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Lincoln Electric 110-A User's Manual

1. 115VAC C 42 6 PIN 14 PIN AMPHENOL AMPHENOL ROTOR FIELD FEEDBACK AUXILIARY AND WIRE FEEDER POWER The AC voltage developed in the field winding is fed to the full wave field bridge The DC output of the bridge is filtered by the field capacitor and controlled by the printed circuit board according to the output control setting This filtered and controlled voltage is fed to the rotor winding via the brush and slip ring configura tion As the feedback voltage is increased or de creased the outputs of the weld and auxiliary windings are increased or decreased When full field voltage is applied to the rotor and the engine is running at high speed 3700 RPM a 230 AC voltage is developed in the stator auxiliary winding This winding is tapped to provide 115 VAC The two voltages 115 VAC and 230 VAC are connected to the appropriate receptacles and offer 9000 watts total of AC power The auxiliary wire feeder winding offers 115VAC and is tapped to also provide 42VAC The current draw from this winding should be limited to 8 amps These volt ages and remote control signals are fed through the by pass filter board to the amphenol receptacles NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 9 LINCOLN RANGER 9 4 4 THEORY OF OPERATION am
2. E 7 Q 0 2 gt a Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 57 Biz iac Return to Section TOC Return to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS RANGER 9 INPUT GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Onan 2 3500 RPM 47 7 cu in Electric Fuel 9 gal 34 1 P218 4 cycle Full load 782 cc air cooled Manual Oil 1 8 qt 1 7 gasoline 3700 RPM choke 18 HP High idle 3600 RPM 2200 RPM Low idle RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 100 Duty Cycle 250 AC Constant Current 100 Duty Cycle 250 DC Constant Current 100 Duty Cycle 250 DC Constant Voltage OUTPUT WELDER AND GENERATOR Auxiliary Power for Welding Ranges Max Open Circuit Voltage Auxiliary Power Wire Feeders 40 250 Amps 80 Volts RMS 9000 Continuous Watts 42 60 Hz 8 Amps 2 3700 RPM 80 Amps 115 V 40 Amps 230 V 115V 60 Hz 8 Amps PHYSICAL DIMENSIONS Height Depth With Onan Engine 30 3 in 42 3 in 770 mm 1074 mm LINCOLN amp RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FE au 5 nile 818 EJE Bi o iac Return to Section TOC Return to M
3. nennen nennen B 3 Operational Features and 22 3 Design Features and nnne nennen B 3 Welding Capability tecti ci p oet ren t ie Ee cad Ee bine ee o oed B 4 4 Coritrols and 4 Engine OperatiOIi ls DER QUO ER ER EORR ERE KE DL ARMORUM B 7 Welding add 10 Summary of Welding 0 001 1 nnne nennen nnn nne B 13 UIS ve ee 14 550 2 E n n aen gh Ee e Section C Maintenance me H Section D SEINE D 2 Routine and Periodic Maintenance eem eene nnne D 2 Major Component 5 eee ee ee ee neni mene eene nnne nennen nen nnn D 9 Theory of Operation ntt edem Hp ie re EIL bed eerie eee Section E Troubleshooting and 000 Section F Electrical 5 n pee da ta era o eade ae Section G Parts Manual P 230 LINCOLN E RANGER 9 RANGER 9 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION g 1n Installation gt 8 Technica
4. R72 gt 1 4936 026 1N4936 26 7K Q4 OVERCURRENT PROTECTION D27 1N4936 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This diagram is intended to provide general information regarding PC board function Lincoln Electric discourages board level trou bleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC RANGER 9 RANGER 9 G 5 G 5 DIAGRAMS 020005 FRANCE CANADA AUSTRALIA NOTES CIRCUIT BOARD MAY CHANGE THE INTERCHANGEABILITY THIS DIAGRAM MAY NOT OR CIRCUITRY ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 ON PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS RF BYPASS PC BOARD M16675 SCHEMATIC DOL Se W UINJ Y DOL
5. 0 2 gt a a Return to Master TOC LINCOLN je RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Biz o iac Return to Section TOC Return to Master TOC B 2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before oper ating your RANGER 9 SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan 23 gerous 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause M fire or explosion Keep flammable material away Do not weld on containers that have held combustibles RANGER 9 LINCOLN A WARNING ARC RAYS can burn Wear eye ear and body protection ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside 9 Do not stack a
6. Return to Section TOC Return to Master TOC 20 volts 5 ms MACHINE LOADED TO 250 AMPS AT 25 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 FE au nile 818 EJE 5 5 DIH o iac Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 40 F 40 TROUBLESHOOTING amp REPAIR TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED Return to Section TOC Return to Master TOC CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms MACHINE LOADED TO 250 AMPS AT 25VDC 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 FE au nile 818 EJE 5 5 DIH o iac Note Scope probe
7. nea eels Section E 8 Battery Starter Engine Rotor E Stator and Idler 5 00100 4 04 044 10 nennen nnnm nnns E 2 E Rotor Field Feedback Auxiliary and Wire Feeder Power E 3 Weld Winding Reactor and Range Switch E 4 Output Bridge Capacitors Choke Polarity Switch Contactor and Output Terminals E 5 0 gt SWITCH 8 Do 5 AC CHOKE x 3 L AWA WORK D OUTPUT PART OF ze TERMINAL RECTIFIER RANGE lt 5 x BRIDGE a SWITCH on E TcAPacrrons REACTOR AC OUTPUT CONTACTOR 2 ELECTRODE TERMINAL 7777 ROTATION ENGINE ROTOR STARTER NGS ROTOR O FLYWHEEL Q4 E ALTERNATOR gt Y Y 0 IDLER XO y i 4 SOLENOID o PRINTER gt CIRCUT 5 BATTERY ED T CAPACITOR E 3 115 amp 230VAC RECEPTACLES A BRIDGE BY PASS BOARD coNTACTOR CLOSURE CONTACTOR CLOSURE OUTPUT CONTROL e SWITCH 115VAC 6 PIN 14 PIN AMPHENOL AMPHE
8. gt hz c a nd LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I ie Return to Section TOC Return to Master TOC Q O H is 0 gt 5 a MAINTENANCE SAFETY PRECAUTIONS A WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine Remove guards only when necessary to perform maintenance and replace them when the mainte nance requiring their removal is complete If guards are missing from the machine get replace ments from a Lincoln Distributor See the EXPLOD ED VIEW AND PARTS LIST at the back of this man ual Read the Safety Precautions in the front of this manu al and in the instruction manual for the Onan gasoline engine used with your machine before working on the RANGER 9 Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the recoil housing fans and all other moving parts when starting operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the spark plug lead before servicing the engine See Table D 2 for a summary of mainten
9. Headshield with No 12 filter GC300 work clamp Cooltong 300 insulated electrode holder The cables are rated at 250 amps 4096 duty cycle RANGER 9 LINCOLN Spark Arrester Kit K894 1 A field installed kit for the RANGER 9 gasoline engine muffler exhaust pipe either engine option Includes a heavy gauge steel approved spark arrester and mounting clamp Rotor Removal Kit 520788 A service kit with thru and impact bolts for removing the generator rotor from the tapered engine crankshaft Remote Control K857 Includes a control box with 25 feet 7 5 meters of 4 conductor cable Allows out put voltage to be controlled remotely GFCI Receptacle Kit K896 1 Includes two UL approved 115 volt ground fault circuit interrupter receptacles duplex type with covers and installation instructions Each receptacle is rated 15 amps but the maximum total current from each GFCI duplex is limited to 20 amps The GFCI receptacles replace the two factory installed 115 volt duplex receptacles RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o n 9 HM E oc Return to Section TOC Return to Master TOC 0 2 gt a a ACCESSORIES TIG WELDING TIG Module K930 1 The TIG Module is an acces sory that provides high frequency and shielding gas control for AC and DC GTAW
10. iac Return to Section TOC Return to Master TOC Return to Master TOC F 14 F 14 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS RECOMMENDED COURSE OF ACTION Output control on welder not func Make sure the REMOTE switch 1 Check the Output Control R3 tioning S4 is in the MACHINE CON TROL position The Output Control R3 may be defective Normal resistance is 10 000 ohms Replace if defective Check the REMOTE switch 54 and associated wiring See Wiring Diagram Leads 75 76 and 77 The Printed Circuit board may be faulty Replace Make sure the REMOTE switch S4 is in the REMOTE position The remote control unit may be defective Repair or replace Check the REMOTE switch S4 and associated wiring See Wiring Diagram Leads 75 76 and 77 The bypass PC board may be faulty Check or replace Remote output control not func tioning A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Se
11. The 12VDC battery powers the starter motor When the engine is started and running the battery circuit voltage is fed through the printed circuit board to the rotating field coil in the rotor via a brush and slip ring configuration This excitation flashing voltage mag netizes the rotor lamination The rotor is mechanically coupled to the engine This rotating magnet induces a voltage in the stationary windings of the main alterna tor stator Four separate and isolated windings are incorporated in the stator lamination assembly Each winding set has a different number of turns producing different magnitudes of AC output voltages The four windings are the weld winding the auxiliary power winding the field feedback winding and the auxiliary power winding for wire feeders The field feedback winding provides rotor current during machine opera tion The output of the RANGER 9 is dependent on two criteria the engine RPM and the amount of current in the rotor winding The flywheel alternator located on the engine supplies charging current for the battery circuit The battery circuit provides power for the printed circuit board and also for the idler solenoid The idler solenoid is mechanically connected to the engine throttle linkage If no current is being drawn from the RANGER 9 the printed circuit board activates the idler solenoid which then brings the engine to a low idle state When out put current is sensed either we
12. UH B 3 Ern B 3 Operational Features and Controls sssssssssseeee eene mene B 3 Design Features and 06 eene nnns B 3 Welding Capability 4 Limitations sine 4 Controls Settings cete rete eerte re orn bnt a e d ab Ace ca B 4 Welder Generator 5 5 D Gasoline Engine Ma RO RO a c Rud B 7 Engine Operation 7 Before Starting the Engine 4 eR n d e FRA E ERR e edu B 8 Starting the Englrie er rsen tied Chia terti su Ead B 8 3 Stopping the ENGING recti dea nacre ecce un B 8 g Break in TAA 8 Welding das 10 General Information tte tei ne rne Y REC ar ERR EE E ed B 10 AC DC Constant Current 5 B 10 AC DC TIG Constant Current Welding seems B 11 DC Wire Feed Welding oorr di t tables d a B 12 Summary of Welding 12 nennen nennen B 13 Auxiliaty POWER aloe Cad dean edet o ede eene a d din B 14 General Information tr ea cenae nte e b Y e n ee E e edd B 14 Q
13. ing cables 2 Remove the flanged nuts from the output termi nals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are iden tified on the case front 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is properly connected to the work clamp and cable 6 Check and tighten the connections periodically A CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and sepa rate from one another RANGER 9 LINCOLN Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the sories section of this manual for more information For more information on welding see WELDING OPERATION and tion welding see WELDING OF WELDING PRO CESSES in the Operations section of this manual MACHINE GROUNDING Because the RANGER 9 creates its own power from its gasoline engine driven generator you do not need to connect the machine frame to an earth ground However for best pro tection against electrical shock connect a heavy gauge wire 48 AWG or larger from the ground stud located on the bottom of the output panel to a suitable earth ground such as metal pipe driven into the ground WARNING Do not ground the
14. lation system with a two blade plug Lincoln offers an accessory plug kit that has the right type of plugs See ih fRecessorlas secton of this manual for details If you need ground fault protection for hand held equipment refer to the secto of this manual for the K896 1 GFCI Receptacle kit CIRCUIT BREAKERS Canadian Standards Association CSA versions of the RANGER 9 are equipped with 50 amp circuit breakers 115 230 15 amp circuit breakers on the 115 V receptacles for overload protection Under high heat a breaker may tend to trip at lower loads than it would normally CAUTION Never bypass the circuit breakers Without overload protection the RANGER 9 could overheat and or cause damage to the equipment being used RANGER 9 LINCOLN P PREMISES WIRING The RANGER 9 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule With its three wire grounded neutral generator it can be permanent ly installed as a standby power unit for 230 volt three wire single phase 40 ampere service WARNING Only a licensed certified trained electrician should install the machine to a premises or residential electri cal system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedbacking
15. 0 D 3 PUM Fite tics tees D 3 UEM 0 4 T Crankcase Breather etia ea ed Ee REM cR HER enda D 5 Clean Engine Clean Air Intake Cooling Areas D 5 g Saddle D 5 gt Clean Spark Arrester Screen 4 11 D 5 8 Remove Combustion Deposits 4 10 eene D 5 8 Engine Maintenance 5 D 6 3 Engine Maintenance eene D 6 Battery MaintenahGe us sre e EXER EROR AR RR RAE a RR D 7 Cleaning the Battery esce ree ec b dt ase HER EL PEE GO a D 7 Checking Specific Gravity erben to tee o etr i inne HEEL Fe ede da da D 7 Checking Electrolyte 21 1 0 0 eene nennen nnns D 7 T Charging the iei med exea bn en ea Edere lec el s E D 7 2 Welder Generator Maintenance D 7 5 Sp t D 7 Cleaning Mm D 7 8 Brush Removal Replacement eene D 7 8 Receptacles evinced aul M M D 8 Cable Connections e i irt hec o Nah en ened D 8 Major Component Locations nennen enne nen D 9 js oO 4
16. 4 Set the welder polarity switch to the desired polarity either DC or DC 5 Setthe RANGE switch to the WIRE FEED posi tion 6 Place the IDLER switch in the HIGH position A CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 7 Place the WELDING TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire feed speed at the LN 8 and set the welding voltage with the output CONTROL to a CV constant voltage position at the welder NOTE optional remote control is ued place the output control switch in the CONTROL REMOTE position FIGURE C 6 RANGER 9 LN 8 CONNECTION DIAGRAM KB67 UNIVERSAL ADAPTER PLUG ELECTRODE CABLE TO WIRE FEED UNIT WIRE FEEDER K196 INPUT CABLE LINCOLN E RANGER 9 RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 E 4 p ac Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 ACCESSORIES CONNECTION OF THE LN 742 TO THE RANGER 9 SEE FIGURE C 7 1 Shu
17. AIR DEFLECTOR PLATE RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 4 p ac Return to Section TOC Return to Master TOC 7 2 gt a MAINTENANCE CRANKCASE BREATHER The Onan engine is equipped with a crankcase breather that prevents pressure from building up inside the crankcase pre vents moisture contamination from moisture gasoline vapors or combustion vapors If the breather valve becomes sticky it can cause oil leaks oil consump tion rough idle reduced power and sludge and var nish buildup in the engine The breather cannot be serviced However it should be periodically inspected and replaced if cracked or broken or if the crankcase becomes pressurized Evidence of high pressure includes oil leaks at the seals or excessive oil in the air cleaner housing CLEAN ENGINE Remove dirt and debris with a cloth or brush Do not clean with a forceful spray of water Water might contaminate the fuel system A CAUTION Periodically clean the muffler area to remove com bustible debris CLEAN AIR INTAKE COOLING AREAS To ensure proper cooling make sure the grass screen cooling fins and other external engine surfaces are always kept clean This will prevent overspeeding overheat ing and engine damage due to dirt or debris buildup Ev
18. EJE 5 5 Bi iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC F 34 RANGER 9 F 34 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJ USTMENT TEST continued FIGURE F 7 BLOWER PADDLE MARKED FOR STROBE TACH METHOD Blower Paddle py 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 screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap Conduct this procedure with the gasoline engine OFF Remove the spark plug wires to prevent accidental engine kickback or starting With the black or red marking pencil place a mark on one of the blower paddles See Figure F 7 for location LINCOLN 10 Connect the strobe tach according the manufacturer s instructions 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 Wi
19. FE au 5 nile 818 EJE 5 DIH o iac Return to Section TOC Return to Master TOC C 6 C 6 ACCESSORIES CONNECTION OF THE LN 25 TO THE RANGER 9 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE SEE FIGURE C 3 1 2 RANGER 9 Shut the welder off Connect the electrode cable from the K626 XX Input Cable Assembly to the ELECTRODE termi nal of the welder and to the LN 25 wire feeder Connect the work cable to the TO WORK termi nal of the welder NOTE Welding cable must be sized for current and duty cycle of application Connect the input cable from the K626 XX Input Cable Assembly to the 14 pin amphenol on the RANGER 9 and the input cable plug on the LN 25 Set the welder polarity switch to the desired polarity either DC or DC Set the RANGE switch to the WIRE FEED posi tion Place the IDLER switch to the AUTO or HIGH position as desired A CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 7 Place the WELDING TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire feed speed at the LN 25 and set
20. In general these tests can be con ducted without removing the case wrap around Step 3 PERFORM COMPONENT TESTS 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 sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate 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 referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION 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 216 383 2531 or 1 800 833 9353 LINCOLN RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FE nile 818 EJE Biz iac Return to Section TOC Re
21. OUTPUT CONTROL MAXIMUM CH1 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms 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 output terminals FP lu nile 818 EJE Bi o aic SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger uu Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 AM o n 9 HM E oc Return to Section TOC Return to Master TOC Q O H f 0 gt 5 46 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician 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 reaso
22. Return to Master TOC LINCOLN amp RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC re 9 E Uu i k 5 42 ac Return to Section TOC Return to Master TOC Q O ks 0 4 gt 5 a MAINTENANCE BATTERY MAINTENANCE A WARNING GASES FROM BATTERY can explode 4 Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY Disconnect the negative cable from the old battery first and connect to the new battery last CONNECTING A BATTERY CHARGER Remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Keep the area well ventilated USING A BOOSTER Connect the positive lead to the battery first then connect the negative lead to the engine foot BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near a battery Follow the instructions printed on the battery CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nectthe battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 113 kg of baking soda and 1 quart 0 946 of water Be sure the b
23. and the heavy lead going to the Range switch Note the order of fasteners and leads LINCOLN 17 18 19 20 With the 1 2 wrench install the W1 lead and the heavy lead going to the Polarity switch Note the order of fasteners and leads With the 1 2 wrench install the two heavy leads and leads 236 and 236A to the rectifier negative heat sink Note the order of fasteners bolt and flat washer from the bottom up through the heat sink on top leads flat washer lock washer and nut With the 1 2 wrench install the choke lead the heavy lead and leads 235 3242 to the rectifier positive heat sink Note the order of fasteners bolt and flat washer from the bottom up through the heat sink on top leads flat washer lock washer and nut Reinstall the case side fuel cap lift bale gasket case top and spark plug wire RANGER 9 58 58 TROUBLESHOOTING amp REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedur
