22

4A

1

2

3

CONNE

CTOR PIN N

UMBE

RS:

7

6

12

12

34

J1

N.

A.

B

J2

SOLENOID

FUEL
SH

UTOFF

OI

L

PRESSU

RE

TERMINAL BLO

CK

(SEE CONN.

)

20

9A

20

9A

22

4C

210

B

B

GE

NERATOR LEA

D E

ND

(N

OTECAVITY NUMBER

S)

LOCATING TA

B

T

ERMINAL BLOCK

CONNECTION

208

208 (CA

VITY #2)

211 (CA

VITY #3)

224C (CAVITY #4)

13

2

4

211

IGNITI

ON

MOD

ULE

M20315PRINT

215

+

EL

ECTRI

CAL SYMBOLS PER E

1537

STAT

OR

REA

CTOR

S1

WORK

D1

B

ROT

OR

PCB1

W1

W2

C1

S1

R1

R5

C1

-

+

+

R3

STAT

OR

REA

CTOR

+

10

8

1

712

6

9

7

20

0A

219

3

ENGI

NE

C

ROSS

SUP

PORT

GROUND SCREW

GND-E

GN

D

-E

GN

D

-G
200A

219

224

215

76A

5E

75A

77A

J1

8

10

5D

254

R1

OUTPU

T

CO

NTROL

7

5A

7

6A

7

7A

75A

77A

76A

ON U

PPERCAS

EFRO

NT

-

209

+

R

R

U

V

W

ENGI

NE

FOO

T

GN

D-D

GN

D-C

5F

22

4A

GN

D-H

T

ERMINALS

6

5

5L

12

0V/240V

5K

GN

D-D

GN

D-C

J4

J3

J2

GND-G

5L

5K

12

0V

12

0V

12

11

11

3A

3A

CB1
5

0A

5

0A

CB2

CB3
2

0A

2

0A

CB4

3

SILVER COLORED

(WHITE W

IRES)

RANGER 3-PHASE

C

CCW

AL

L CASE FRONT COMPONENTS SHO

WN

VIEWED

FROM

N

.A. G

ROUNDIN

G THIS TERMINAL S

TOPSTHE ENGI

NE.

210

CB7
2

5A

R = RED ORPIN

K

B

=BLACK OR GR

AY

V

=VIO

LET

U = BLU

E

W

=WHI

TE

L

EAD COLOR CODE

:

254

3

12

3

4

261
260

LEADS 254 PASSES THRU
TOROID 1 TIME

211

213

20

8C

6A

6

LEADS

3

AND

6:

2 T

URNS

T

HRU TOROID IN

OPPOS

IT

EDIRECTIONS

6

6

79

J2

S2

E

GND-J

P5

J5

GROUND SCREW
ONLOWER
CASEFRONT

S3

3B

6B

5

6

3

X

Y

Z

Z

X

480 V

3-

PHASE

CB1

15 AMP

X

X

Y

Z

6

3

GND-I

Z

Y

SLIP RING NEAREST LAMINATION

6

3

GND-I

GND-I

ELECTRODE

WAC

W1

WAC

X

LEAD X FROM STATOR TO
PASS THROUGH TOROID
ONCE

(

NOT SHOWN)
IN SAME DIRECTION
AS LEAD 6.

NE

UT

HOT

HOT

NE

UT

12

0V

GFCI

GFCI

LEAD X PASSES THRU TOROID
ONCE

I

NSAMEDIRECTION

AS

L

EAD

6.

21

3A

213A

C

HOKE

L1

PO

SITI

VE

S3

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

G-2

WiriNG DiaGram - cOmplETE machiNE - m20315

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

ElEcTrical DiaGramS

G-2

raNGEr® 3 phaSE

L12259

RANGER 3 PHASE KOHLER

MACHINE SCHEMATIC

NONE

L12249

BAM

BAM

-

U

NLESS

OTHERW

ISE

SPECIFIED

TOLERANCE

MANUFACTURING TOLERANCE PER

E2056

ON 2 PLACE DECIMA

LS IS ± .02

ON 3

PLAC

E DECI

MAL

S I

S ± .002

ON ALL ANGLE

S IS ±

.5 OF A DEG

REE

WITH PUBLISHED STANDARDS.