24. 115 volts 2 amps will need 230 watts of power 115 x 2 230 You use Table B 6 GENERATOR POWER APPLI CATIONS to determine the wattage requirements of some common types of loads you can power with the RANGER 9 Be sure to read the notes at the bottom of the table TABLE B 4A MAXIMUM CURRENT DRAW FROM 115V DUPLEX RECEPTACLES NO WELDING Powering Motors You can start most 1 5 HP single phase electric motors if there is no load on the motor or other load connected to the RANGER 9 After starting the motor may be run at full load Larger motors up to 2 HP may be started and run as long as you don t exceed the current rating of the receptacle This may mean that only 230 volt motors of this size may be operated Using Auxiliary Power and Welding at the Same Time It is possible to weld and use the RANGER 9 for auxil iary power at the same time However the size of the loads you can power is reduced when you weld See Table 5 this section of the manual for a list of per missible simultaneous welding and load ratings The table assumes that power is being drawn from either a 115 volt or the 230 volt receptacle but not both at the same time NOTE For simultaneous welding and power set the OUTPUT CONTROL at 10 for maximum auxiliary power At settings below 10 only incandescent loads should be connected to the auxiliary recepta cles To use the generator as an auxiliary power supply 1 St
25. 5 5 DIH o iac Return to Section TOC Return to Master TOC Return to Master TOC B 5 OPERATION FIGURE 1 OUTPUT PANEL CONTROLS ORS oe vain RANGER 9 WELDER GENERATOR CONTROLS See Figure B 1 for the location of the following fea tures 1 OUTPUT RANGE SELECTOR Selects continuous current output for constant current stick or TIG applications blue settings and constant voltage wire feed applications red settings The amper ages on the dial correspond to the maximum amperages for each corresponding range setting Never change the range switch setting while welding since this could damage the switch 2 FINE OUTPUT CONTROL Allows fine adjustment of current or voltage within the selected output range 3 POLARITY SWITCH Selects DC DC or AC welding output Color codings aid in the proper selection of stick blue or wire feed red polarity setting The color setting of the polarity switch must match the color setting of the OUTPUT RANGE SELECTOR Never change the polarity switch setting while welding since this could damage the switch RANGER 9 0 URWNE oono q 10 11 12 13 LINCOLN P OUTPUT RANGE SELECTOR FINE OUTPUT CONTROL POLARITY SWITCH CONTROL AT WELDER REMOTE CON
26. Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual FIGURE C 1 RANGER 9 K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM 14 PIN AMPHENOL ELECTRODE CABLE WIRE FEED UNIT TO WORK RANGER 9 LINCOLN A 82 o NOT USED ON RANGER POWER SOURCES SPARE o 2 0 TOGETHER FOR __ 4 9 WELDING OUTPUT 42 VAC 42 o gt C 5 nsvac GNG o POWER SOURCE FRAME CONNECTION 21 WIRE FEEDER VOLTMETER CONNECTION CONNECTS TO WORK TERMINAL OF POWER SOURCE Dn 10K 76 REMOTE OUTPUT CONTROL MIN RANGER 9 Return to Section TOC Return to Master TOC ACCESSORIES Place the WELDING TERMINALS switch in the REMOTELY CONTROLLED position Adjust wire feed speed at the wire feeder and set the welding voltage with the output CONTROL to a CV constant voltage position at the welder NOTE optional remote control is used place the output control switch in the CON Place the IDLER switch in the AUTO position Place the WELDING TERMINALS switch in the ALWAYS ON position Adjust wire feed speed
27. CAPACITOR CD 05 600V 80 20 C19 CAPACITOR PEMF 047 100V 10 C18 CAPACITOR ALEL 100 50V 75 1096 C16 C23 C35 CAPACITOR TAEL 18 15V 10 12 37 38 CAPACITOR TAEL 1 8 20V 10 C10 C11 C15 C17 0 1 50 10 C7 C8 C9 CAPACITOR CD 0047 005 1400V 20 C6 CAPACITOR ALEL 100 15 16V 75 10 C2 CAPACITOR CEMO 820P 50V 5 C1 C13 C14 C29 C30 C31 C32 CAPACITOR CEMO 022 50V 20 C33 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This dia gram is intended to provide general information regarding PC board function Lincoln Electric discour ages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in dam age to the machine RANGER 9 LINCOLN E RANGER 9 DIAGRAMS RF BYPASS PC BOARD M16675 LAYOUT Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 DIH o iac NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board leve
28. E High Idle No Load 3700 RPM 82 Gallons hour 3 10 liters hour CC Weld Output 250 Amps 25 Volts 1 7 Gallons hour 6 5 liters hour DC CC Weld Output 250 Amps Q 25 Volts 1 7 Gallons hour 6 5 liters hour DC CV Weld Output 250 Amps 25 Volts 1 7 Gallons hour 6 5 liters hour Auxiliary Power 9000 kVA 1 7 Gallons hour 6 5 liters hour Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC re 9 E 4 p ac Return to Section TOC Return to Master TOC g o 0 2 gt a B 10 OPERATION WELDING OPERATION GENERAL INFORMATION A WARNING Do not touch electrically live parts or elec trodes with your skin or wet clothing Do not breathe welding fumes or gases Use ventilation or exhaust to remove welding fumes from the breathing area T Keep flammable material away Wear eye ear and body protection The RANGER 9 can deliver from 40 to 250 amps of constant current for AC DC stick welding or from 40 to 250 amps of constant voltage current for DC semiau tomatic wire feed welding AC DC TIG welding is pos sible across the entire range from 40 to to maximum rated output Output ca
29. INPUT CABLE PLUG K592 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 ACCESSORIES CONNECTION OF THE K488 SG CON TROL MODULE AND K487 MAGNUM SPOOL GUN TO THE RANGER 9 SEE FIGURE C 8 1 Shut the welder off 2 Connect the electrode cable from the SG Control Module to the ELECTRODE terminal of the welder Connectthe work cable to the TO WORK terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K691 10 Input Cable to the SG Control Module and the 14 pin amphenol of the RANGER 9 as indicated in Figure C 8 4 Set the slide switch on the SG Control Module to the Lincoln position CAUTION Be sure this switch is set to the Lincoln contact clo sure position before attempting to operate the SG Control Module Incorrect switch position could result in damage to the SG Control Module and or the RANGER 9 5 Set the welder polarity switch to the desired polarity either DC or DC 6 Set the RANGE switch to the WIRE FEED posi tion 7 Place the IDLER switch in the HIGH position A CAUTION Any increase of the high idle engine RPM b
30. Master TOC FE au nile 818 EJE 5 5 DIH ro O iac Return to Section TOC Return to Master TOC Return to Master TOC F 30 RANGER 9 F 30 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST continued FIGURE F 5 LOCATION OF OUTPUT RECTIFIER LEADS Pigtail Output rectifier Bridge Assembly Machine Front TEST PROCEDURE 1 Remove the spark plug wires to prevent accidental engine kickback or starting With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Conduct the test with the gasoline engine OFF Locate the Output Rectifier Bridge behind the machine case front LINCOLN P 10 11 12 13 14 15 16 Ohmmeter Probes With the 1 2 socket wrench remove the nuts and washers holding the diode bridge pigtails and the heavy current carrying leads to the studs located in the middle of the rectifier assembly Note their locations and the order of fasteners for reassembly Electrically isolate the diode pigtails by bending them back into free air With an ohm
31. RANGER 9 F 66 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued ENGINE AND ROTOR REMOVAL PROCEDURE 1 10 11 12 13 14 15 Refer to Figure F 17 for component loca tions Remove the engine spark plug wires With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top the reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side and the 5 screws holding the left case side Remove the case sides by lifting up and out With the 3 8 wrench remove the battery Cover Disconnect the negative battery cable then the positive battery cable BE SURE TO DISCONNECT THE NEGATIVE BAT TERY CABLE FIRST Remove the battery and set it aside With the diagonal cutters cut the cable ties around the leads from the starter sole noid and disconnect the leads Disconnect the large black plug in front of the fuel tank spout With the 3 8 wrench remove the cowling covers at the rear on the stator both sides of the machine With the 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 Hold the rotor shaft with lo
32. SLIP 800 C1 RING NEAREST N ROTOR FIELD LAMINATION REGULATOR 8 DIAGRAM A ENGINE TERMINAL BLOCK CONNECTION 208 CAVITY 3 LOCATING i ENGINE TAB N CROSS WELDER LEAD END SUPPORT NOTE CAVITY NUMBERS 212 N 27 224A8B CAVITY 4 224B CAVITY 2 12 16 93A CLEVELAND OHIO U S A 19113 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels Return to Section TOC Return to Master TOC RANGER 9 RANGER 9 G 4 G 4 DIAGRAMS CONTROL PC BOARD L9062 SCHEMATIC J2 ME Cu 232 amp lt NOT USED V Return to Section TOC Return to Master TOC RANGER 9 SCHEMATIC CONTROL BOARD 2 7 3 018 J TO IDLER D n 216 SWITCH gt J2 m hor a lt 1 2200 017 184936 L EARTH GROUND CONNECTION 57 COMMON CONNECTION SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT 1 17 FRAME CONNECTION SNUBBER Q6 OVERCURRENT PROTECTION C34 4 130V 2 600v aN 1 ser 2 RESET MONO IN 3J
33. TIG welding applica tions It provides contactor control of constant current welding power sources having an internal contactor K930 1 TIG Module is supplied without accessories Arc Start switches Amptrols cables torches and mounting brackets must be purchased separately Docking Kit K939 1 For mounting the K930 1 TIG Module on top of the RANGER 9 Control C able K936 1 Control cable for connecting the K930 1 TIG Module to a RANGER 9 9 Socket at the TIG Module to 14 pin at RANGER 9 Contains circuits 2 4 31 32 75 76 77 and ground Arc Start Switch K814 A remote start switch used in conjunction with the K930 1 TIG Module to energize the output terminals via the TIG Module K812 Hand Amptrol K870 Foot Amptrol NOTE TIG welding requires a Magnum TIG Gun appropriate Magnum Parts Kit and argon gas RANGER 9 LINCOLN SEMIAUTOMATIC FCAW AND MIG WELDING LN 25 Wire Feeder K449 This portable unit provides CC CV for flux cored arc welding FCAW and metal inert gas welding MIG Includes a gas solenoid and an internal contactor that allows across the arc oper ation with no control cable The LN 25 provides a cold electrode until the gun trigger is pressed For voltage control at the feeder a 444 1 Remote Voltage Control Kit is required Refer to connection instruc tions later in this section LN 7 or LN 8 Wire Feeder Semiautomatic con stant speed wire feeders NOTE
34. UOn298S 03 UINJ Y THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY SINCE COMPONENTS OR CIRCUITRY ON OF A COMPLETE SHOW THE EXACT COMPONENTS CONTROLS HAVING A COMMON CODE NUMBER UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO AND IS NOT GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS RESISTORS Ohms DOL Se W 0 DOL uonoes o3 WINDY MFD 022 50V UNLESS OTHERWISE SPECIFIED 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED 520272 1 TO REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION LABELS SUPPLY VOLTAGE ETT power SUPPLY SOURCE POINT a FRAME CONNECTION EARTH GROUND CONNECTION COMMON CONNECTION THE LINCOLN ELECTRIC CO TPE THE LINCOLN ELECTRIC CO Improper PC board repairs could result in dam CLEVELAND OHIO U S A suu BYPASS SCHEMATIC scALE _ SHT DR LE B pate 38 1 01 BS SUP S D G 520272 DOL 4 35 03 DOL uonoes o3 WINDY Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This dia ages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machi
35. at the LN 25 and adjust the welding voltage with the output CONTROL at the welder NOTE optional remote control is used place TROL REMOTE position CONNECTION OF THE LN 25 TO THE RANGER 9 ACROSS THE ARC SEE FIGURE C 2 1 Shut the welder off 2 Connect the electrode cable from the LN 25 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of the welder the output control switch in the CON TROL REMOTE position NOTE Welding cable must be sized for current and duty cycle of application 3 Set the welder polarity switch to the desired polarity either DC or DC 4 Set the RANGE switch to the WIRE FEED posi tion 5 Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead This is only a control lead it carries no welding current Return to Section TOC Return to Master TOC FIGURE C 2 RANGER 9 LN 25 ACROSS THE ARC CONNECTION DIAGRAM 6 PIN AMPHENOL 14 PIN AMPHENOL OPTIONAL 444 1 REMOTE CONTROL LN 25 WIRE FEEDER FE au nile 818 EJE 5 5 DIH o iac WORK CLIP LEAD TO WORK TO WORK Bu ELECTRODE CABLE Yio FE e g 4 u 3 p o iac LINCOLN je RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
36. connectors from the current sensing leads 254 and 254 see the Wiring Diagram These leads attach to the current sensor located on the printed circuit board Remove lead 3 from the 115 VAC recep tacle Thread the lead through the hole in the current sensor in order to separate it from the printed circuit board It will prob ably be necessary to cut any cable ties restraining the wiring Use the diagonal cutters RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 4 p ac Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 F 54 RANGER 9 12 13 14 15 F 54 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued CAUTION 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 With the 1 4 nut driver remove five screws holding the printed circuit board Replace the old printed circuit board with a new one Thread lead 3 back through the current sensor on the printed circuit board and reattach the lead to the 115 VAC recepta cle Connect current sensing leads 254 and 3254A See the Wiring Diagram for the proper connections LINCOLN 16 17 18 19 Connect the two molex
37. in the Change the Oil section above Startthe engine and check for leaks around the filter element Correct any leaks usually by retightening the filter but only enough to stop leaks before placing the RANGER 9 back in service RANGER 9 LINCOLN 3 OIL FILTER 6 If there are no leaks stop the engine and recheck the oil level If necessary add oil to bring the level up to the FULL mark but do not overfill FUEL Atthe end of each day s use refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Use only fresh unleaded gasoline with octane rating 87 or higher Gasoline alcohol blends are approved for use with your engine as long as the blend does not exceed 10 ethyl alcohol by volume Other gaso line alcohol blends are not approved and their use may damage fuel system and engine parts FUEL FILTER Your engine may be equipped with an in line fuel filter Inspect the fuel filter periodically and replace it if it appears dirty RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Fe lu 5 nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC Return to Master TOC D 4 MAINTENANCE AIR CLEANER Your air cleaner may have only the paper element or it may H have the cartridge and a foam preclean If it has the precleaner service the eleme
38. int Oso INH 2 DECODE 13 5 our2 8 BY PASS 1 clock In SCALE 45368 THE LINCOLN ELECTRIC GENERAL INFORMATION SYMBOLS CLEVELAND OHIO U S A Return to Section TOC Return to Master TOC Q5 OVERCURRENT 1N4007 a p PROTECTION CHANGE OARD THIS DIAGRAM MAY OLS HAVING A COMMON CODE 75 R93 Jt MAX OUT AT LOW IDLE gt 4 gt 2008 FIELD 2 7 7 REMOTE INPUT CURRENT HYSTERESIS 10 SWITCH R58 COM 47 5 47 5 10V A Oojo GIS 2 2 8 y lo ojo 10K LEVEL SHIFT 475 IRFP250 818104 1 FETDRIVER HEAT SINK
39. loaded Welding output and auxiliary power output is normal when Idler switch is in the HIGH position Make sure the welding cables and connections are tight Automatic idler may not func tion if the auxiliary power is loaded to less than 150 watts Check for broken or faulty con nections in the sensing leads 254 and 4254A sure their connections are tight at the work output terminal and also at the Polarity switch See Wiring Diagram Check lead 3 making sure it is looped through the current sen sor on the printed circuit board The printed circuit board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN B RANGER 9 F 12 F 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fe au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PROBLEMS SYMPTOMS Engine will not crank or cranks very slowly POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 1 Check for loose or faulty bat tery cable con
40. machine to a pipe that carries explosive or combustible material RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC re E Uu Eid 5 per Return to Section TOC Return to Master TOC g o 7 2 gt a INSTALLATION When the RANGER 9 is mounted on a truck or a trailer the machine generator ground stud MUST be securely connect ed to the metal frame of the vehicle See The ground stud is marked with the ground symbol If the RANGER 9 is connected to premises wiring such as a home or shop it must be properly connected to the system earth ground See the PREMISES WIRING section of this manual for details AUXILIARY POWER RECEPTACLES PLUGS AND HAND HELD EQUIPMENT The control panel of the RANGER 9 features two aux iliary power receptacles See Figure A 1 Two 20 amp 115 volt duplex double outlet recep tacles One 50 amp 115 230 volt simplex single outlet receptacle Through these receptacles the machine can supply up to 9 000 rated continuous watts of single phase 60 Hz AC power The machine output voltages fall within 1096 ofthe rated voltage For further protection against electric shock any elec trical equipment connected to the generator recepta cles must use a three blade grounded type plug or an Underwriter s Laboratories UL approved double insu
41. nile 818 EJE Bi o iac CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC x nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC Return to Master TOC F 18 F 18 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION The output contactor does NOT drop out FUNCTION PROBLEMS Make sure the WELDING TER MINALS switch S6 is in the REMOTELY CONTROLLED position Remove the wire feeder control cable from the amphenol If the 1 Remove lead 232 from the output contactor If the contac tor drops out then make sure that lead 232 is NOT ground ed Also check the WELDING TERMINALS switch S6 for proper operation Check asso contactor drops out then the problem is external to the RANGER 9 Check the control cable or the wire feeder ciated wiring See Wiring Diagram The printed circuit board may be
42. oil to fill it to the full mark For more oil fill and service information see the MAINTENANCE section of this manual FUEL Fill the fuel tank with clean fresh regular grade lead free gasoline DO NOT MIX OIL WITH THE GASOLINE The RANGER 9 has a 9 gallon 34 1 litre bottom mounted fuel tank with a top fill and fuel gauge See the and sec tions of this manual for more details about fuel BATTERY CONNECTIONS The RANGER 9 is shipped with the nega tive battery cable disconnected Before you operate the machine make sure the Engine Switch is in the STOP position and attach the discon nected cable securely to the battery terminal If the battery is discharged and won t start the engine see the battery charging instructions in Maintenance section RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FE lu nile 818 EJE Bi iac Return to Section TOC Return to Master TOC Return to Master TOC A 5 A 5 INSTALLATION FIGURE 1 RANGER 9 OUTPUT CONNECTIONS E 1 PES GA vene o RANGER 9 MUFFLER RELOCATION A WARNING Shut off the machine and allow the muffler to cool before touching the muffler The RANGER 9 is shipped with the exhaust coming out
43. or auxiliary power applications See ENGINE OPERA TION in the Operation of this manual for details about starting running stopping and breaking in the gasoline engine RANGER 9 LINCOLN DESIGN FEATURES AND ADVANTAGES 9 000 watts of auxiliary power Enhanced constant voltage capability with low 12 21 volts medium 15 27 volts and high 18 35 volts range settings for greater control of wire feed applications Built in contactor with front panel selection of cold or hot welding terminals Cold WELDING TERMINALS REMOTELY CONTROLLED Closing wire feeder trigger switch or amptrol causes con tactor to close and engine to accelerate to high idle Hot WELDING TERMINALS ALWAYS ON The contactor is closed and welding begins when elec trode touches work engine automatically goes to high idle Constant current AC DC Stick welding GMAW process capability with output range from 40 250 amps AC or 40 250 amps DC Constant voltage DC Semiautomatic Wire Feed Welding with output range from 40 250 amps Constant current AC DC TIG Welding with output across the entire range of settings Polarity switch for selecting DC DC or AC weld ing output Separate ground stud for safe connection of case to earth ground Single 50 amp 230 volt full 9 kVA auxiliary power receptacle Double duplex 20 amp 115 volt auxiliary power receptacles Electric starting Batte
44. 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in accessing and removing the field capacitor and rectifier bridge for maintenance or replacement of either component Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver J umper wire with alligator clips on each end for discharging the field capacitor Slot head screw driver Needle nose pliers Wiring Diagram FE au nile 818 EJE Bi iac Return to Section TOC Return to Master TOC LINCOLN 8 RANGER 9 RANGER 9 F 50 F 50 TROUBLESHOOTING amp REPAIR FIELD CAPACITOR AND OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 11 RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR Return to Section TOC Return to Master TOC E RS p o n 9 oc Return to Section TOC Return
45. the RANGER 9 by hand Overall width is 29 inches 74 mm Caster for Undercarriage K893 1 Mounts to the front of the K889 2 to allow easy movement on smooth surfaces Includes a 6 inch 152 4 mm diam eter hard rubber wheel and convenient toe on toe off locking brake Four Wheel Undercarriage K933 1 Allows move ment of the RANGER 9 by hand without lifting Easily assembles to RANGER 9 Includes two rugged hard molded wheels and two durable pneumatic tires The spring loaded handle provides convenient comfort able steering The K934 1 Bracket is available for mounting a gas cylinder on the undercarriage Bracket for Mounting a Gas Cylinder to a K933 1 Undercarriage K934 1 Easily mounts on the back of the K933 1 Four Wheel Undercarriage to carry a welding gas cylinder Canvas Cover K886 1 For protecting the RANGER 9 when it s not in use Material is flame retar dant mildew resistant and water repellent Color red Power Plug Kit K802 N Provides four 20 amp 115 volt plugs and one 50 amp dual voltage 115 230V full kVA plug NOTE For CSA machines K1418 2 or K1419 2 and machines with GFCI receptacles use Power Plug Kit K802 R Power Plug Kit K802 R Provides four 15 amp 115 volt plugs and one 50 amp dual voltage 115 230V full kVA plug Accessory Kit K702 Includes the following Thirty five feet 10 5 meters of 42 AWG electrode cable Thirty feet 9 1 meters of 2 AWG work cable
46. the lower the welding current Fe au nile 818 EJE Bi iac If a constant voltage is desired for wire feeding then the reactor is bypassed and the range switch is con nected to one of three taps on the stator weld winding to provide a lower but stiffer output voltage NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 5 5 THEORY OF OPERATION 6 8 FIGURE E 5 OUTPUT BRIDGE CAPACITOR CHOKE POLARITY SWITCH CONTACTOR AND OUTPUT TERMINALS a pes 8 8 c EJE L 6 CHOKE tz WORK 5 a 4 RECTIFIER E RANGE zE O TERMINAL AC TUE 1 OUTPUT CONTACTOR C ELECTRODE TERMINAL STATOR MECHANICAL ROTATION ENGINE ROTOR SLIP O RINGS ROTOR o 9 LESE 1 RAR EE IDLER SOLENOID HE Du US BOARD pir BATTERY ED E E CAPACITOR 512 d JE 115 amp 230VAC RECEPTACLES x LI
47. the welding voltage with the output CONTROL at a CV constant voltage position at the welder NOTE optional remote control is used place the output control switch in the CON TROL position FIGURE C 3 RANGER 9 LN 25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM 14 PIN AMPHENOL rs K626 XX INPUT CABLE ASSEMBLY TO WORK TO LN 25 INPUT CABLE PLUG ELECTRODE CABLE TO WIRE FEED UNIT LINCOLN 8 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 ACCESSORIES CONNECTION OF THE LN 7 TO THE RANGER 9 USING K584 INPUT CABLE ASSEMBLY SEE FIGURE 4 NOTE If your LN 7 comes equipped with a K291 or K404 Input able refer to CONNECTION OF THE LN 7 Using K867 UNIVERSAL ADAPTER rather than this discussion to connect your RANGER 9 for wire feed welding 1 Shut the welder off 2 Connect the electrode cable from the K584 XX Input Cable Assembly to the ELECTRODE termi nal of the welder and to the LN 7 wire feeder Connect the work cable to the TO WORK termi nal of the welder NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the input cable from the K584 XX Input Cable Assembly to t
48. the RANGER 9 for weld ing disconnect the welding cables from the weld output terminals Reattach the flange nuts and leave them on the terminals FIGURE B 3 WELDING CIRCUIT CONNECTIONS FOR STICK WELDING 9 RANGER 9 mn RANGER 9 LINCOLN P OUTPUT CONTROL PANEL ELECTRODE CABLE ELECTRODE HOLDER ELECTRODE OUTPUT TERMINALS WORK WORK CLAMP WORK CABLE ONDURWNE RANGER 9 OPERATION To Use the RANGER 9 for AC DC TIG After you finish welding Constant Current Welding 1 Stop the gasoline engine See ENGINE OPERA Fionlin this section of the manual 1 Connect the K930 1 TIG Module to the RANGER 9 Follow the installation instructions provided with the kit Also be sure to follow the special machine grounding instructions given in the man ual r2 Allow the electrode and work to cool completely 3 Remove the work clamp from the work Return to Section TOC Return to Master TOC 2 Referto the instruction manual with the TIG mod ule IM 528 for operation with a RANGER 9 and proper machine settings 3 Set the OUTPUT RANGE dial to the appropriate setting for the electrode you are using Refer to IM 528 with the TIG module or refer to Table B 2 for AC TIG welding 4 Setthe POLARITY SWITCH to the des
49. the frame to pre Container vent static build up Be sure not Do Not Destroy to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative RANGER 9 LINCOLN 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 f 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 Testthe machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all elec trical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a 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 termi nal strips b If the original problem is recreated by the subs
50. the governor setting or overriding the throttle linkage 1 Shut the welder off will cause an increase in the AC auxiliary voltage If 2 Connect the electrode cable from the LN 7 to the this voltage goes over 140 volts wire feeder control ELECTRODE terminal of the welder Connect the circuits may be damaged The engine governor set cable to the TO WORK terminal of the is preset at the factory do adjust above welder RPM specifications listed in this manual Return to Section TOC Return to Master TOC NOTE Welding cable must be sized for current and duty cycle of application 7 Place the WELDING TERMINALS switch in the 3 Connect the K867 Universal Adapter to the LN 7 wire feeder and the 14 pin amphenol of the RANGER 9 as indicated in Figure C 5 Make the proper connections for local or remote control according Figure C 5 and the following NOTES REMOTELY CONTROLLED position Adjust wire feed speed at the LN 7 and set the welding voltage with the output CONTROL to a CV constant voltage position at the welder indicated on the figure NOTE optional remote control is used place the output control switch in the CONTROL position A Insulate each unused lead individually B Splice the leads and insulate 4 Set the welder polarity switch to the desired polarity either DC or DC 5 Setthe RANGE switch to the WIRE FEED posi tion 6 Place t
51. the installa tion instructions in the ACCESSORIES section of this manual Some recommended Innershield electrodes are NR 211MP NR 311 NR 203 series as well as Lincore 33 and 55 hardfacing electrodes Diameters from 035 0 9mm up to and including 5 64 2 0mm be used 5 64 2 0mm NS 3M can be used in limited applications Cable length and other conditions can affect the ultimate results of this application Request Lincoln publi cation N 675 for additional information Recommended Outershield electrodes are 045 052 and 1 16 Outershield 71 and 1 16 Outershield 70 Request Lincoln publication GS 200 for additional information For MIG welding the recommended electrodes are 030 035 and 045 L 50 and L 56 You must use a blended shielding gas such as C25 7596 Argon 25 CO Request Lincoln publication GS 100 for additional information Set the IDLER CONTROL to AUTO for the LN 25 or LN 742 or HIGH for the LN 7 or LN 8 and start the gasoline engine See TION in this section of the manual 4 7 Set the OUTPUT RANGE dial to either HIGH MED or LOW depending on your wire size and speed Set the POLARITY SWITCH to either WIRE FEED DC or WIRE FEED DC red depending on the electrode Set the FINE OUTPUT CONTROL to a setting that gives the most stable arc for the application Strike an arc and begin welding After you finish welding 1 LINCOLN Stop the gasoline engine S
52. the panel Replace the cable tie Discharge the field capacitor by connecting the jumper wire clips on the black and the 13 Reinstall the case side fuel Cap lift bale gasket case top and spark plug wires RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 Bi iac Return to Section TOC Return to Master TOC F 51 RANGER 9 F 51 TROUBLESHOOTING amp REPAIR FIELD CAPACITOR AND OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued PROCEDURE RECTIFIER BRIDGE REMOVAL AND REPLACEMENT 1 To remove the rectifier bridge first you will have to remove the field capacitor Follow Steps 1 10 above Depress the retainer clip on the molded plastic holder and slide the rectifier bridge out With the needle nose pliers gently remove the 6 wires from the rectifier bridge Replace the wires to their appropriate loca tions on the new rectifier bridge See the Wiring Diagram Lead 200 and 200 are piggybacked the positive terminal Depending on the bridge used this corner may be beveled and or marked with a sign Lead 201 and 201 are piggybacked on the negative terminal which will always be located diagonally across from the pos itive terminal The two leads 7 and 9 are the AC side of the bridge and attach to the other two cor ners Either lead ca
53. to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram FE au nile 818 EJE 5 5 Bi iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP au nile 818 EJE 5 5 Bi oO aic Return to Section TOC Return to Master TOC F 20 F 20 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST continued FIGURE F 1 LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST Lead 200 Lead 219 RANGER 9 TEST PROCEDURE 1 With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Set the volt ohmmeter to the DC volts position Connect the positive meter probe to the brush nearest the rotor lamination lead 200A See Figure F 1 for location LINCOLN 10 11 12 13 Connect the negative meter probe to the other brush lead 219 Start the engine and run it at high idle 3700 RPM Set th
54. top Remove the case top then reinstall the fuel With the 5 16 nut driver remove the five screws holding the right case side Remove the right case side by lifting up and out Remove the engine spark plug wires With the needle nose pliers remove all 4232 and 224 leads from the contactor coil Note placement for reassembly With the 1 2 wrench remove the two nuts bolts and associated washers holding the two heavy leads to the output contactor LINCOLN amp 10 11 12 13 14 CONTACTOR COIL LEAD CONNECTIONS HEAVY LEAD CONNECTIONS MOUNTING HARDWARE 3 SETS VERTICAL BAFFLE With the slot head screw driver and 3 8 wrench remove the three mounting screws from the contactor The contactor can now be removed To reinstall the output contactor use the slothead screw driver and 3 8 wrench to attach the three mounting screws that hold the contactor to the vertical baffle With the 1 2 wrench and the two nuts bolts and associated washers attach the two heavy leads to the output contactor With the needle nose pliers carefully attach all 4232 and 7224 leads to the contactor coil See the Wiring Diagram and F 16 for lead placement Reinstall the case side fuel cap lift bail gas ket and case top 1 906 RANGER 9 F 63 F 63 TROUBLESHOOTING amp REPAIRs OUTPUT CONTACTOR REMOVAL AND REPLACEMENT continued FIGURE F 16 CONTACTOR COIL LEAD
55. you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC LINCOLN RANGER 9 RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FP lu 5 nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine has low welding output 1 Make sure the REMOTE switch 1 Ifthe engine HIGH IDLE RPM is and low auxiliary output is in the proper position low then perform the MACHINE CONTROL if a Adjustment Test remote control unit is NOT con Perform the Rotor Voltage nected to the machine The brushes may be worn Contact your local Lincoln Authorized Service Facility If the rotor voltage is low the field capacitor C1 or the field bridge D2 may be faulty Test 3 The Engine RPM may be low and replace if necessary Check the Output Control potentiometer Normal resis tance is 10 000 ohms Also check associated wiring for loose or faulty connections The rotor may be faulty Perform the Rotor Resistance The printed circuit board may be faulty Replace If the engine HIGH IDLE RPM IS OK then the engine may have lost hors
56. 15 15 OPERATION 918 p TABLE B 5 SIMULTANEOUS WELDING AND AUXILIARY POWER 9 9 515 E Output Selector Welding Permissible Power in Watts Permissible Auxiliary Current 8 Setting Output Unity Power Factor in Amperes E 5 9 115 9230 250 250 None 200 200 2500 22 11 160 160 3700 32 16 120 120 5000 44 22 90 90 6000 52 26 45 45 7500 65 32 5 CV Low 200 5000 43 21 5 60 7500 65 32 5 Ojo CV Medium 250 2750 40 20 8 80 6500 56 28 9 2 cV High 250 1200 10 5 olg 100 6000 52 26 EJE ala gle FP au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN H RANGER 9 RANGER 9 16 16 OPERATION Qjo 8 8 TABLE B 6 9 TYPICAL GENERATOR POWER APPLICATIONS 512 Suggested Power Applications Running Watts Start up Watts 2 Air Compressor 3 4 HP 1 250 3 100 5 000 Airless Sprayer 1 3 HP 600 1 500 2 400 Chain Saw 1 200 Circular Saw 1 200 Coffee Maker 1 000 Deep Freezer 500 750 2 000 Electric Motor 1 HP 1 000 2 500 4 000 Electric Range 1 element 1 500 els Electric Skillet 1 250 IE Furnace Fan 1 3 HP 1 200 3 000 4 800 2 Portable Grinder 4 1 2 600 8 8 Portable Grinder 7 2 000 EB Halogen Work Light 500 2 4 Hand Drill 1
57. 15 VAC auxiliary receptacles LINCOLN FIGURE F 9 LOW IDLE ADJUSTMENT NUT 3 8 Low Idle Adjustment Nut Muffler Housing Rod Solenoid Start the engine and check the frequency counter At HIGH IDLE 3700 RPM the counter should read 63 Hz At LOW IDLE 2200 RPM the counter should read 37 Hz Note that these are median measure ments hertz readings may vary slightly above or below 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 adjust ment nut Turn the nut clockwise to in crease HIGH IDLE speed Adjust the speed until the frequency reads 63 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 9 for location of the adjustment nut Adjustthe nut until the fre quency reads 37 Hz RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o n 9 HM oc Return to Section TOC Return to Master TOC g o 0 2 a a F 36 RANGER 9 F 36 TROUBLESHOOTING amp REPAIR ENGINE THROTTL
58. 2 CURRENT Q MOMENTARY ELECTRODE POLARITY WITCH oso PC GO CLOSED CLOSED CLOSED 242 S3 SWITCH LOGIC Return to Section TOC Return to Master TOC WELDING TERMINAL CONTROL SWITCH SHOWN IN ALWAYS ON POSITION 31 000 MFD CAPACITORS REACTOR Return to Section TOC O O C 2g 12 3 cle y 4 vio ojo Return to Master TOC CX O WORRN ELECTRODE i GND AMPHENOL 1 J 0 314 115VAC C 132 02 04 44 CONTACTOR 1 07 024 WORK H 1 1 1 1 1 1 E gt O p77C 1 1 760 5 gt 5 TOT 318 CK 42 end 01 1 1 1 1 EMOTE CONTROL gt B OL768 cmolise D O 2B CONTACTOR Lye rol 4B gt gt 0 0 GROUND AMPHENOL 2 ELECTRICAL SYMBOLS E1537 ALL CASE FRONT COMPONENTS VIEWED FROM REAR IN LINE CONNECTORS 8 PLACES GROUND SCREW BETWEEN AMPHENOL HOLES STATOR 125 250V SINGLE RECEPTACLE SILVER COLORED TERMINALS SILVER COLORED TERMINALS OUTPUT RHEOSTAT 75 MAX 10K POT 75 5 760 TID SHOWN IN POSITION SOLENOID 2C 3 224 3 GROUND SCREW BLOWER BAFFLE CAPACITOR 50 5B 1 ENGINE IGNITION FOUR VETER MODULE FLYWHEEL ALTERNATOR SLIP RINGS Nul positive
59. 3 R79 RESISTOR MF 1 4W 6 81K 1 R69 R70 R48 R49 R50 R51 R52 R68 R40 R41 R44 R45 R37 R90 R35 R36 R86 R91 R32 R22 R31 R59 R61 R20 R27 R19 R30 R89 R18 R26 R39 R54 R63 R66 R15 R12 R13 R11 R10 R5 R6 R21 R38 R4 RESISTOR MF 1 4W 475 1 RESISTOR MF 1 4W 47 5 1 THERMISTOR PTC 56 OHMS 90MA RESISTOR MF 1 4W 68 1 1 RESISTOR MF 1 4W 6 19K 1 RESISTOR MF 1 4W 26 7K 1 RESISTOR MF 1 4W 47 5K 1 RESISTOR MF 1 4W 133K 1 RESISTOR MF 1 4W 10 0K 1 RESISTOR MF 1 4W 2 00K 1 RESISTOR WW 5W 20 5 SQ RESISTOR MF 1 4W 13 7K 1 RESISTOR MF 1 4W 33 2K 1 RESISTOR MF 1 4W 3 32K 1 RESISTOR CC 2W 4 7K 10 R82 R88 R92 R2 R42 R43 R46 R47 R57 R81 R1 R3 RESISTOR MF 1 4W 100 1 Q5 Q6 TRANSISTOR NMF T220 18A 200V IRF6 Q3 TRANSISTOR P T226 0 5A 40V 2N4403 Q2 TRANSISTOR P T226 0 5A 300V MP S A92 Q1 TRANSISTOR NMF 4P DIP 1A 100V RFD110 12 CONNECTOR MOLEX MINI PCB 12 PIN 1 CONNECTOR MOLEX MINI PCB 8 PIN DZ11 ZENER DIODE 1W 18V 5 1N4746A DZ9 ZENER DIODE 1W 10V 5 1N4740A DZ6 ZENER DIODE 5W 20V 5 1N5357B DZ5 ZENER DIODE 1W 75V 5 1N4761A 074 078 0710 0712 ZENER DIODE 1W 15V 5 1 4744 DZ1 ZENER DIODE 5W 10V 5 1N5347B D31 D36 DIODE AXLDS 1A 1000V D30 DIODE AXLDS 3A 200V 1N5402 D24 DIODE FR 1220 14A 200V MUR1520 D18 D19 D42 DIODE AXLDS 3A 600V 1N5406 D16 D17 D20 D22 DIODE AXLDS 1A 400V FR 1N4936 D25 D26 D27 D1 D2 D3 D4 D7 D8 D11 D14 DIODE AXLDS 1A 400V D21 D28 D29 D32 D35 D37 D38 D39 D40 D41 22 34 39
60. 4 500 Hand Drill 3 8 700 1500 Watt Heater 1 750 Hedge Trimmer 450 Light Bulb 100 Reciprocating Saw 900 Radial Arm Saw 2 600 e Radio 50 Refrigerator F reezer small 600 1 500 2 400 5 Slow Cooker 200 gt Submersible Pump 1 HP 1 000 2 500 4 000 8 8 Sump Pump 600 1 500 2 400 E Toaster 1 100 9 9 Weed Trimmer 500 Lincoln 100 or 125 Amp Wire Feeder Welder 4 000 NOTES Wattages listed are approximate Check your equipment for actual wattage Equipment with unusually high START UP WATTS are listed For start up of other equipment listed in the table multiply RUNNING WATTS by 2 Multiple loads can be used as long as the total load does not exceed 9 000 watts Be sure to start the largest loads first For example a 1 HP motor needs approximately 1 000 watts while running but may require 2 500 watts to start Some inductive motors may require as much as 4 times running watts to start FE 5 nile 818 DIH o iac LINCOLN H RANGER 9 RANGER 9 Return to Master Return to Master TOC Q Q 0 2 gt a Return to Master TOC Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES PCC CD C oii oi ia Section C 0 5 6550 6 EE C 2 3 Semiautomatic FCAW
61. 833 9353 WELD TEST DESCRIPTION This test will determine if there is a shorted winding in the rotor or if the rotor is grounded Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN amp RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o n 9 HM E oc Return to Section TOC Return to Master TOC 0 2 gt a F 22 RANGER 9 F 22 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST continued FIGURE F 2 LOCATION OF ROTOR SLIP RINGS o off p Me LL 7 d Tfi y d D Lead 200 a LIO e Lead 219A TEST PROCEDURE 1 With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then replace the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out Conduct the test with the gasoline engine OFF Remove the spark plug wire
62. ATION below for details on setting the choke 2 IDLER CONTROL SWITCH Adjusts the running speed of the engine The switch has two positions HIGH and AUTO In HIGH the engine runs con tinuously at high idle In AUTO idler control works as follows Stick Welding WELDING TERMINALS ALWAYS ON mode The engine accelerates to high speed when the electrode touches the work and strikes a welding arc The engine returns to low idle ap proximately 10 14 seconds after welding stops as long as no auxiliary power is being drawn Wire Welding WELDING TERMINALS ALWAYS ON mode The engine accelerates to high speed when the wire feeder gun trigger or amptrol is closed The engine returns to low idle approxi mately 10 14 seconds after the gun trigger is released and the welding stops provided that no auxiliary power is being drawn Auxiliary Power The engine accelerates to high speed when power is drawn at the receptacles for lights or tools The engine returns to low idle approximately 10 14 seconds after demand for auxiliary power stops RANGER 9 LINCOLN P 3 START STOP SWITCH Has three positions START RUN and STOP When the switch is held in the START position the starter motor cranks over the engine release the switch once the engine starts The STOP position stops the engine NOTE If you place the switch in the START posi tion when the engine is running you may damage the ring gear or starter m
63. BY PASS BOARD CONTACTOR CLOSURE CONTACTOR CLOSURE OUTPUT CONTROL OFS REMOTE 2225 SWITCH C 42VAC 6 PIN 14 PIN AMPHENOL AMPHENOL OUTPUT BRIDGE CHOKE If a CV constant voltage mode is desired the reactor is passed by The range switch applies a lower AC POLARITY SWITCH AND OUTPUT voltage to the rectifier bridge The DC output of the TERMINALS bridge is filtered and stiffened by the capacitors S This lower but stiffer DC output is passed through The AC voltage developed in the stator weld winding the choke polarity switch and contactor and then on is delivered through the reactor and range switch to to the output terminals the output bridge and polarity switch Depending upon the setting of the polarity switch either AC volt age or DC voltage is delivered through the output con tactor which is activated by the printed circuit board to the output terminals If AC output is selected then the current path is from the stator weld winding through the reactor range switch polarity switch and output contactor to the output terminals If a DC out put is called for then the current path is through the output bridge where the AC voltage is rectified to a DC voltage and then to the choke where the DC out put is filtered The filtered DC current path is through the polarity switch and output contactor and then on to the output terminals NOTE Unshaded areas of Block Logic Diagram are the su