MA

TERIA

L TO

LERANCE ("") TO AGREE

t

DO N

OT SCALE

THISD

RAW

ING

DRAWNB

Y:

DESIGN INFORMATION

E

NGINEER:

APPROVED:

REFERENCE:

EQUIPMENTTYPE

:

SUBJEC

T:

SCALE:

L12259

MATERIAL
DISPOS

ITI

ON:

APPROVAL
DATE:

PROJECT
NUMBER:

UF

C

RM3563

0

PAGE___

OF

___

1

ENGINE

ERING CONTROLLED

MANUFACTURER:

No

DOCUME

NT

N

UMBER:

DOCUMENT
REVISION:

T

HIS

DOC

UMENT CONTAINS PROP

RIETA

RY INFORMATIONOWNED BY LINC

OLN

GLOBAL, IN

C. AND MAY NOT BE DUPLICATED,C

OMMUNICATED

TO OTHER PARTIES ORUSEDFO

R A

NY PURP

OSE WIT

HOU

T THE EXPRESSWRITTE

N PE

RMISSIONOF LINCOLN

GLOBAL, IN

C.

PROPRI

ETA

RY & CONFIDE

NTIAL:

A

11/20/03

RELEASE

D "A

.02"FROM "X"

CHANGE DETAIL:

1

W2

D1 - BRIDGE RECTIFIE

R

7

21920

0A

W1

L1 CH

OKE

3

5

6

GNDE

12

0 V

AC

24

0 V

AC

12

0 V

AC

ST

ATORAUX

ILI

ARY

POWE

RWINDINGS

9

TWOPOLE

360

0 R

PM

ALTERNATO

R

R1

OUTPUT
CO

NTROL

10K

77A (J1

-4)

76A (J1

-8)

75A (J1-10

)

260
(J

2-4)

261
(J2-3)

TOROID:SENSES
W

ELDOR

AC

POWE

R LOAD TO

A

CTIVATE IDLER

IDLESOLENOID C

OIL

-ENERG

IZE

D FO

R

LOW IDLE.

21

5 (J

1-3)

FIELD & IDLE CONTROL
PC BOARD (L12198-1)

41

TO 45 V

AC

12 VOLT
B

ATTER

Y

B

ATTER

Y

CHA

RGING

ALT/R

EG

FU

EL

SH

UTOF

F

S

OLENOID

ENGINE OIL
PRESSURE
SW

ITCH
OPENS ON
LOW OIL
PRESSURE

HO

UR

MET

ER

22

4 (J1-9)

C

B7 25A

20

9A

20

8

5E

(J

1-2)

FRAM

E

GROU

ND

ENGINE DIO

DES

ELECTRODE
TERMINAL

WORK
TERMINAL

ENGIN

E

STARTE

R

S

OLENOID

ENGIN

E

STARTE

R

22

4C

21

0

+

SLIP RIN

GS

10

TO 50 VDCAT

1.7 TO 6.8 AM

PS

+

4.74 V

0.64 V

15 Ohms

21

3A (J2

-1)

+14V @ NORMALOILPRES.

PCBoar

d

located on rea

r
of fan
baffle nea

r to

p

of machine.

Contr

ol board commo

n is

on

e diode drop a

bov

e

welder frame grou

nd.

Choke mou

nted o

n bas

e in

fro

nt of generato

r.

Rotor

Flashing: 2.5

volts @

0.5 amps.

until

generato

r b

uild-u

p.

78

TO 82 VACBET

WEENW1
ANDW2ATHIGH IDLE AND
MAXIMUM RHEOSTATNO LOAD.

Rectifier mo

unte

d on top of chok

e an

d

A

C reacto

r in fr

ont of generato

r..

RESISTANCE
APP

ROX. 5

OHMS @ 75F

Open Circuit Volts

:

AC

Max

Min

7638

68

34

32 18

DC
CV

Torroid Core locate

d on

w

iring be

hindrece

ptacles.

Bat

ter

y voltage:

12.6 volts at rest
14 volts engine run

ning

J51

-2

J51

-3

J51

-4

Resis

tance of fuel
solenoid cannot be
accurately
measured through
diodes.

J51

- Engine

Connecto

r

If engine oi

l pressure drops b

elow safe

operating pressure, the oi

l press

ure

sw

itch opens removing 1

2 volts

fro

m

circuit 224 sh

utting off

fuel so

lenoid to

stop en

gine. Hourm

ete

r will a

lso stop

running an

d PCB1

wil

l denergize id

le

solenoid.

22

4C

Fu

el solenoid is

mounte

d

on e

ngine carbureto

r.