64. DLE NO LOAD OUTPUT CONTROL AT MAXIMUM OUTPUT CAPACITOR BANK NOT FUNCTIONING Return to Section TOC Return to Master TOC CH1 Hits ty 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms This is NOT the typical CV output voltage waveform The capacitor bank is not functioning Note the ripple in the waveform The capac itor bank was disconnected to simu late an open or non functioning capacitor bank Each vertical divi sion represents 50 volts and each horizontal division represents 5 mil liseconds in time FE au nile 818 EJE Bi o iac Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling s DC 99 Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 43 F 43 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH CV MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM Return to Section TOC Return to Master TOC CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is the typical CV output voltage generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizo
65. E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC F 56 RANGER 9 F 56 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 13 OUTPUT RECTIFIER CONNECTIONS Mounting Screws with Insulators To capacitor bank PROCEDURE Remove the engine spark plug wires With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube will come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out LINCOLN For the remaining steps refer to Figure F 13 8 With the 1 2 wrench remove the choke 10 11 lead heavy lead from the S2 range switch leads 235 242 from the rectifier pos itive heat sink With the 1 2 wrench remove the two heavy leads and leads 236 and 236 from the rectifier negative heat sink With the 1 2 wrench remove the W1 lead and the heavy lead going to the S1 Polarity switch Note lead and washer placement With the 1 2 wrench remove the S2 l
66. E ADJ USTMENT TEST continued Oscilloscope Method 1 Connect the oscilloscope to the 115 receptacle according to the manufactur er s instructions At 3700 RPM the wave form should exhibit a period of 15 8 mil liseconds At 2200 RPM the waveform should exhibit a period of 27 02 millisec onds Refer to NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY HIGH IDLE NO LOAD in this section of the manual 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 adjust ment nut Adjustthe speed until the period is 15 8 mililseconds 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 9 location of the adjustment nut Adjust the speed until the period is 27 02 milliseconds LINCOLN P 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 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 2200 RPM the whip handle should exhibit minimum os
67. ER 9 17 17 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC The output contactor does not pull in when using a wire feeder with a control cable connected to the RANGER 9 amphenol FUNCTION PROBLEMS Make sure the WELDING TER MINALS switch S6 is in the REMOTELY CONTROLLED position Install a jumper wire from pins D to C on the 14 pin amphe nol If the output contactor acti vates the problem is external to the RANGER 9 The wire feed er or the control cable may be faulty 1 With the jumper installed in pins D and C in the 14 pin amphenol check for 12VDC from leads 224 to 232 at the output contactor If 12VDC is present and the con tactor does not activate then the contactor may be defective If the correct voltage is NOT present in step 2 check from lead 224 to ground lead 5 for the presence of 12VDC If 12VDC is present then check the continuity of the lead 232A to the idler printed circuit board Return to Section TOC Return to Master TOC 3 The printed circuit board may be faulty Replace If 12VDC is NOT present from lead 224 to ground lead 5 then check the 224 lead for an open circuit See Wiring Diagram oio FE E lu 5
68. Gas shielded welding requires a Magnum Gun Gasless welding requires an Innershield Gun LN 742 Wire Feeder A semiautomatic wire feeder with cold electrode Requires K589 1 Remote Control Kit for remote voltage and wire speed control K857 Remote Voltage Control Kit connects to the RANGER 9 for voltage control at the feeder Refer to connection instructions later in this section Magnum Spool Gun K487 25 A lightweight semi automatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the handle Requires the K488 SG Control Module Includes 50 feet 15 2 meters of power cable SG Control Module K488 Controls wire speed and gas flow Provides the required control interface between the RANGER 9 and the K487 25 Magnum Spool Gun RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 0 4 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING ELECTRIC SHOCK can kill Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts MOVING PARTS can injure SM Keep guards in place Keep away from moving parts Only qualified personnel should in
69. HITE 0O 31B SILVER 1 1 1 1 1 1 1 LI 42 ENGINE IGNITION 1 1 HOUR METER MODULE 1 1 1 FLYWHEEL REMOTE CONTROL 1 ALTERNATOR gt 77 gt 768 208 CAVITY 3 4 224 amp CAVITY 4 O O C 2g 12 3 cle y 4 vio ojo 75B 1 SR LOCATING MP TAB 05 0 28 Q NOTE CAVITY NUMBERS VOLTAGE etal REGULATOR branten GROUND P7O10ND 8 ALCA 224B CAVITY 2 AMPHENOL 2 ROTOR FIELD DIAGRAM A ENGINE TERMINAL BLOCK CONNECTION SLIP RING NEAREST LAMINATION T 5 COLORED TERMINALS 182 486 382 NOTES GROUND SCREW 38 BETWEEN AMPHENOL HOLES MONETARY 08085 ELECTRICAL SYMBOLS E1537 en C I ALL CASE FRONT COMPONENTS VIEWED FROM REAR crosep S3 SWITCH LOGIC 12 16 93A CLEVELAND OHIO U S A 19112 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels Return to Section TOC Return to Master TOC RANGER 9 RANGER 9 G 3 G 3 DIAGRAMS WIRING DIAGRAM RANGER 9 ONAN CSA CODE 9976 RANGER 9 ONAN CSA VERSION 3 TURNS L1 IDLER 1 amp 2 4 amp 6 3 amp
70. Lincoln Electric discour ages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in dam age to the machine LINCOLN E RANGER 9 RANGER 9
71. Load Volts Load Amps Volts WELDER AC OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Maximum 73 80 25 35 250 260 Return to Section TOC Return to Master TOC WELDER CV OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Wire Feed CV High 50 54 25 35 250 260 Maximum Wire Feed CV Med 35 38 20 24 200 240 Maximum Wire Feed CV Low 34 38 16 19 155 190 AUXILIARY POWER RECEPTACLE OUTPUT 230 Volt Receptacle 115 Volt Receptacle Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 236 255 207 245 39 43 118 127 5 103 122 78 83 Fe au 5 nile 818 E Bi AMPHENOL AUXILIARY OUTPUT 42 Volt Auxiliary 115 Volt Receptacle Open Circuit Load Volts Open Circuit Load Volts Voltage Voltage 43 50 40 48 115 126 110 126 FIELD AND VOLTS Slip Ring Volts Field Amps 40 50 VDC 5 2 5 8 Amps DC 1OUTPUT CONTROL switch set at MAXIMUM position 10 Output values of each receptacle can vary within the range shown but must be within 2 volts of each other LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Section G 1 Section G 1 TABLE OF CONTENTS 5 DIAGRAMS SECTION 9 Diagrams Sectlon ore hebes cun a iv ET d Ee ER Ye E e e aed a Section G 8 Wiring Diagram RANGER 9 O
72. MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram FE a nile 818 EJE 5 5 Bi iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC F 32 F 32 TROUBLESHOOTING amp REPAIR CHARGING CIRCUIT TEST continued FIGURE F 6 LOCATION OF VOLTAGE REGULATOR Voltage Regulator AC Lead DC Lead AC Lead Engine Cooling Shroud TEST PROCEDURE l Start the engine and run it at high idle 3700 RPM 2 Set the voltmeter for AC volts and place one meter probe on each of the two out side leads that attach to the engine voltage regulator See Figure F 6 for location Check for 52 VAC atthe 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 deter mine the charging voltage for the battery Run the engine at high idle 3700 RPM Set the voltmeter for DC volts and place one meter probe on any good ground See Figure F 6 Check for 13 15 VDC LINCOLN RANGER 9 If the DC voltage reading is incorrect or not present the v
73. MIG Welding meme C 3 Connection of Lincoln Electric Wire Feeders mmm C 4 Connection of the K867 Universal Adapter eme C 4 Connection of the LN 25 Across the C 5 Connection of the LN 25 with 42V Remote Output Control C 6 Connection of the LN 7 Using the K584 Input Cable 5 C 7 Connection of the LN 7 Using the K867 Universal C 8 Connection of the LN 8 oo eee ete eee teeter ener eter ene enne nennen nennen 9 Connection of the LN 742 E SR da C 10 Connection of the K488 SG Control Module and the K487 Magnum Spool Gun C 11 RANGER 9 LINCOLN RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fe au nile 818 EJE 5 5 Bi 21 aic Return to Section TOC Return to Master TOC 2 ACCESSORIES OPTIONS ACCESSORIES The following options accessories are available for your RANGER 9 from your local Lincoln Distributor Two Wheel Trailer K768 2 For in plant or yard towing of the RANGER 9 Not intended for highway towing as equipped For highway use of this trailer consult applicable federal state and local laws about possible requirements for brakes lights fenders etc Two Wheel Undercarriage K889 2 For moving
74. NOL FIGURE E 1 RANGER 9 BLOCK LOGIC DIAGRAM Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Fe au 5 nile 818 EJE 5 Bi iac Return to Section TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 BATTERY STARTER ENGINE ROTOR STATOR AND IDLER SOLENOID RANGE SWITCH DS J REACTOR AC CHOKE PART OF L SWITCH CAPACITORS WORK TERMINAL SWITCH OUTPUT RECTIFIER BRIDGE POLARITY AC OUTPUT L CONTACTOR MECHANICAL ROTATION ENGINE ROTOR STARTER ROTOR FLYWHEEL ALTERNATOR APP C ELECTRODE STATOR TERMINAL zn IDLER SOLENOID o PRINTER CIRCUT BOARD BATTERY FIELD CAPACITOR FIELD BRIDGE BY PASS BOARD CONTACTOR CLOSURE 115 amp 230VAC RECEPTACLES CONTACTOR CLOSURE OUTPUT CONTROL REMOTE SWITCH 115 6 PIN 14 PIN AMPHENOL AMPHENOL BATTERY STARTER ENGINE ROTOR STATOR AND IDLER SOLENOID
75. ON If you operate the RANGER 9 at altitudes above 5000 feet you should install a carburetor jet designed for high altitude operation This will result in better fuel economy cleaner exhaust and longer spark plug life It won t give increased power Power is decreased at higher altitudes Contact the engine manufacturer to obtain these high altitude jet kits Onan kit part num ber 146 0458 A CAUTION Do not operate a RANGER 9 with a high altitude jet installed at altitudes below 5000 feet The engine will run too lean and operate at higher engine tempera tures which can shorten engine life PRE OPERATION ENGINE SERVICE Read and understand the information about the gaso line engine in the Operation and Maintenance sec tions of this manual before you operate the RANGER 9 RANGER 9 LINCOLN WARNING Keep hands away from the engine muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Remove the fuel cap slowly to release pressure Do not overfill the fuel tank Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank OIL RANGER 9 is shipped with the engine filled with SAE 10W 30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precaution When full the oil level should be up to but not over the FULL mark on the dipstick If it is not full add enough
76. PLACEMENT Return to Section TOC Return to Master TOC Heavy Lead Connections Leads 224 Return to Section TOC Return to Master TOC Leads 232 FP lu nile 818 EJE 5 5 Bi aic Return to Section TOC Return to Master TOC LINCOLN amp RANGER9 1 96 RANGER 9 F 64 F 64 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the engine and or rotor for main tenance or replacement of either component Return to Section TOC Return to Master TOC MATERIALS NEEDED Lincoln Electric Rotor Removal Kit 520788 FOR ROTOR REMOVAL ONLY 1 4 nut drive
77. RANGER 9 case front RANGER 9 INSTALLATION amp S FIGURE A 2 CONNECTION OF RANGER 9 TO PREMISES WIRING 4 215 Qin gt Uu 0 9 230 VOLT 4 ele GROUNDED CONDUCTOR 5 5 230 Volt 9 60 Hz EET x COMPANY 3 Wire 15 Service lt NEUTRAL Bus Q gt gt LOAD DOUBLE POLE DOUBLE THROW O T SWITCH RATING TO BE THE SAME ols AS OR GREATER THAN PREMISES Fle SERVICE OVERCURRENT amp n PROTECTION gt B Siu nile g B RES PREMISES EJS DISCONNECT AND ilg GROUND SERVICE x x OVERCURRENT PROTECTION 50 AMP 115 230 dim CIRCUIT VOLT PLUG 230 VOLTS BREAKER NEMA TYPE 14 50 2 N 50 115 230 VOLT U 77 NOTE No 8 COPPER CONDUCTOR CABLE RECEPTACLE SEE NATIONAL ELECTRIC CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Section B 1 Section B 1 TABLE OF CONTENTS 9 e OPERATION SECTION 8 SON Section B Safety dw e FEE RES B 2 8 General Description Enea rro E rd oa B 2 i Recommended Applications ret eri e de n a d d RE ei B 3 oc W prge MM
78. Return to Master TOC Return to Master TOC vy dud c 0 ad Return to Master TOC View Safety Info View Safety Info D 5 gt View Safety Info SVM 110 A RANGER g January 1996 For use with machine code numbers 9975 and 9976 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful LINCOLN ELECTRIC Sales and Service through subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors Return to Master Return to Master TOC Q 0 4 gt 5 a Return to Master TOC SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects
79. Snap the plastic clip back into place Connect the engine choke cable at the position marked during disassembly 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 Reposition the vertical fan baffle and secure it with the two screws Install the muffler support hardware Install the two cowling covers at the rear of the stator Connect the black plug in front of the fuel tank fill spout Connect the leads to the starter solenoid and replace any cable ties cut during disas sembly Install the battery Connect the positive battery cable then the negative battery cable BE SURE TO CONNECT THE POS ITIVE BATTERY CABLE FIRST Replace the battery cover Reinstall the case sides fuel cap lift bale gasket and case top Connect the spark plug wires Conduct the Retest after Repair proce dure the following topic in this section of the manual RANGER 9 F 69 F 69 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine fitis 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 Return to Section TOC Return to Master TOC ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 2150 2250 NA High Idle 3700 3750 3100 3650 WELDER DC OUTPUT Output Control Range Switch
80. TROL SWITCH WELDING TERMINALS ALWAYS ON WELDING TERMINALS REMOTELY CONTROLLED SWITCH WIRE FEEDER POWER CIRCUIT BREAKER 115 VOLT 20 AMP RECEPTACLES 2 115 230 VOLT 50 AMP RECEPTACLE WELD OUTPUT TERMINAL TO WORK WELD OUTPUT TERMINAL TO ELECTRODE HOLDER GROUND STUD 14 PIN AMPHENOL 6 PIN AMPHENOL 4 CONTROL AT WELDER REMOTE CONTROL SWITCH Allows the operator to control welding output at the welding control panel or at a remote station Remote connections are made at the 6 pin or 14 pin amphenol connector 5 WELDING TERMINALS ALWAYS ON WELDING TERMINALS REMOTELY CONTROLLED SWITCH Allows control of the RANGER 9 output contactor In the ALWAYS ON position the switch closes the output contactor and welding begins when an arc is struck between the electrode and the workpiece In the REMOTELY CONTROLLED position the switch places control of the contactor at the wire feeder The contactor closes when the wire feeder gun trigger or amptrol switch closes and opens when it is released 6 WIRE FEEDER POWER CIRUIT BREAKER Opens the wire feeder circuit and disables the feeder if a fault is detected in the circuit RANGER 9 OPERATION 7 20 AMP 115 VOLT DUPLEX RECEPTACLES Connection point for supplying 115 volt power to operate one or two electrical devices 8 50 AMP 230 VOLT RECEPTACLE Connection pointfor supplying 230 volt powerto operate one electrical device 9 WELD OUTPUT TERMINAL TO WORK WITH FLANGE N
81. UT Provides the connection point for the work cable 10 WELD OUTPUT TERMINAL TO ELECTRODE HOLDER WITH FLANGE NUT Provides the con nection point for the electrode holder 11 GROUND STUD Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure 12 14 PIN AMPHENOL For attaching wire feeder control cables to the RANGER 9 13 6 PIN AMPHENOL For attaching optional remote control equipment to the RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC LINCOLN H RANGER 9 RANGER 9 OPERATION FIGURE B 2 GASOLINE ENGINE CONTROLS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 E 4 p ac Return to Section TOC Return to Master TOC 0 2 gt a 1 ENGINE CHOKE CONTROL E 2 IDLER CONTROL SWITCH 3 START STOP SWITCH 4 ENGINE HOUR METER RANGER 9 5 BATTERY CHARGING SYSTEM METER E GASOLINE ENGINE CONTROLS See Figure B 2 for the location of the following fea tures 1 ENGINE CHOKE CONTROL Provides a richer air fuel mixture for cold engine starting conditions See the topic ENGINE OPER
82. across each of the four output capacitors If a voltage is present use a 25 watt resistor to discharge each capacitor With the 1 2 wrench remove the two nuts bolts and associated washers holding the two heavy leads to the positive and negative capacitor buss bars LINCOLN P 13 14 15 16 17 18 19 With the phillips head screw driver remove the four mounting screws holding the capacitor bank assembly to the vertical baf fle Carefully remove the capacitor bank assem bly To replace the capacitor bank assembly mount the assembly to the vertical baffle with four phillips head screws With the 1 2 wrench attach the two heavy leads and associated fasteners to the posi tive and negative buss bars Observe capacitor polarity With the 1 4 nut driver mount the printed circuit board to the vertical baffle five screws With the 5 16 nut driver install the printed circuit board cover Reinstall the case side fuel cap lift bail gas ket and case top RANGER 9 F 61 F 61 TROUBLESHOOTING amp REPAIR OUTPUT CONTACTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precau
83. agonal cutters Wiring Diagram FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC F 53 RANGER 9 F 53 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued FIGURE F 12 PRINTED CIRCUIT BOARD LOCATION Current Sensor In Line Connectors Screw 2 Current Sensing Leads 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 the 5 16 nut driver remove the 6 sheet metal screws from the case top 3 Remove the rubber gasket cover seal from the lift bale 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 With the 5 16 nut driver remove the printed circuit board cover See Figure F 12 LINCOLN P 10 11 Remove the two molex plugs from the printed circuit board Detach the two in line
84. ance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More fre quent service may be required depending on your specific application and operating conditions cs shows engine maintenance replacement parts and numbers RANGER 9 LINCOLN OIL Check the oil level after every 5 hours of operation daily SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 25 hours of opera tion Then under normal operating conditions change the oil as specified in Table D 3 If the engine is operated under heavy load or in high ambient tem peratures change the oil more frequently CHANGE THE OIL Change the oil while the engine is still warm as fol lows 1 Drain the oil from the drain plug located on the engine bottom as shown in Figure D 1 For the RANGER 9 a short pipe nipple has been installed to extend the drain plug access for easier service ability 2 Replace the cap on the drain extension and tighten it securely 3 Remove the oil fill cap and add oil until the level reaches the full mark on the dipstick Use high quality detergent oil of API service class SF SF CC or SF CD See Table D 1 for recommended vis cosity grades Straight weight oils are recom mended for severe duty use and at temperatures above 32 F 0 for minimum oil consumption Always check the level with the dipstick before adding more oil 4 Reinstall t
85. and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 copy of Safety in Welding amp Cutting ANSI Standard 249 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 cm 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop t
86. ant voltage DC at 100 duty cycle on a ten minute basis The current is continuously variable from 40 to 250 amps AC or 40 to 250 amps DC The RANGER 9 can weld with all 3 32 and most 1 8 inch and 1 16 diame ter Lincoln AC stick electrodes Wire feed processes using wire diameters from 030 to 068 inch are possi ble depending on the specific process and wire feed er See LIMITATIONS RANGER 9 LINCOLN LIMITATIONS RANGER 9 is not recommended for any processes besides those that are normally per formed using stick welding SMAW TIG welding GMAW welding and Innershield FCAW welding Specific limitations on using the RANGER 9 for these processes are described in the WELDING OPERATION section of this manual The RANGER 9 is not recommended for pipe thaw ing During welding generator power is limited and out put voltages can drop Therefore DO NOT OPER ATE ANY SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE WELDING See fable 4 per missible simultaneous welding and auxiliary power loads CONTROLS AND SETTINGS All generator welder controls are located on the Output Control Panel of the machine case front Gasoline engine choke control idler control and start stop controls are also on the case front See Figure B 1 and the explanations that follow RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FE nile 818 EJE
87. aring 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 Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes
88. art the gasoline engine See ENGINE OPERA TION Jin this section of the manual 2 Setthe IDLER CONTROL to the desired operating mode HIGH or AUTO Set the OUTPUT CON TROL to 10 See Figure B 1 3 Plug the load s into the appropriate 115 volt or 230 volt power receptacle NOTE The 115 volt auxillary power receptacles should only be used with three wire grounded type plugs or approved double insulated devices with two wire plugs TABLE B 4B MAXIMUM CURRENT DRAW FROM OPTIONAL 115V GFCI DUPLEX RECEPTACLES NO WELDING d K1420 1 K1420 2 CSA N K1420 1 K1420 2 Load From Each Total Each Total Load From Each Total Each Total 115 230 Half of from Half of from 115V 230V Half of from Half of from Dual Voltage Each 115V Both 115V Each 115V Both 115V Dual Voltage 115V Both 115V Each 115V Both 115V Receptacle Duplex Duplexes Duplex Duplexes Receptacle Duplex Duplexes Duplex Duplexes Vly 0 20 78 15 60 0 15 40 15 30 2 2 KW 20 60 15 60 2 2 KW 15 40 15 30 c 918 45 20 40 15 40 4 5 15 40 15 30 gt 6 7 KW 20 20 15 20 6 7 KW 15 20 15 20 olo 43 0 KW 0 elel 590 0 0 0 jJ X 90KW 0 0 0 0 J i NEMA 5 20P plug required for 20 amp draw Maximum current draw from each 115V GFCI Duplex is 20 amps a t M aximum current draw from each 115V Duplex is 15 amps LINCOLN RANGER 9 RANGER 9
89. aster TOC Return to Master TOC A 3 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry gloves insulating ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the out side Do notstack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment RANGER 9 LINCOLN LOCATION AND VENTILATION Whenever you use the RANGER 9 be sure that clean cooling air can flow through the machine s gasoline engine and the machine case Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ven
90. ation of the Range switch S2 and check the associated wires for loose or faulty connections See Wiring Diagram Check for continuity from leads C1 C2 and C3 to lead W1 located in the main stator See Wiring Diagram The constant voltage CV welding output is low unstable Constant current CC and the aux iliary power are operating normally Make sure the Range switch S2 is in the proper position CV and seated correctly Make sure the wire feeder and welding cables are connected correctly Check the operation of the Range switch 52 and check the associated wires for loose or faulty connections See Wiring Diagram The capacitor bank C2 C3 C4 C5 may be faulty Check or replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN P RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio FE lu nile 818 EJE Biz iac Return to Section TOC Return to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Engine will not idle down to low speed Machine has no
91. attery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petrole um jelly or a non conductive grease to retard corro sion Keep the battery clean and dry Moisture accumula tion on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific gravity of 1 260 Charge the battery if the reading is below 1 215 RANGER 9 LINCOLN NOTE Correct the specific gravity reading by adding four gravity points 0 004 for every five degrees the electrolyte temperature is above 80 degrees F 27 degrees C Subtract four gravity points 9 004 for every five degrees the electrolyte temperature is below 80 degrees F 27 degrees C CHECKING ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The RANGER 9 positive 4 battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the
92. bject of discussion LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION 5 2 Troubleshooting amp Repair 2 2 4 Section F 5 How to Use Troubleshooting F 2 Board Troubleshooting 3 9 Troubleshooting Guide iiem a F4 F 18 Test Procedures Rotor Volt ge Test rire inerte leas POR uda ra F 19 Rotor Resistance Test si ioci e e RE ER D TEC RU e Ch d AR ER REX D RA AN F 21 Auxiliary and Field Winding meme F 24 Output Rectifier Bridge Test ener F 29 Charging Circuit Test pue Gp d ru F 31 Engine Throttle Adjustment eene F 33 Oscilloscope Waveforms ra pda rr Pe b Engin F 37 Normal Open Circuit Voltage Waveform 115 F 37 5 Typical DC Weld Output Waveform CV Mode Machine Loaded F 38 Typical DC Weld Output Waveform Machine F 39 z Typical AC Weld Output Waveform Machine F 40 8 Abnormal Open Circuit We
93. cillation that these are median measurements vibrat ach readings may vary slightly above or below 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 for location of the adjust ment nut Turn the nut clockwise to increase HIGH IDLE speed Adjust the speed until the vibratach whip handle exhibits maximum oscillation at 3700 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 9 for loca tion of the adjustment nut Adjust the speed until the vibratach whip handle exhibits minimum oscillation at 2150 to 2250 RPM RANGER 9 37 37 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM Return to Section TOC Return to Master TOC 15 8 ms CH1 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms 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 rep resents 5 milliseconds in time Note S
94. cking pliers and unscrew the blower fan Turn the fan counterclockwise You do not need to remove the fan from the machine but be sure it is completely unscrewed from the rotor shaft LINCOLN 16 17 18 19 20 21 22 23 24 25 With the 5 16 nut driver disconnect the engine choke cable from the engine Mark the location of the retainer for reassembly The other end can remain connected 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 Disconnect the fuel line from the fuel tank Plug the hose and also plug the connec tion at the fuel tank to prevent the escape of gasoline fumes With the 9 16 wrenches remove the ground lead from the right engine foot mounting bolt With the 7 16 wrench remove the brush holder bracket and leads 219 and 200A from the stator frame With the 1 2 wrench remove the muffler suport bolt Support the engine with a chain hoist Lift bales are provided on the top of the engine for this purpose With the 9 16 wrench remove the right and left engine foot mounting bolts With the 9 16 wrench remove the four bolts that hold the stator to the engine There is one lock washer per bolt 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
95. cope probes connected at machine 115VAC receptacle FP lu nile 818 EJE Bi o iac SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling ertet DC Trigger Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 38 F 38 TROUBLESHOOTING amp REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MODE HIGH 8 MACHINE LOADED Sls 8 8 CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms MACHINE LOADED TO 250 AMPS AT 25VDC 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 FE au nile 818 EJE 5 5 DIH o iac Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 39 F 39 TROUBLESHOOTING amp REPAIR F TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM 25 MACHINE LOADED 212 8 8 CH1 0 volts
96. ction TOC Return to Master TOC FP x nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The wire feeder does not work 1 Check circuit breaker 1 Check for the presence of when connected to the welder Reset is tripped 115VAC at leads 31A and 32 amphenol The wire feeder control cable Winny Diagram may be faulty Check 2 Check for the presence of replace 42VAC at leads 31B to 42 See The wire feeder may be faulty Wing Diagram Check or replace If any of the above voltages are missing or low then check the circuit breaker 1 for proper operation The bypass PC board may be defective Check or replace 5 Perform the Auxiliary and Field Winding Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN RANGER 9 RANGER 9 Return to Section TOC Return to Section TOC Return to Master TOC FP x nile 818 EJE Bi o iac Return to Sect
97. e Wire Feed CV Yes Auto Remote Remote Cold Press gun trigger LN 742 RANGER 9 contactor closes Welding starts immediately and engine goes to high idle Wire Feed CV Yes High Remote Remote Cold Press gun trigger LN 7 RANGER 9 contactor closes Welding starts immediately LINCOLN S RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC re 9 E 4 k 42 ac g o H 7 2 gt gt OPERATION AUXILIARY POWER A WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a 10 voltage and a 3 frequency variation GENERAL INFORMATION The RANGER 9 generator is rated at 9000 continuous watts It provides both 115 volt and 230 volt power You can draw up to 80 amps total from the 115 volt receptacles but more than 20 amps 15 amps CSA from each receptacle at once See Tables B 4A and B 4B Up to 40 amps can be drawn from the single 230 volt receptacle The current rating of any plug used must be at least equal to the current load being drawn from the recep tacle Do not try to connect the receptacles in paral lel Electrical loads in watts are calculated by multiplying the voltage rating of the load by the number of amps it draws This information is given on the load device nameplate For example a device rated
98. e Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS u The welding arc is cold The engine runs normally 3700 RPM no load The auxiliary power is functioning normally POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check for loose or faulty con nections at the weld output ter minals and welding cable con nections The welding cable may be too long or coiled causing an excessive voltage drop TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check for the correct open cir cuit voltage OCV at the weld ing output terminals 80VAC Max 75VDC Max If the cor rect voltage is present at the output terminals then check for loose connections on the heavy current carrying leads inside the RANGER 9 See Wiring Diagram If the is low at the welder output terminals then perform the Perform the Output Bridge Check for shorted or grounded windings in the reactor and also in the main stator See Wiring Diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN B RANGER 9 Return to Section TOC Return to Section TOC Return to Master TOC FP au nile 818 EJE Bi o
99. e U S National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master Return to Master TOC o 0 iz gt hz c a nd Return to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce qu
100. e bolt to 50 ft Ibs 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 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 Ib moving diagonally from bolt to bolt 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 mea sured 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 Fasten the ground lead to the right engine mounting bolt and install both bolts Install the brush holder bracket back into the stator frame Refer to the topic Brush Removal and Replacement in this section of the manual LINCOLN 8 Unplug the fuel tank connection and fuel 10 11 12 13 14 15 16 17 18 19 20 hose and connect them Connect the idle linkage to the idler rod
101. e faulty Replace the stator LINCOLN E RANGER 9 RANGER 9 FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC FP au nile 818 EJE 5 5 DIH ro O aic Return to Master TOC F 27 F 27 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST continued FIGURE F 4A 14 PIN AMPHENOL PIN ASSIGNMENTS To test the feeder winding 1 Remove the fuel cap and lift bail rubber gasket With the 5 16 nut driver remove the case top and left side then reinstall the fuel cap Connectthe volt ohmmeter probes to leads 31 and 32 where they connect to the cir cuit breaker CB1 and the 14 pin amphenol See the Wiring Diagram NOTE It is possible to check this voltage reading at the amphenol by inserting the test probes at pin A for lead 32 and J for lead 431A See Figure 4A However if you use this method and get no voltage reading it could mean there is a break or loose connection in the leads between the circuit breaker and the amphenol Check the reading again with one probe at the circuit breaker connection for lead 31 and Set the output control to the maximum position 10 Check the AC voltage reading It should be between 115 and 126 VAC Connect the volt ohmmeter probes to leads 31 and 42 where they connec
102. e la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 1 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afi
103. e output control to the MAXIMUM position position 10 Check the voltage reading on the volt meter It should read between 40 and 50 VDC If the voltage reading is low or not pre sent the generator field is not functioning properly Perform the Test The Field Diode Bridge D2 the Field Capacitor C1 and or the Printed Circuit Board may be faulty If the voltage reading is normal the field circuit is functioning properly Install the right case side with the 5 sheet metal screws with the 5 16 nut driver Remove the fuel cap install the case top and tight en the 6 sheet metal screws with the 5 16 nut driver Install the rubber gasket over the lift bale and install the fuel cap RANGER 9 21 21 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800
104. e output control to the maximum position position 10 Check the AC voltage reading It should be approximately 240 VAC RANGER 9 F 26 F 26 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST continued FIGURE F 4 LOCATION OF LEADS 7 AND 9 AT FIELD BRIDGE RECTIFIER Return to Section TOC Return to Master TOC Field Bridge Rectifier Return to Section TOC Return to Master TOC Retaining Tab Cable Tie Capacitor To test the field winding 1 Remove the fuel cap and lift bale rubber If the voltage readings are within specifica gasket With the 5 16 nut driver remove tions then the windings are good and func the case top and left side then reinstall tioning properly MIB quet Caps 6 Reinstall the case side case top fuel cap 2 Connectthe volt ohmmeter probes to leads and lift bale gasket 7 and 9 where they connect to the Field Bridge Rectifier See Figure F 4 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 40 and 50 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 b
105. e screws previously removed Remove the cable tie or wooden stick and the brushes will seat onto the slip rings RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always firm FIGURE D 4 BRUSH REMOVAL AND REPLACEMENT 1 BRUSHES 2 CABLE TIE RANGER 9 LINCOLN RANGER 9 Lu x o a gt 0 z 4 Q o 2 gt lt zi tc 21 O w gt 255 20 uw oc 2 0 lt ASO wn czgazouu rmr om lt U y lt m co 5 FOXrFrFWHNHELY a 2252253410410 lt 4 2 Oru oouoacmzrznaoo lt lt O o E 2 2 o 8 md 2 5 a lt lt gt 2 o tc o 2 lt DOL ISe W uinjeu DOL JSE W uinjeu DOL JSE W 031 UINJ Y DOL J893se A UINJY DOL uonaes UNY DOL uonoes o3 UNY DOL gt 5 o3 UNY DOL uonoes Q UNY Section E 1 Section E 1 TABLE OF CONTENTS Q F THEORY OF OPERATION SECTION 9 Theory of Operation aerei e E
106. e you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio FE 5 nile 818 Bi iac Return to Section TOC Return to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Engine will not go to high idle when attempting to weld Welding out put is normal when Idler switch is in HIGH position Automatic idle function works properly when the auxiliary power is loaded Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 1 Make sure the welding cables and connections are tight If attempting to scratch start the WELDING TERMINALS switch 56 must be in the ALWAYS ON position RECOMMENDED COURSE OF ACTION Check for broken or faulty con nections in the sensing leads 254 and 254 Make sure their connections are tight at the work output terminal and also at the Polarity switch See Wiring Diagram Make sure the leads are looped three times through the current sensor on the printed circuit board If using a wire feeder with a control cable check the 2 and 4 circuit in the cable and in the machine See Wiring Diagram Engine will not go to high idle when attempting to weld or when the auxiliary power is
107. ead and the heavy lead going to the S2 Range switch Note lead and washer placement RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC F 57 RANGER 9 12 13 14 F 57 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued With the 3 8 wrench and slot head screw driver remove the four mounting screws two on each side Note the placement of the nylon insulators These must be in place when you reinstall the rectifier bridge assembly in order to electrically insulate the bridge from the choke lam ination assembly Remove the rectifier assembly by tilting it up and lifting it toward the front of the machine Reassembly Refer to the Wiring Diagram for proper connections to the positive and negative sides of the rectifier assembly The two sides of the bridge are marked and respectively NOTE Use Dow Corning 340 on all aluminum electrical connection surfaces 15 16 With the 3 8 wrench and slot head screw driver install the four mounting screws two on each side Note the placement of the nylon insulators These must be in place when you install the rectifier bridge assembly in order to electrically insulate the bridge from the choke lam ination assembly With the 1 2 wrench install the S2 lead
108. ee ENGINE OPERA TION jin this section of the manual Allow the work to cool completely The wire gun and wire are cold Remove the work clamp from the work RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 E 4 k 42 ac Return to Section TOC Return to Master TOC Q O H f 0 gt 5 ac OPERATION SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS Table B 3 summarizes the requirements for various welding processes you can perform with the K930 1 K936 1 With Amptrol RANGER 9 TABLE B 3 SUMMARY OF WELDING PROCESSES Process Control Idle Output Welding Electrode To Start Welding Cable Mode Control Terminals State When Used Switch Switch Not Welding Stick CC No Auto At Welder Always Hot Touch electrode to work Welding starts immedi ately and engine goes to high idle TIG CC Yes Auto Remote Remote Cold Press Amptrol Welding starts immediately Wire Feed CV Yes Auto Remote Remote Cold LN 25 with 42V Remote Control Kit Press gun trigger RANGER 9 contactor closes Welding starts immediately and engine goes to high idle Wire Feed CV No Auto At Welder Always on Cold Press gun trigger LN 25 LN 25 with internal contactor closes Weld contactor ing starts immediately and engine goes to high idl
109. ely controlled switch 115 and 230 volt receptacles weld output terminals and ground stud RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei ie Return to Section TOC Return to Master TOC Q O ks 0 41 gt gt 5 5 a INSTALLATION WELDING CABLE CONNECTIONS CABLE SIZE AND LENGTH Be sure to use welding cables that are large enough The correct size and length becomes especially impor tant when you are welding at a distance from the welder Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 250 Amp Cable Size for 250 Amp Cable Length 40 Duty Cycle 100 Duty Cycle 0 50 feet 0 15 meters 2 AWG 1AWG 50 100 feet 15 39 meters 2 AWG 1 AWG 100 150 feet 30 46 meters 1 AWG 1 AWG 150 200 feet 46 61 meters 1 AWG 1 AWG 200 250 feet 61 76 meters 1 0 AWG 1 0 AWG CABLE INSTALLATION Install the welding cables to your RANGER 9 as fol lows See Figure A 1 for the location of parts l The gasoline engine must be OFF to install weld
110. epower and be in need of major repair CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN amp RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE lau 5 nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No DC welding output AC welding output and auxiliary power are nor mal No AC welding output DC weld ing output and auxiliary power are normal POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure the Polarity switch S1 is in the proper position and is seated correctly Make sure the electrode and polarity are correct for the process being used Make sure the Polarity switch S1 is in the proper position and is seated correctly Make sure the electrode is cor rect for the process being used Make sure the welding cables are not coiled or too long TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Perform the Output Rectifier Check the choke L1 the Polarity switch S1 and a
111. ery 50 operating hours or as often as necessary remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as neces sary Make sure to replace all the cooling shrouds Running the engine without the cooling shrouds will cause damage to the engine from overheating CLEAN OR REPLACE SPARK PLUGS Clean or replace the spark plugs after every 500 hours of oper ation as follows 1 Before removing the plugs clean the base area to keep dirt from falling into the engine through the plug hole 2 Remove and inspect the plugs Plugs showing signs of fouling or electrode wear should be replaced Do not blast the spark plugs clean with an abrasive cleaning device Clean the plugs by scraping or by using a wire brush Wash the plugs with a commercial solvent 3 After cleaning or when installing a new spark plug set the terminal gap with a feeler gauge See Figure D 3 RANGER 9 LINCOLN Gap Specifications 0 025 inch 64 mm FIGURE D 3 SET SPARK PLUG GAP Spark Plug Wire Gauge _ Electrode gt Ground Gap 0 025 inch 64 mm CLEAN SPARK ARRESTER SCREEN If the muffler has the optional spark arrester remove it every 50 hours or once a year whichever comes first and inspectit Clean the arrester Replace it if you find any damage REMOVE COMBUSTION DEPOSITS Combustion deposits carbon can form on the cylinder cylinder head top of the piston and around t