Engine diodes
ar

e in engine

w

ire harness.

C1

37

TO 41 VACBET

WEENW1

ANDC1 ATHIGH IDL

EAND

MAXIMUM RHEOSTATNO LOAD.

S1

R1

R3

R5

S2

E

S2
POLAR

ITY

SWITC

H

DC+

AC

D

C-

D

C-

DC+

AC

A

C T

APPEDREA

CTOR

ST

ATO

R

W

EL

D

W

INDINGS

ACtappedr

eacto

r mounted

on b

ase in fro

nt of generato

r.

S1 - SELECTORSWITCH

21

0DC

/225AC

14

5

90

CV

REV

OLVING

FIELD

S

+

-

BRUSHES

U

RR

GN

D

B+

AC

AC

21

1

22

4A

25

4

2 TURN

S

2 TURN

S

C

B1

40A

C

B2

40A

C

B4

20A

C

B3

20A

6A

3A

J4

12

11

GN

D-G

6B

3B

GN

D-D

GN

D-C

J2

J3

5L

5K

10(J1

-6)

8 (J1-12)

7

9

219
(J

1-5)

200A
(J1-11

)

OF

F

S3

A

UTO IDLE

(2

)

HIGH IDLE

(3

)

START (

4)

20

8C

21

3

Idle solenoid is
located on top of
generato

r stato

r

assem

bly

+14V INA

UTO IDLE

/ OV I

N HIGH IDLE

+B

AT (1

)

+14V R

UN

12

3

CONNECTOR

PIN NUMBE

RS:

7

6

12

12

34

J1J2

1

4

2

3

S3

OPER

ATIO

N

OF

F

A

UTO

HI

GH

START

123

4

XXX
XX

XX

X

X=

CLOSEDCIRCUIT

.05

5K

13

0V

38

J

LOAD
SENS

OR

+10

V

+

-

IDLE TIME

R

20

FIELD
F

LASHING

CIRCUIT

+10

V

+10VOL

T

RE

GULATOR

CIRCUIT

(

12 SEC.)

+10

V

IDLESOLENOID
CO

IL

SW

ITCHING

TRA

NSI

STO

R

F

LYB

ACK

DIODE

LEVEL
CHANGIN

G

AN

DDRI

VER

CIRCUIT

F

LYB

ACK

DIODE

0.1

FIELD
CURRE

NT

FE

EDBACK

RESI

STO

R

FIELD

CURRE

NT

SW

ITCHING

TRA

NSI

STO

R

+

4700

uF

80VD

C

FIELD

CURRE

NT FE

EDBACK

+

-

+

-

REVERSE V

OL

TAG

E

P

ROTECTIO

NDIODE

47.5

47.5

68.1K

HYSTERESIS SW

ITCH

FE

EDBACKAM

P

ST

ATO

R

EX

CIT

ATIO

N

W

INDINGS

SUPPRESSOR FOR
D1RECTIFIE

R

12 to 14 volts
across coil

when

energized

44

TO 45 V

AC

B

ET

WEENAC

TERMINAL

S

ATHIGH IDL

E

EX

CIT

ATIONW

INDI

NG

V

OLTS M

EASUREDAT

MAX R

HEOSTATHIGH

IDLE N

O LO

AD

J51

-1

NO CONNECTION

IGNITION
MODUL

E

6

3

5

X

1

T
U
R
N

Y

Z

1 TURNSAM

E

DIRECTIONAS

LEAD 6

X

480

V

3

-PH

ASE

C

B5

15 AM

P

3 P

OLE

X

Y

Z

GND

-I

Z

Y

J1

37VA

C

W

AC

74

TO 78 VACBET

WEENWAC

AN

DW2ATHIGH IDL

EAND

MAXIMUM RHEOSTATNO LOAD.

LE

ADS

3 AND 6

PASS

THROUGH TORRO

ID

TWO

TIMES I

N

OPPOS

ITEDIRE

CTIO

NS

(OVE

R-CU

RRENTP

ROTECTE

D)

(OVE

R-CU

RRENTP

ROTECTE

D)

G-3

SchEmaTic - cOmplETE machiNE - l12259

ElEcTrical DiaGramS

G-3

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

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

raNGEr® 3 phaSE

G-4

SchEmaTic - cONTrOl pc bOarD - l12197-1

ElEcTrical DiaGramS

G-4

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

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

raNGEr® 3 phaSE