112. es Return to Section TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 24 F 24 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct AC voltages are being generated from the stator windings Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram FE au nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH
113. es or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output capacitor bank of four capacitors for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 25 watt resistor 5 16 Nut driver 1 4 Nut driver Phillips head screw driver Wiring Diagram FE au nile 818 EJE 5 5 Bi iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 59 F 59 TROUBLESHOOTING amp REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 14 OUTPUT CAPACITOR BANK PRINTED CIRCUIT BOARD LOCATION 1 PC BOARD COVER 2 PC BOARD COVER MOUNTING SCREW 2 Q E 6 o n 9 HM oc Return to Master TOC 3 PC BOARD MOUNTING SCREW 5 4 CAPACITOR BANK MOUNTING SCREW 4 5 VERTICAL BAFFLE 6 CAPACITOR 4 7 BUSS BAR 2 8 PC BOARD P E 09 8 3 Bis c PROCEDURE Before starting the following procedure refer to 5 With the 5 16 nut driver remove the five the topic PC Board Troubleshooting Proce screws holding the right case side 6 Remove the right case side by lifting u
114. eturn to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 E 4 p ac Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 RANGER 9 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only 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 malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main categories Output Problems Engine Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJ USTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed
115. faulty Replace If in step 1 the contactor does NOT drop out then the contac tor may be stuck Repair or replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN RANGER 9 RANGER 9 19 19 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 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 gen erator field is operating properly Return to Section TOC Return
116. from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 787 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 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 2 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 below Threshold Limit Values TLV 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosge
117. ge Test is nor mal then perform the Resistance Test If the Rotor Voltage Test is NOT normal perform the Then check the field diode bridge D2 the field capacitor C1 and the Output Control Replace if necessary If the field bridge field capacitor and Output Control are good then the printed circuit board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio FE 5 nile 818 EJE Bi iac Return to Section TOC Return to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No weld output the auxiliary power 230 115VAC is operating normally Engine operates normal ly Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 With the WELDING TERMINAL switch in the ALWAYS ON position check the open circuit voltage OCV at the welder out put terminals Normal maxi mum is 73 to 80VAC Normal DC maximum is 65 to 75VDC If the OCV is OK then proceed to Step 2 If the OCV i
118. he IDLER switch in the HIGH position Return to Section TOC Return to Master TOC FIGURE C 5 Q gt RANGER 9 LN 7 WITH K867 ADAPTER CONNECTION DIAGRAM E E T o dei 14 AMPHEHOL TO WORK ELECIROOE m UNIVERSAL ADAPTER PLUG ELECTRODE CABLE TO WIRE FEED UNIT TENES K775 OPTIONAL B REMOTE CONTROL Return to Section TOC Return to Master TOC RANGER 9 RANGER 9 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei Return to Section TOC Return to Master TOC Q O H f 0 41 gt gt 5 ACCESSORIES CONNECTION OF THE LN 8 TO THE RANGER 9 SEE FIGURE C 6 1 Shut the welder off 2 Connect the electrode cable from the LN 8 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K867 Universal adapter to the LN 8 wire feeder and the 14 pin amphenol of the RANGER 9 as indicated in Figure C 6 Make the proper connections for local or remote control according to Figure C 6 and the following NOTES indicated on the figure A Insulate each unused lead individually B Splice the leads and insulate
119. he 14 pin amphenol on the RANGER 9 and the input cable plug on the LN 7 4 Set the welder polarity switch to the desired polarity either DC or DC 5 Setthe RANGE switch to the WIRE FEED posi tion 6 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 7 Place the WELDING TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire feed speed at the LN 7 and set the welding voltage with the output CONTROL at a CV constant voltage position at the welder NOTE optional remote control is used place the output control switch in the CONTROL REMOTE position FIGURE C 4 RANGER 9 LN 7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM 14 PIN AMPHENOL 6 PIN AMPHENOL RANGER 9 TO WORK LINCOLN TO LN 7 INPUT CABLE PLUG OPTIONAL K857 REMOTE CONTROL K584 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT RANGER 9 ACCESSORIES NNECTION OF THE LN 7 TO THE SLE CAUTION RANGER 9 USING K867 UNIVERSAL ADAPTER SEE FIGURE C 5 Any increase of the high idle engine RPM by changing
120. he engine and allow it to cool before refuel ing 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 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known 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 1 6 some cases it may be necessary to remove safety them with tape when possible 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 2 d 2 Never coil the electrode lead aro
121. he oil fill cap and dipstick TABLE D 1 RECOMMENDED OIL VISCOSITY GRADES USE THESE SAE VISCOSITY GRADES TEMPERATURE RANGE YOU EXPECT BEFORE NEXT OIL CHANGE 15 1170 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ra o n 9 c oc Return to Section TOC Return to Master TOC Q Es 7 2 gt t a MAINTENANCE FIGURE D 1 OIL DRAIN AND REFILL LOCATION 1 DIPSTICK OIL FILL 2 OIL DRAIN PLUG CHANGE THE OIL FILTER Change the oil filter the first time after 25 hours of operation Then under normal operating conditions change the oil filter after every other oil change If the engine is operated under heavy load or in high ambi ent temperatures change the oil filter more frequently See able D 3 for recommended maintenance inter vals Change the oil filter as follows 1 Drain the oil from the engine and allow the oil filter to drain 2 Remove the old filter spin it off and discard it Wipe off the filter mounting surface and adapter 3 Apply a thin coat of new oil to the rubber gasket on the new oil filter 4 Spin the new filter onto the mounting adapter until the gasket just touches the mounting surface then turn it down another 1 2 to 3 4 turn Do not over tighten the new filter 5 Refill the engine with the proper amount and type of oil as described
122. he valves over time depending on engine loading conditions type of fuel used and other factors that affect engine perfor mance Consult your local Onan engine distributor for recommended cleaning intervals and procedures RANGER 9 MAINTENANCE TABLE D 2 ONAN ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine Fill fuel tank Check oil level Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Return to Section TOC Return to Master TOC Every 25 Hours Service precleaner element Service air cleaner element Change oil Every 50 Hours Every 100 Hours Check spark plug condition and gap Remove cooling shrouds and clean cooling areas Change oil filter Note 1 Change oil every 25 hours when operating under heavy load in high ambient temperatures Note 2 Clean more often under dusty conditions or when airborne debris is present E S p o n 9 oc Return to Master TOC S8 TABLE D 3 2 ENGINE MAINTENANCE PARTS 219 E E Part Part Number Onan 23 313 Oil Filter Onan 122 0645 2 FRAM PH3614 Fuel Filter Onan 149 2005 FRAM G1 Air Cleaner Element Onan 140 2628 01 FRAM CA140PL Air Cleaner Precleaner Onan 140 1496 Spark Plugs Onan 167 0263 Champion RS14YC 025 gap 64 mm Return to Section TOC
123. heating and create a fire hazard 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 though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 LINCOLN xa CYLINDER may explode 76 if damaged 7 a Use only compressed gas cylinders containing the correct shie
124. incoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN RANGER 9 F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual Return to Section TOC Return to Master TOC PROBLEMS SYMPTOMS No auxiliary power at receptacles welding output is normal engine runs normally POSSIBLE AREAS OF MISADJUSTMENT S 1 OUTPUT PROBLEMS If the machine is equipped with circuit breakers check circuit breakers CB2 through CB7 Reset if tripped Make sure the Output Control R3 is set at the maximum RECOMMENDED COURSE OF ACTION 1 2 Check the auxiliary power receptacles and associated wires for loose or faulty con nections Perform the Auxiliary and Field Winding Voltage Test position If the machine is equipped with circuit breakers check for faulty breakers and loose or faulty connections on associat ed wiring Check for a loose or faulty plug s at the power recepta cle s Return to Section TOC Return to Master TOC oio lu nile 818 E Bi iac A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before
125. ine the oil fill cap and dipstick are a unit See Figure D Ilin the Maintenance section of this manual 3 Add oil if necessary to bring the level up to the full mark Do not overfill Replace the dipstick and tighten it securely Check and fill the engine fuel tank 1 Remove the fuel tank cap 2 Fill the tank approximately 4 inches 100 mm from the top of the filler neck to allow for fuel expansion observe the fuel gauge DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely NOTE Use only fresh unleaded gasoline with octane rating 87 or higher Gasoline alcohol blends are approved for use with your engine as long as the blend does not exceed 1096 ethyl alcohol by volume Other gasoline alcohol blends are not approved and their use may damage fuel system and engine parts NOTE Purchase gasoline in quantities that will be used within 30 days to assure freshness STARTING THE ENGINE NOTE Remove all loads connected to the AC power receptacles before starting the gasoline engine e If the engine is cold pull the choke For a cold engine 1 Set the Idler Control Switch in the AUTO position Use the Choke Control as follows control out If the engine is warm or hot DO NOT use the choke control RANGER 9 LINCOLN 2 Hold the Engine Switch in the START position Release the switch when the engine starts Slowly return the choke control to the ful
126. into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in con junction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter The following information and the connection diagram Figure A 2 can be used as a guide by the electrician for most applications to premises wiring 1 Install a double pole double throw switch between the power company meter and the premises dis connect The switch rating must be the same as or greater than the premises disconnect and service overcurrent protection 2 Take the necessary steps to assure that the load is limited to the capacity of the RANGER 9 by installing 40 amp 230 volt double pole circuit breaker Maximum rated load for the 230 volt aux is 40 amperes Loading above 40 amperes will reduce output voltage below the allowable 1096 of rated voltage This may damage appli ances or other motor driven equipment 3 Install a 50 amp 115 230 volt plug NEMA type 14 50 to a double pole circuit breaker using No 8 4 conductor cable of the desired length The 50 amp 115 230 volt plug is available in the optional power plug kit See the Accessories section for details 4 Plug this cable into the 50 amp 115 230 volt receptacle on the
127. ion TOC Return to Master TOC Return to Master TOC F 16 F 16 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The contactor does not pull in 1 Make sure the WELDING TER 1 Check the WELDING TERMI when scratch starting when the MINALS switch S6 is in the NAL switch S6 and associated engine goes to high idle ALWAYS position wiring Check for the presence of 12VDC from lead 224 to lead 232 at the output con tactor If the correct voltage IS present and the contactor does not activate then the contactor may be defective Replace If the correct voltage is present in step 2 check from lead 224 to ground lead 5 for the presence of 12VDC If the 12VDC is present then check lead 232A to the Idler printed circuit board The printed circuit board be faulty Replace If 12VDC is NOT present from lead 224 to ground lead 5 then check the 224 lead for an open circuit See Wiring Diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN E RANGER 9 RANG
128. ired polarity 5 Do not AC TIG weld on the 250 AC range setting The output current may exceed the rating of the RANGER 9 6 Start the arc and begin welding NOTE When using the RANGER 9 for AC TIG weld ing of aluminum the TIG Module is to be set for CONTINUOUS HF o n 9 oc Return to Master TOC 918 512 TABLE 2 AC TIG WELDING ELECTRODE RANGE SETTINGS c JE 9 Settings for Pure Tungsten Tungsten Diameter inches Range Switch Settings Appropriate Current Range 1 8 90 or 120 160 200 Amps 3 32 45 or 90 45 140 Amps 1 16 45 or 90 45 100 Amps Settings for 1 Thoriated Tungsten 5 5 Tungsten Diameter inches Range Switch Settings Appropriate Current Range S ys 90 120 or 180 160 250 Amps 818 3 32 45 90 120 100 180 Amps c E S 116 45 or 90 60 120 Amps 0 iac LINCOLN amp RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o n 9 HM E oc Return to Section TOC Return to Master TOC g o 7 2 gt a a OPERATION To Use the RANGER 9 for DC Wire Feed Welding Constant Voltage 1 RANGER 9 Connect one of the following the LN 25 LN 7 LN 8 or LN 742 Wire Feeder Follow
129. l in position engine will run at high idle for 10 14 seconds then go to low idle 3 Letthe engine run at low idle for a few minutes to warm up before you use the RANGER 9 for weld ing or auxiliary power If the engine will not start see the shooting section of this manual STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by running it for several minutes at low idle 2 Stop the engine by placing the Engine Switch in the STOP position A fuel shutoff valve is not required on the RANGER 9 because the fuel tank is mounted below the engine BREAK IN PERIOD Any engine will use a small amount of oil during its break in period For the gasoline engine on the RANGER 9 break in is about 50 running hours Check the oil at least twice a day during break in Change the oil after the first 25 hours of operation Change the oil filter at the second oil change For more details see the Maintenance section of this manual CAUTION During break in subject the RANGER 9 to moderate loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes RANGER 9 OPERATION Qjo 1 TYPICAL RANGER 9 FUEL CONSUMPTION E 5 gt j 9 ONAN P218 PERFORMER Low Idle No Load 2150 RPM 40 Gallons hour 1 5 liters hour B Li 9
130. l Specifications ET 2 9 3 Location and 3 3 SEAC KING 4 4 ee ves 4 5 High Altitude Operaatio Msisi A 4 Ja Pre operation Engine 4 1 1 emen nnne nenne nennen nnne A 4 a nah 4 gt 2 I TIE 4 Battery Conn HORS 4 9 Muffler Relocation 5 S 5 Electrical Output nennen nne 5 Welding Cable Connections iade etr b ad Ha a dein ee Ein A 6 Cable Size and 3 2 eene A 6 Cable Installationz uis url 6 Machine Grounding thm 6 Auxiliary Power Receptacles Plugs and Hand Held A 7 Circ UIE BEAK ONS ri ioco pne 7 Premises WIRING
131. l troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This dia gram is intended to provide general information regarding PC board function Lincoln Electric discour ages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in dam age to the machine LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC DIAGRAMS RF BYPASS PC BOARD M16675 COMPONENTS Item Description 13 CONNECTOR MOLEX MINI PCB 4 P IN J4 CONNECTOR MOLEX MINI PCB 6 P IN 5 CONNECTOR MOLEX MINI PCB 8 PIN 1 2 3 4 CAPACITOR CD 0047 005 1400V 20 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This dia gram is intended to provide general information regarding PC board function
132. ld Voltage Waveform one diode F 41 Abnormal Open Circuit DC Weld Voltage Waveform High CV Mode Output Capacitor Bank not FUNCTIONING F 42 Normal Open Circuit Weld Voltage Waveform High CV Mode F 43 Normal Open Circuit DC Weld Voltage Waveform ssssseee em F 44 Normal Open Circuit AC Weld Voltage 2 F 45 Replacement Procedures om coord tpe egre m alo brc V feud dro F 46 Brush Removal and Replacement 60 ee eene F 46 Field Capacitor and Rectifier Bridge Removal and Replacement F 49 Printed Circuit Board Removal and F 52 Output Rectifier Bridge Removal and F 55 Output Capacitor Removal and F 58 Output Contactor Removal and 0 een F 61 Engine Rotor Removal and Replacement Kit 520788 F 64 Retest After o ecu e RS F 69 o 0 4 gt hz c a 0 a Return to Master TOC LINCOLN E RANGER 9 RANGER 9 R
133. ld or auxiliary the print ed circuit board deactivates the idler solenoid and the engine returns to high RPM NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 9 LINCOLN RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FP au 5 nile 818 EJE E Bi iac Return to Section TOC Return to Master TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 ROTOR FIELD FEEDBACK AUXILIARY AND WIRE FEEDER POWER RANGE SWITCH NS REACTOR WORK TERMINAL PART OF FF RANGE 1 SWITCH CAPACITORS POLARITY SWITCH OUTPUT RECTIFIER BRIDGE AC gt OUTPUT L contactor MECHANICAL ROTOR STARTER RINGS FLYWHEEL ALTERNATOR LILA C ELECTRODE TERMINAL m IDLER SOLENOID DEAL PRINTER CIRCUT BOARD BATTERY FIELD CAPACITOR 31 FIELD BRIDGE BY PASS BOARD CONTACTOR CLOSURE 115 amp 230VAC RECEPTACLES CONTACTOR CLOSURE OUTPUT CONTROL REMOTE SWITCH
134. lding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with th
135. ll with fresh 10W30 oil Change the oil filter 4 Remove the spark plugs and add one to two table spoons of engine oil or rust inhibitor into each cylinder Replace the spark plugs but do not con nect the plug leads Crank the engine two or three times to distribute the oil 5 Clean any dirt and debris from the cylinder and cylinder head fins and other exterior surfaces 6 Store ina clean dry area RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FE nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC 4 INSTALLATION STACKING RANGER 9 machines CANNOT be stacked TILTING Place the machine on a secure level surface whenev er you use it or store it Any surfaces you place it on other than the ground must be firm non skid and structurally sound The gasoline engine is designed to run in a level posi tion for best performance It can operate at an angle but this should never be more than 15 degrees in any direction If you do operate it at a slight angle be sure to check the oil regularly and keep the oil level at the FULL mark as it would be in its normal level condition Also fuel capacity will be a little less at an angle LIFTING The RANGER 9 weighs 562 105 255 kg A lift bail is mounted to the generator stator frame and should always be used when lifting the machine HIGH ALTITUDE OPERATI
136. meter or diode tester check each of the four diodes from their pigtails to their respective heat sinks See Figure Reverse the tester leads and check the diodes again Diodes should have a low resistance in one polarity and a very high resistance in the opposite polarity Replace any shorted or open diode as the tests indicate Reconnect the diode pigtails and heavy leads to their respective studs Reinstall the case side case top fuel cap lift bale gasket and spark plug wires RANGER 9 31 31 TROUBLESHOOTING amp REPAIR CHARGING CIRCUIT TEST WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the Flywheel Alternator Regulator and associated circuitry are functioning properly Return to Section TOC Return to Master TOC
137. miautomatic wire feed welding For more details on using the machine as a welder see WELD ING OPERATION in the Operation section of this manual GENERATOR The RANGER 9 gives AC generator output for medium use demands Formore details on operating the gen erator see AUXILIARY POWER in the Operation tion of this manual OPERATIONAL FEATURES AND CONTROLS The RANGER 9 was designed for simplicity There fore it has very few operating controls Three switch es are used for welding operations Anine position output range selector switch selects current output for constant current stick or TIG applications and constant voltage wire feed appli cations A fine output control switch for fine adjustment of current or voltage within the selected output range three position polarity switch for selecting DC DC or AC welding output A two position toggle switch for selecting between CONTROL AT WELDER or REMOTE CONTROL Remote control connections are made at either the 6 pin or the 14 pin amphenol connector A two position toggle switch for selecting between control of the output contactor by the RANGER 9 WELDING TERMINALS ALWAYS ON or control of the output contactor by a cable from a wire feeder gun WELDING TERMINALS REMOTELY CON TROLLED The gasoline engine control is a three position toggle switch for START RUN and STOP and a two position IDLER switch that selects engine speed for welding
138. n be adjusted by setting the POLARITY SWITCH the OUTPUT RANGE dial and the FINE CONTROL dial on the output control panel to the settings that are best for your selected welding process To use the RANGER 9 for AC DC Constant Current Stick Welding 1 Removethe flange nuts from output terminals and place the work and electrode welding cables over the terminals See Figure B 3 Replace and tight en the flange nuts securely Be sure the connec tions are tight 2 Select the appropriate electrode See Welding Tips 1 included with your RANGER 9 3 Attach the work clamp securely to the work you are welding Insert the electrode into the electrode holder 5 Setthe IDLER CONTROL to AUTO and start the gasoline engine See ENGINE OPERATION in this section of the manual 6 Setthe OUTPUT RANGE dial to a setting equal to or slightly higher than the welding current recom mended for the electrode being used 7 Setthe POLARITY SWITCH to the desired polarity Set the FINE OUTPUT CONTROL Use a setting that results in the highest output at the lowest set ting of the RANGE switch for the application 9 Strike an arc and begin welding After you finish welding 1 Stop the gasoline engine See ENGINE OPERA TION Jin this section of the manual 2 Allow the electrode and work to cool completely 3 Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder 5 f you are finished using
139. n de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis d
140. n go on either terminal LINCOLN 5 Slide the bridge back into the molded plas tic holder until the retainer clip snaps it securely in place Snap the capacitor back into the holder and then slide the unit back into position in the panel Replace the cable tie Check that the leads are not grounded and for clearance and tightness Reinstall the case side fuel cap lift bale gasket and case top RANGER 9 F 52 F 52 TROUBLESHOOTING amp REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this man ual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the printed circuit board for main tenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 1 4 Nut driver Di
141. n you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in accessing the generator brushes for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 5 16 Open end wrench 3 8 Wrench 7 16 Wrench Slot head screw driver Needle nose pliers LINCOLN E RANGERS F 46 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O FP AE nile 518 EJE 5 5 DIH ro O aic Return to Section TOC Return to Master TOC F 47 RANGER 9 F 47 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT continued PROCEDURE 1 2 10 11 12 13 Remove the spark plug wires With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bale Remove the fuel cap The rubber gasket for the fill tube with come off with the case top Remove the case top then reinstall the fuel cap With the 5 16 nut driver remove the 5 screws holding the right case side Remove the right case side by lifting up and out With the 3 8 wrench remove the screws holding the right stator cover Thi
142. nan Code 9975 G 2 Wiring Diagram RANGER 9 Onan CSA Code 9976 G 3 Control PC Board 19062 5 0002010 meer G 4 RF Bypass PC Board 16675 Schematic sssseeeennnemnnnnnennnns G 5 0 EE G 6 Control PC Board 19062 Layout eee nennen nnns G 7 Control PC Board 19062 5 00 nennen nnne nnns G 8 RF Bypass PC Board M16675 Layout eene nennen G 9 RF Bypass PC Board M16675 Components sss emm eem G 10 Return to Master TOC Q 7 4 gt gt 5 Return to Master TOC LINCOLN E RANGER 9 RANGER 9 G 2 G 2 DIAGRAMS WIRING DIAGRAM RANGER 9 ONAN CODE 9975 RANGER 9 ONAN 3 TURNS IDLER CURRENT SENSOR Return to Section TOC Return to Master TOC WELDING TERMINAL CONTROL SWITCH SHOWN IN ALWAYS ON POSITION 31 000 MFD CAPACITORS E REACTOR 3 TT Return to Master TOC OUTPUT RHEOSTAT 75 te MAX 10K POT 75A Q oW rep WORI ELECTRODE 77D Return to Section TOC IDLER SHOWN IN SOLENOID HIGH 1 POSITION AMPHENOL 1 ouod i E 208 Dj D 0 4A 1 ok 224A 4 212 465 224B 4O 2 fil WORKS 21 REMOTE CONTROL 1 E0477 n CAPACITOR 76 l XR CONTACTOR BLACK W
143. ne a highly toxic gas and other irritating products 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 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 Mar 95 Return to Master TOC Return to Master TOC Q 0 2 gt a a Return to Master TOC 7 WELDING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If 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 adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause over
144. ne Operator or Technician Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting PC age to the machine gram is intended to provide general information regarding PC board function Lincoln Electric discour NOTE DOL J931se u 03 unge d DOL uonoes oj WINDY LINCOLN E RANGER 9 RANGER 9 G 6 G 6 DIAGRAMS OF SHAFT 2 75 FOR OIL FILTER REMOVAL DIMENSION PRINT DOL Se W UINJ Y DOL UOn298S 03 UINJ Y DOL Se W 0 DOL uonoes o3 WINDY CENTER OF GRAVITY WITH OIL ULL FUEL TANK 21 21 1 20 51 N rm 2 2 rm gt 2 10 32 Qo de E 880 30 00 42 00 UNDERCARRIAGE MOUNTING HOLES RANGER 9 ONAN DIMENSION PRINT 7216 12 16 93 DOL J931se A 03 unge d DOL uonoes o3 WINDY DOL 4 35 03 unge d DOL uonoes oj WINDY RANGER 9 LINCOLN E RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC T o dei I Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 DIAGRAMS CONTROL PC BOARD L9062 LAYOUT ES RANGER 9 CONTROL Jt NOTE Lincoln Electric assumes no respon
145. nections The battery may be faulty RECOMMENDED COURSE OF ACTION l If the battery is replaced or tests good then the charging circuit may be faulty Perform the Charging Circuit Test The starter motor or starter solenoid may be faulty The engine may be hard to crank due to a mechanical fail ure in the engine The engine shuts off or will not start The engine may be low or out of fuel The oil level may below Check and fill to proper level The fuel filter may be clogged The oil pressure switch may be faulty Replace if necessary See Wiring Diagram The engine does not develop full power The fuel filter may be clogged Replace if necessary The air filter may be clogged Replace if necessary The spark plug may be faulty Replace if necessary Due to wear the engine may be in need of major repair CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN RANGER 9 Return to Section TOC Return to Section TOC Return to Master TOC oio Fe au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC Return to Master TOC F 13 F 13 TROUBLESHOOTING amp REPAIR Observ
146. negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time WELDER GENERATOR MAINTENANCE STORAGE Store the RANGER 9 in clean dry pro tected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It s normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary Remove the brushes and clean the slip rings with fine emery paper Refer to the Brush Removal and Replacement procedure in the Trouble shooting and Repair section of this manual CAUTION Do not attempt to polish slip rings while the engine is running RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC Return to Master TOC D 8 MAINTENANCE To reinstall the brushes press them upward and slide a cable tie or wooden stick through the brush holder tabs See Figure D 4 Install the brush holder into position and secure with th
147. nt every 50 hours and the pre cleaner every 25 hours If the air cleaner doesn t have the precleaner service the element every 25 hours Under dusty conditions service more often Check the air cleaner every day or before starting the engine for any buildup of dirt debris or loose or damaged components CAUTION DO NOT OIL THE ELEMENT OR USE PRESSURIZED AIR TO CLEAN THE ELEMENT DO NOT WASH THE ELEMENT Remove the air cleaner cover 1 Remove the cover nut cover element cover nut and element cover Figure D 2 2 Carefully remove the foam precleaner if equipped from the element To service the precleaner Wash in liquid detergent and water Squeeze dry in a clean cloth Saturate in clean engine oil gt WN LG Squeeze in a clean absorbent cloth to remove all excess oil To service the element 1 Tap gently on a clean surface 2 Inspect all air cleaner components including cover and base components for wear or damage Check that all sealing surfaces are in good condition 3 Replace with a new element if the old one is very dirty bent or otherwise damaged Carefully place the precleaner back over the element and reinstall and secure the air cleaner cover compo nents RANGER 9 LINCOLN P FIGURE D 2 AIR CLEANER COMPONENTS ONAN ENGINE 1 COVER NUT 2 COVER 2A ELEMENT COVER NUT ELEMENT COVER ELEMENT PRECLEANER ELEMENT BASE
148. ntal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals FP lu nile 818 EJE 5 5 DIH o aic SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 44 F 44 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM Return to Section TOC Return to Master TOC CH1 0 volts Return to Section TOC Return to Master TOC 50V 5 ms 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 output terminals FP lu nile 818 EJE 5 5 DIH o aic SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div COUDIING s DC Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 45 F 45 TROUBLESHOOTING amp REPAIR Q NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE LOAD
149. nything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it AX Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPTION The RANGER 9 is a gasoline engine driven multi process arc welder and AC power generator for com mercial and residential applications As a generator it can supply up to 9 000 continuous watts of 115 230 volt 60 Hz single phase AC power to operate AC power tools battery chargers and lighting it can also be used to provide standby power As a welder it pro vides 250 amps of AC current for welding with AC stick electrodes or 250 amps of DC current for DC stick welding RANGER 9 can also perform AC DC TIG welding and DC semiautomatic wire feed welding The RANGER 9 is powered by the Onan P218 Performer air cooled twin cylinder engine RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC AM o n 9 HM oc Return to Section TOC Return to Master TOC o o Es 0 2 5 gt a J a OPERATION RECOMMENDED APPLICATIONS WELDER The RANGER 9 provides excellent constant current AC DC welding output for stick GMAW welding and for TIG welding and it offers constant voltage output for DC se
150. o aic Return to Section TOC Return to Master TOC F 25 RANGER 9 F 25 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST continued FIGURE F 3 LOCATION OF LEADS 3 AND 5 115V me Lead 5 TEST PROCEDURE To test the 115 VAC winding 1 Remove the fuel cap and lift bale rubber gasket With the 5 16 nut driver remove the case top and left side then reinstall the fuel cap Connect the volt ohmmeter probes to leads 3 and 5 where they connect to the 115 VAC receptacle See Figure F 3 Startthe engine and run it at high idle 3700 RPM Set the output control to the maximum position position 10 Checkthe AC voltage reading It should be approximately 125 VAC LINCOLN Machine Case To test the 230 VAC winding 1 Remove the fuel cap and lift bale rubber gasket With the 5 16 nut driver remove the case top and left side then reinstall the fuel cap Connect the volt ohmmeter probes to leads 6 and 3 where they connect to the 230 VAC receptacle NOTE It is easier to insert the probes direct ly into the receptacle to perform this test However the probes may not reach in far enough to make or keep a good connection In this case before you start the gasoline engine insert two test probes into the recep tacle Hold the test probes firmly in place to measure voltage Step 5 3 Start the engine and run it at high idle 3700 RPM Set th
151. oltage regulator may be faulty Replace the entire voltage regulator module If the DC voltage reading is correct check the associated wiring and circuitry See the Wiring Diagram RANGER 9 33 33 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJ USTMENT TEST WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION If the machine output is low this test will determine whether the gasoline engine is operating atthe correct speed RPM during both HIGH and LOW idle conditions Directions for adjust ing the throttle to the correct RPM are given Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 open end or box wrench Strobe tach frequency counter oscilloscope or vibratach Black or red marking pencil FE au nile 818
152. on the left side It can be changed to the right side by removing two screws that hold the exhaust port cover in place and installing the cover on the opposite side NOTE Operating the RANGER 9 without the cover in place will not increase the machine output and will result in a higher noise level SPARK ARRESTER Gasoline engine mufflers may emit sparks when the engine is running Some federal state or local laws require spark arresters in locations where unarrested Sparks could present a fire hazard RANGER 9 LINCOLN OUTPUT RANGE SELECTOR FINE OUTPUT CONTROL CONTROL AT WELDER REMOTE CONTROL SWITCH WELDING TERMINALS SWITCH POLARITY SWITCH 115 230 VOLT 50 AMP RECEPTACLE 115 VOLT 20 AMP RECEPTACLES 2 WELD OUTPUT TERMINALS 2 GROUND STUD Standard mufflers and deflectors like the ones includ ed with the RANGER 9 do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly maintained An optional spark arrester kit K894 1 is available for your RANGER 9 See of this ual for more information CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the output range selector fine output control polarity switch control at welder remote control switch welding terminals always on remot
153. otor 4 ENGINE HOUR METER Records engine running time Use the meter to determine when to perform required maintenance 5 BATTERY CHARGING SYSTEM METER Shows whether the charging circuit is performing its job of charging the battery when the engine is running The meter will register discharge during starting but then the needle should return to a position slightly toward positive during running The needle will hold position when the engine stops ENGINE OPERATION WARNING DO NOT RUN THE ENGINE EXCESSIVE SPEEDS The maximum allowable high idle speed for the RANGER 9 is 3750 RPM no load Do NOT adjust the governor screw on the engine Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed Read and understand all safety instructions included in the Onan instruction manual that is shipped with your RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC re 9 E 4 42 ac Return to Section TOC Return to Master TOC o 7 2 gt a OPERATION BEFORE STARTING THE ENGINE Check and fill the engine oil level 1 Be sure the machine is on a level surface 2 Remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dipstick On the Onan eng
154. p FIGURE E 4 WELD WINDING REACTOR AND RANGE SWITCH 519 D D RANGE gt SWITCH 81 8 x EJE AC CHOKE 5 5 7 OUTPUT _ PART OF EE SR 92 az NR n CAPACITORS C Y L CONTACTOR LA K ELECTRODE TERMINAL MECHANICAL ROTATION ENGINE ROTOR e anes ROTOR FLYWHEEL olg D MN ae a Lg IDLER J SOLENOID 9 6 gt PRINTER CIRCUT BOARD olg BATTERY m Em CAPACITOR I Zils 115 amp 230VAC 4 RECEPTACLES t e 3L e BRIDGE BY PASS BOARD CONTACTOR CLOSURE CONTACTOR CLOSURE OUTPUT CONTROL SWITCH 115VAC ji 42VAC 6 PIN 14 PIN AMPHENOL AMPHENOL WELD WINDING REACTOR AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch The inductance in the reactor offers an impedance to current flow The reactor coil is tapped at various points As the range switch is ro tated different amounts of reactor coil are brought into the current path As more turns of reactor are brought into the circuit the more impedance there is to current flow Simply stated the more reactor in the circuit
155. p and 1 With the 5 16 nut driver remove the 6 sheet out 7 Remove the engine spark plug wires 8 With the 5 16 nut driver remove the printed circuit board cover See Figure F 14 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 Return to Section TOC Return to Master TOC 4 Remove the case top then reinstall the fuel cap Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 AM o n 9 HM E oc Return to Section TOC Return to Master TOC Q O H f 0 gt gt 5 F 60 F 60 TROUBLESHOOTING amp REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT continued 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 9 With the 1 4 nut driver remove the five 10 11 12 RANGER 9 screws holding the printed circuit board Carefully pull the printed circuit board aside supported by the leads still connected to it so that all the screws that mount the capac itor bank to the vertical baffle are accessi ble With the volt ohmmeter check the voltage
156. plugs Replace any cable ties that were cut dur ing the removal procedure With the 5 16 nut driver install the printed circuit board cover Reinstall the case side fuel cap lift bale gasket case top and spark plug wires RANGER 9 55 55 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output rectifier bridge for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 1 2 Wrench 3 8 Wrench Slot head screw driver Dow Corning 340 Wiring Diagram FP lu nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN
157. r 5 16 nut driver Slot head screw driver 3 8 Wrench 7 16 Wrench 1 2 Wrench 9 16 Wrench 5 8 Wrench Locking pliers Needle nose pliers Diagonal cutters Impact wrench Torque wrench ft lbs Feeler gauge 017 FP lu nile 818 EJE Bi o iac INSTRUCTIONS For Engine and Rotor removal only follow steps 1 25 under ENGINE AND ROTOR REMOVAL PROCEDURE For reassembly of engine and rotor go to REASSEMBLY PROCEDURE For rotor removal follow the ENGINE AND ROTOR REMOVAL PROCEDURE and ROTOR REMOVAL PROCEDURE Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 65 F 65 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 17 COMPONENT LOCATIONS ENGINE ROTOR REMOVAL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC STATOR COWLING COVER BLOWER FAN IDLE LINKAGE BRUSH HOLDER BRACKET ENGINE LIFT BAILS STATOR ENGINE MOUNTING BOLT ROTOR ROTOR SHAFT BEARING ROTOR THRU BOLT FP lu 5 nile 818 EJE 5 5 DIH o iac Return to Section TOC Return to Master TOC LINCOLN amp RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio FE AE 9 5 nile 818 EJE 5 5 DIH ro O iac Return to Section TOC Return to Master TOC F 66
158. rmal weld output and auxiliary power POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 1 Make sure the Idler switch 55 is in the Auto position Make sure there is NOT an external load on the weld termi nals nor the auxiliary power receptacles TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 With the Idler switch S5 in the AUTO position and the engine running check for the presence of 12VDC at leads 224D to 214 located at the Idler sole noid If 12VDC is present and the idler solenoid is not activat ing then the solenoid may be faulty or there is a mechanical restriction preventing it from functioning If there is NOT 12VDC at leads 224D to 214 then test for 12VDC from lead 224D to ground lead 5 See Wiring Diagram If 12VDC is present then check lead 7214 for conti nuity zero ohms from the idler solenoid to the printed circuit board plug 8 1 Also check the idler switch 55 and the associ ated leads See Wiring Diagram If the above are OK then the printed circuit board may be faulty Replace If there is NOT 12VDC from lead 2240 to ground lead 5 then check the wiring to the engine terminal block connection See Wiring Diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance befor
159. ry Charging Ammeter Engine Hour Meter for determining periodic mainte nance Top of the line 18 HP Onan P218 Performer engine Durable heavy gauge steel case Built in feet for easy mounting to truck bed or trailer Bottom mounted 10 gallon 38 0 litre fuel tank with convenient top fill and fuel gauge RANGER 9 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC AM o n 9 HM E oc Return to Section TOC Return to Master TOC o 0 2 5 gt a a OPERATION Quiet engine muffler with reversible exhaust feature for right or left side All copper alternator windings and high quality insu lation for dependable long life Automatic engine shutdown protection for low oil pressure Automatic engine idler goes to low idle 10 to 14 seconds after welding for greater fuel economy includes high idle switch Standard Remote Control Receptacle provides interface for Lincoln remote control accessories Both 6 pin and 14 pin amphenols are provided for ease in hooking up wire feeders Canadian Standard Association CSA approved models available include integrated generator out put overload protection through two 50 amp circuit breakers WELDING CAPABILITY The RANGER 9 is rated 250 amps 25 volts constant current AC or 250 amps 25 volts constant current DC 250 amps 25 volts const
160. s NOT present at the welder output terminals contact your local Lincoln Authorized Field Service Facility Check the welding cables clamps and electrode holder for loose or broken connec tions RECOMMENDED COURSE OF ACTION Make sure the output contactor is being activated Also make sure there is continuity zero ohms through the contactor contacts 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 See 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 if necessary If the correct AC voltage is pre sent proceed to step 8 Check the reactor Range Switch S2 and associated wiring for loose or faulty con nections Check the reactor winding for continuity and test to be sure itis NOT grounded to the reactor iron Check the choke L1 Polarity Switch S1 and associated wires for loose or faulty connec tions Check the choke winding for continuity and test to be sure it is NOT grounded to the choke iron Check the weld output termi nals and associated wires for loose or faulty connections Perform the Output Rectifier Bridge Test A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the L
161. s connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 41 F 41 TROUBLESHOOTING amp REPAIR OJo ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM 9 5 HIGH IDLE NO LOAD OUTPUT CONTROL MAXIMUM j 9 ONE OUTPUT DIODE NOT FUNCTIONING 24 CH1 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms 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 non functioning output diode Each vertical division represents 50 volts and each horizontal division repre sents 5 milliseconds in time FP lu nile 818 EJE Bi o aic Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling n DC Trigger Internal Return to Section TOC Return to Master TOC LINCOLN 8 RANGER 9 RANGER 9 F 42 F 42 TROUBLESHOOTING amp REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH CV MODE HIGH I
162. s to prevent accidental engine kickback or starting LINCOLN P 10 11 12 Isolate the rotor electrically by removing the generator brush leads Refer to Figure F 2 as you perform the remaining steps Remove lead 219 from the negative brush Remove lead 200 from the positive brush Measure the resistance across the rotor slip rings A Set the ohmmeter on the low scale X1 B Place one meter probe on one of the rotor slip rings Place the other probe on the other slip ring C Check the resistance across the slip rings It should read between 7 and 8 ohms RANGER 9 23 23 TROUBLESHOOTING amp REPAIR 13 Measure the resistance to ground A Setthe 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 Return to Section TOC Return to Master TOC C Checkthe 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 then the rotor is okay 14 Connect lead 200 to the positive brush which is the one nearest the rotor lamination Connect lead 219 to the negative brush Return to Master TOC 15 Reinstall the case side case top fuel cap lift bale gasket and spark plug wir
163. s will expose the brush holder assembly With the needle nose pliers gently remove the blue and the red wires from the brushes Figure F 10 With the 7 16 wrench remove the brush holder assembly bracket from the stator frame With the 5 16 open end wrench remove the two screws that secure the brush hold er assembly to the bracket Slide the brush holder assembly out of the bracket To change the brushes use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly 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 LINCOLN P 14 15 16 17 18 19 20 21 Snap the plastic retainer back onto the brush holder The brushes may need some repositioning wiggle them slightly to help them seat properly on the slip rings To reinstall the brushes depress the spring loaded 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 see Figure F 10 This will hold the brushes up so that you can easily install the holder 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 With the 7 16 wrench install the brush holder assembly bracket to the stator frame Slowly remove the non me
164. sibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC board version This dia gram is intended to provide general information regarding PC board function Lincoln Electric discour ages board level troubleshooting and repair since it may compromise the quality of the design and may result in Danger to the Machine Operator or Technician Improper PC board repairs could result in dam age to the machine LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC FE au nile 818 EJE 5 21 Return to Section TOC Return to Master TOC Return to Master TOC G 8 G 8 DIAGRAMS CONTROL PC BOARD L9062 COMPONENTS X7 IC VOLT REF ADJ PRECISION 4311 X4 IC VOLT REG ADJ 3 T A X3 IC CMOS TIMER PROGRAMMABLE 4536 1 IC OP AMP QUAD GEN PURPOSE 224N TP2 MOV 130VRMS 38J 14MM 1 MOV 50VRMS 15 14MM R93 R94 RESISTOR MF 1 4W 75 0 1 R83 RESISTOR CC 1 2W 5 1 5 R71 RESISTOR MF 1 4W 332 1 R67 RESISTOR WW 5W 390 5 SQ R65 RESISTOR MF 1 4W 681K 1 R64 RESISTOR MF 1 4W 52 3K 1 R62 RESISTOR MF 1 4W 15 0K 1 R60 RESISTOR MF 1 4W 39 2K 1 R58 RESISTOR MF 1 4W 100K 1 R56 R72 RESISTOR MF 1 4W 1 00K 1 R55 RESISTOR MF 1 4W 1 82K 1 R5
165. ssoci ated wires for loose or faulty connections Check the choke winding for continuity and test to be sure itis NOT grounded to the choke iron Check the operation of the Polarity switch S1 Also check the associated wires for loose or faulty connections See Wiring Diagram Check for continuity from lead S2 to lead E located in the main stator See Wiring Dia gram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 RANGER 9 LINCOLN RANGER 9 Return to Section TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC Return to Master TOC F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No constant voltage CV welding output Constant current CC and the auxiliary power are operating normally Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make sure the Range switch S2 is in the proper position CV and seated correctly Make sure the wire feeder and welding cables are connected correctly RECOMMENDED COURSE OF ACTION Check the oper
166. stall use or service this equipment CONNECTION OF THE RANGER 9 WIRE FEEDERS USING K867 UNIVERSAL ADAPTER SEE FIGURE C 1 NOTE When you use the RANGER 9 with non Lincoln Electric wire feeders or with cer tain earlier models of Lincoln wire feeders you will require the K867 Univeral Adapter The following discussion and connection diagram explain in general how to make the proper connections 1 Shut the welder off 2 Connectthe electrode cable from the wire feeder to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K867 Universal Adapter to the 14 pin amphenol of the RANGER 9 as shown in Figure F 1 Make the proper connections for local or remote control according to Figure C 1 and the following NOTES indicated on the figure A These leads are not used for the RANGER 9 Insulate each unused lead individually B For wire feeders that return a signal for weld ing output use an isolation relay to close leads 2 TO 2 and 4 m MEE 4071 FEEDER C Referto the OPER ATION section of this manual for maximum auxiliary current draw 4 Set the welder polarity switch to the desired polarity either DC or DC 5 Setthe RANGE switch to the WIRE FEED posi tion 6 Place the IDLER switch in the HIGH position CAUTION
167. t case side case top fuel cap and lift bail gasket Return to Section TOC Return to Master TOC FP lu nile 818 EJE 5 5 DIH o aic Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 29 F 29 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST WARNING Service and repair should be performed by only 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there are faulty diodes in the Output Rectifier Bridge Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Diode Tester 5 16 Nut driver 1 2 Socket wrench Wiring Diagram FE a nile 818 EJE 5 5 Bi iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Section TOC Return to
168. t the welder off 2 Connect the electrode cable from the LN 742 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of hte welder NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K592 Control Cable to the 14 pin amphenol on the RANGER 9 and the input cable plug on the LN 742 4 Set the welder polarity switch to the desired polarity either DC or DC 5 Set the RANGE switch to the WIRE FEED posi tion 6 Place the IDLER switch in the AUTO or HIGH position as desired A CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary volage If this voltage goes over 140 volts wire feeder control cir cuits may be damaged The engine governor setting is preset at the factory do not adjust above RPM specifications listed in this manual 7 Place the WELDING TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire feed speed at the LN 742 and set the welding voltage with the output CONTROL to a CV constant voltage position at the welder NOTE If optional remote control is used place the output control switch in the CONTROL position FIGURE C 7 RANGER 9 LN 742 CONNECTION DIAGRAM 14 PIN AMPHENOL RANGER 9 TO WORK LINCOLN TO LN 742
169. t to the cir buit breaker CB1 and the 14 pin amphenol See the Wiring Diagram NOTE It is possible to check this voltage reading at the amphenol by inserting the test probes at pin K for lead 42 and for lead 31B See Figure 4A However if you use this method and get no voltage reading it could mean there is a break or loose connection in the leads between the circuit breaker and the amphenol Check the reading again with one probe at the circuit breaker connection for lead 31 and the other probe at amphenol pin K the other probe at amphenol pin A 3 Start the engine and run it at high idle 3700 RPM 7 Set the output control to the maximum position position 10 8 Check the AC voltage reading It should be between 43 and 50 VAC Return to Section TOC Return to Master TOC LINCOLN RANGER 9 RANGER 9 F 28 F 28 TROUBLESHOOTING amp REPAIR AUXILIARY AND FIELD WINDING TEST continued If the voltage readings are within specifica tions then the windings are good and func tioning correctly Return to Section TOC Return to Master TOC 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 that the windings are NOT grounded internally to the stator iron If the leads are intact then the stator may be faulty Replace the stator 9 Reinstall the lef
170. tallic retainer from the brush holder and let the brushes snap back against the slip rings With the needle nose pliers connect the red and the black wires to the appropriate terminals on the brushes The red wire is inboard Check the wire connections for clearance and tightness Reinstall the right stator cover case side fuel cap lift bale gasket case top and spark plug wires RANGER 9 F 48 F 48 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT continued SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal Brushes CAUTION should be inspected when a general overhaul is necessary If brushes are to be replaced clean Do not attempt to polish slip rings while engine slip rings with a fine emery paper is running Return to Section TOC Return to Master TOC FIGURE F 10 BRUSH LEADS BRUSHES RETAINED WITH CABLE TIE Return to Section TOC Return to Master TOC lu 5 nile 818 EJE Bi iac 1 BRUSH HOLDER ASSEMBLY BRACKET BOLTS 1 CABLE TIE 2 BRUSHES Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 F 49 F 49 TROUBLESHOOTING amp REPAIR FIELD CAPACITOR AND OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service repair should be performed by only Lincoln Electric factory trained personnel Unauthorized
171. th 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 2250 RPM RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o n 9 HM E oc Return to Section TOC Return to Master TOC 0 2 gt a a F 35 F 35 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE USTMENT TEST continued FIGURE F 8 HIGH IDLE USTMENT NUT vin Throttle Linkage 3 8 High Idle Adjustment Nut Choke Cable RANGER 9 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 adjust ment 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 9 for location of the adjustment nut Adjust the nut until the tach reads between 2150 and 2250 RPM Frequency Counter Method 1 Plug the frequency counter into one of the 1
172. tilated to an open outside area The RANGER 9 may be used outdoors Do not set the machine in puddles or otherwise submerge it in water Such practices pose safety hazards and cause improper operation and corrosion of parts Always operate the RANGER 9 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices WARNING Damage to the fuel tank may cause fire or explosion Do not drill holes in the RANGER 9 base or weld to the RANGER 9 base STORING 1 Store the machine in a cool dry place when it s not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from con struction activities moving vehicles and other hazards 2 If you will be storing the machine for over 30 days you should drain the fuel to protect fuel system and carburetor parts from gum deposits Empty all fuel from the tank and run the engine until it stops from lack of fuel If you prefer you can treat the gasoline with a stabilizer to prevent deteriora tion rather than drain the system Follow the sta bilizer manufacturer s instructions Add the cor rect amount of stabilizer for the size of the RANGER 9 fuel tank Fill the tank with clean fresh gasoline Run the engine for two to three minutes to circulate the stabilizer through the carburetor 3 While the engine is still warm drain the oil and refi
173. tions detailed throughout this manu al Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output contactor for mainte nance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Needle nose pliers 1 2 Wrench 3 8 Wrench Slot head screw driver Wiring Diagram FP lu nile 818 EJE 5 5 Bi iac Return to Section TOC Return to Master TOC LINCOLN E RANGER 9 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o n 9 HM oc Return to Section TOC Return to Master TOC 0 2 gt a a F 62 F 62 TROUBLESHOOTING amp REPAIR OUTPUT CONTACTOR REMOVAL AND REPLACEMENT continued FIGURE F 15 OUTPUT CONTACTOR LOCATION PROCEDURE 1 RANGER 9 With the 5 16 nut driver remove the 6 sheet metal screws from the case top Remove the rubber gasket cover seal from the lift bail Remove the fuel cap The rubber gasket for the fill tube will come off with the case
174. titution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports 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 RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP a nile 818 EJE 21 Return to Section TOC Return to Master TOC F 4 F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident No weld output and no auxiliary power Engine operates normally POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Lincoln Service local Field 1 Contact your Authorized Facility Make sure the REMOTE switch S4 is in the proper position MACHINE CONTROL if a remote control unit is NOT con nected to the machine Check the brushes for wear and proper contact to the rotor slip rings TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact The Lincoln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD Perform the Rotor Voltage Test If the Rotor Volta
175. to Master TOC Return to Master TOC RANGER 9 Rectifier Retaining Tab Cable Tie Capacitor red wire terminals on the top of the capac itor See Figure F 11 for location Leave the clips on for at least 5 seconds then remove LINCOLN P 200 200A 200B Jumper PROCEDURE 9 Both the capacitor and the rectifier bridge are mounted in a molded plastic holder E Remove the engine spark plug wires To remove it pull out on the top of the 5 8 With the 5 16 nut driver remove the 6 holder then slide it upward 9 ky sheet metal screws from the case top 10 Cut the cable tie and then snap the 9 9 Remove the rubber gasket cover seal from capacitor out of the assembly E E the lift bale 11 Loosen the two screws on the top of the 5 Remove the fuel The rubber gasket for capacitor Lead 200 attaches to the posi lt the fill tube will come off with the case top tive terminal Lead 201 attaches to the negative terminal terminal Remove the case top then reinstall the fuel cap 12 To install the capacitor reattach the leads to their respective terminals 200 to posi With the 5 16 nut driver remove the 5 tive 201 to negative and tighten screws holding the right case side the screws Snap the capacitor back into Remove the right case side by lifting up and the molded plastic holder and slide the out holder back into position in
176. turn to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure l Determine to the best of your technical ability that the PC board is the most likely component caus ing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect 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 Remove your body s static charge before opening the static shield ing bag Wear an anti static wrist Aa ATTENTION strap For safety use a 1 Meg Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame adsl M If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Reusable Keep touching
177. u poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 RETURN MAIN INDEX id MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page nuieme e O i iv Installation sinna e nbl en De ahi s a G Section A Installation Section Table of Contents nennen nnns A 1 5 Dea me t P a d dane rd D nd s A 2 Safety Precautiors iter ien n des pe UC ee d Rl vader P d e be A 3 Location and p eei un 3 Pre operation Engine 0 4 Electrical Output 1 enne nennen nenne nnne enne A 5 Operation da Section B Safety Iristr ctloris nere cin dt edie teat aan etr en nes ee AE Ree ded nodes e ta Ceo B 2 General DESCNPUON ied a 2 Recommended Applications
178. und your body 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 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 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 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 8 Return to Master Return to Master TOC Q 0 2 gt a a Return to Master TOC 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 we
179. 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 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 wooden two by four before unhooking the chain hoist RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FP lu nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC F 67 RANGER 9 F 67 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 18 ENGINE AND ROTOR REMOVED FROM STATOR ROTOR REMOVAL PROCEDURE 1 To remove the rotor double check that the engine spark plug wires are disconnect ed You will be turning the rotor during this procedure and this could accidentally cause engine kickback With an impact wrench remove the rotor thru bolt See Figure F 18 an impact wrench is not available use the 5 8 box wrench Hold the rotor with one hand and shock the wrench with the mallet to loosen the thru bolt The thru bolt has a star wash er and lock washer beveled to conform to the rotor shaft Pull out the thru bolt Install the appropriate long thru bolt two are provided supplied with Lincoln Electric Rotor Removal Kit S20788 The slot head must face o
180. ut Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft about 3 4 LINCOLN 1 THRU BOLT 2 ROTOR Turning it counterclockwise screw in the left hand thread rotor removal tool from the kit into the rotor shaft Supportthe rotor with one hand and tighten the tool to approxi mately 50 ft Ibs with the torque or impact wrench 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 wash er that fits between the blower fan and the rotor RANGER 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O FP AE nile 8 8 EJE 5 5 Bi oO aic Return to Section TOC Return to Master TOC F 68 RANGER 9 bly 1 F 68 TROUBLESHOOTING amp REPAIR ENGINE ROTOR REMOVAL AND REPLACEMENT KIT S20788 continued REASSEMBLY PROCEDURE NOTE Lincoln Electric recommends that a new bearing Lincoln part 2M 9300 85 be installed when you replace the rotor and blower assem Clean the tapered engine crankshaft Slide the rotor onto the shaft Insert the rotor thru bolt and with the torque wrench tighten th
181. y changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 8 Place the WELDING TERMINALS switch in the REMOTELY CONTROLLED position 9 Adjust wire feed speed at the SG Control Module and set the welding voltage with the output CON TROL to a CV constant voltage position at the welder NOTE optional remote control is used place the output control switch in the CONTROL position FIGURE C 8 RANGER 9 AND 10LX K691 10 K488 K487 SPOOL GUN CONNECTION DIAGRAM 14 PIN WIRE FEEDER RECEPTACLE TO WORK ELECTRODE 6 PIN REMOTE RECEPTACLE ELECTRODE CABLE CONTROL MODULE TO WORK RANGER 9 LINCOLN K488 SG CONTROL MODULE K487 25 SPOOL GUN INPUT CABLE RANGER 9 Section D 1 Section D 1 TABLE OF CONTENTS 9 P MAINTENANCE 8 Maintenance ERR Section D 2 Safety Precautions e dco ape e e D 2 8 Routine and Periodic Maintenance nnne nennen nn D 2 8 Engine Maintenance enemies D 2 Change the re o D 2 Change the Oil Filter orbe ri eri dede D Rr D 3 d

Lincoln Electric 110-A User's Manual

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