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Lincoln Electric SVM150-A User's Manual

1. NC lt jeu HI AT THERMAL SENSE INDICATES OV D HERMAL LAMP ACTUATOR VERSION LESS OTHERWISE SPECIFIED Ge THE LINCOLN ELECTRIC CO Type _ ANALOG WELD CONTROL PCB CLEVELAND OHIO U S susyect CUR LIM TIG FEEDBACK ETC 04 t NOME rt pate 03 23 00 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN je co 3 RANGER 250 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Qjo ojo E E S o B olse wl SIS SIE s p w o o IG Return to Section TOC Return to Master TOC Gis ELECTRICAL DIAGRAMS el SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 5 Qumpen in Plug COIL DRIVE CIRCUIT IDLE HOLD COIL MULTIARC FAN w SHORT CIRCUIT PROTECTION FOR AUX USE PULL TO COM TO REMAIN TO IDLE PULL COIL CIRC COWL PCB METER_WELD_SIGNAL
2. V FEEOBACK Return to Master TOC Return to Section TOC Er MIN POT ENABLE fpga LO PINCH PO o o Ka Be g uo 8g E Li gt ES o ec o o FE E B ES o o wn 8g E 2 ES o ec ARC FORCE
3. REMOTE THE LINCOLN ELECTRIC CO E ANALOG WELD CONTROL PCB CLEVELAND OHIO U S A sussect SETPOINT PWM amp ARC CONTROL NONE AM SUP S D G Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 250 ols ELECTRICAL DIAGRAMS meis SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC RANGE END POINT CIRCUI D SUPPLY GN OUT DISCHG rs
4. o o Ka Be g uo 8g E Li gt ES o ec o o FE E B ES o o wn 8g E 2 ES o ec MIN POT END PT THE LINCOLN ELECTRIC CO ANALOG WELD CONTROL PCB VERSION TINA CLEVELAND OHIO U S A suasect POWER CONNECTIONS ECT a 3 03 E SHT 4 No G 3661 2 NUMBER Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 250 ST ELECTRICAL DIAGRAMS SH SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 4 START TIG CIRCUIT we 5 REFERENCE SUPPLY OCV CONTROL CIRCUIT approx 78v ocv Return to Section TOC Return to Master TOC N MIN
5. TO IDLE HOLD OIL fpga VOL TMFTFR ON HI SUPPLY ON TO VO ER cls AN 0022 NA 50V Viena 406680 13 ED A S METER HOLD HI HOLD C DC 1 CNY17 3VC TO AMMETER INPU 01W PNE d IN K PRESET LEVEL INPUT 1 0 J VOLTMETER INPU OLTMETE V RIGHT DECIMAL PT B1 DECIMAL PT COMMON 725 Zuele Plug NA Vai URING HOLD METER PRESET CIRCUIT MAX_POT_END_PT 4700pF AN Sov MAX POT PRESET LEVEI REMOTE WELDING CONTACTOR C
6. Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 250 G 7 RANGER 250 6QETT 1 0N EISES ai 66 L0 0L_ 310 83 21 HC E LAS JNON 32S I9 9d ES JILVWSHIS God AUilivg S V S 1 OIHO ONVT3A312 zoo Fs ISIN KI 03 21812313 N109NT1 JHL 02 31419373 N IOONT 1 SHL IOISSIWH3d SS3HdX3 JHL LNOF G3sn uo GASOTISIO GSINGOwdSY 38 OL LON ST SNNOI ONNOYS H1HV3 Z J313 NTIOONT 1 SH1 Ag cat NOLLYWHOANT ABV L3IHdOHd SNIYLNOI 133H S ER odd NOLLO3NNO2 3AVu4 LYS VOT 60ETT1 JAVN3 114 NOILISNNOI NOWWOD AN 3002 NOWWOJ V ONIAVH S 10H1NO23 40 AYLINDYID 80 SINSNOdWOD 129VX3 SHL LS e AA WgHOVIQ SIL C408 313 400 Y JO ALTTIAVIONVHOMSLNT IHL 9NI1234 amp 1n0HLIM SA S M 1NIOd I94NOS ATddNS 30d C JONVHO AYW GYVOS LINDYID OJLNIHd Y NO AHLINDHIJ HO SIN3NOdAOJ 3ONIS VN LIN 39V 0A Adans y 03141934S ISIM SFINM A007VI Sam S310N ST38V1 03141934S 3SIMH3H10 SSIINN sug SUOLSISZY ap 031412348 3SIMN3H10 SSIINN A ON SHOLID d 9 ane LEST 43d STOBWAS 791419973 RECKEN NOLLVAHOJ3NI VH3N39 NTO6Z IS manua d by th y MI AZT Wives Ines covere
7. 4 Attach the single lead from the LN 25 to the work using the spring clip on the end of the lead This is only a sense lead it carries no welding current 5 Place the IDLER switch in the AUTO or HIGH position as desired A CAUTION If you are using an LN 25 without an internal contactor the electrode will be HOT when the Ranger 250 is started Set the MODE switch to CV WIRE Set the WELD TERMINALS switch to WELD TERMINALS ON 8 Set the VOLTMETER switch to or depending on the polarity chosen 9 Adjust wire feed speed at the LN 25 and adjust the welding voltage with the K857 if optional remote control is used 10 Adjust the ARC control to 0 initially and adjust to suit FIGURE CA RANGER 250 LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL 67PIN AM PHENOL 14 PIN AMBIEN Se OPTIONAL K857 REMOTE CONTROL LN 25 WIRE FEEDER s CLIP LEAD DE NAN x 10 WORK TO WORK ELECTRODE CABLE RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC g 1 8 E e Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 7 TO THE RANGER 250 USING K584 CONTROL CABLE SEE FIGURE C 5 NOTE If your LN 7 comes equipped with a K291 or K404
8. ET Me 009 OEY VE ota gt i A009 VE ELECTRICAL DIAGRAMS NOH Act NV8J AOT is for reference only It may not be accurate for all mach iagram is d Th NOTE A009 VE 210 kd ES Lg Ai W wu oie xwvuo Aor V LLYJ A7T NOT AOT L 11309 SCHEMATIC BATTERY PRINTED CIRCUIT BOARD LINCOLN P G 7 DOL J9jse 4 0 UNY 20 uon2es oj UIMaY DOL J93se 4 0 UNY 20 uon2es o UIMaY 20 Jeep 03 Uie Y 290 1 uon es o ua 20 J91Se N 03 Uie Y JOL uon es oj uinjeu Return to Section TOC Return to Master TOC Return to Section TOC HO ojo Fr SIS o lk SIS wl SIS SIE s p w o o IG Return to Section TOC Return to Master TOC Return to Master TOC me ELECTRICAL DIAGRAMS SCHEMATIC BYPASS PRINTED CIRCUIT BOARD QULICO 206B 208 GND K 4A 4B 75A 75B 75C 76A 76B 76C A AAAAAA AAA AAA AAA 3 1 2 4 6 7 8 8 4 9 10 5 N ZTs A
9. a o amp i f dl 1 ke e yr 1 pata 28 CRI ENGINE PCB7 Battery Display ELECTRICAL SYMBOLS PER E1537 TERMINAL BLOCK STARTER CONNECTORS VIEWED FROM INSERTION END TO SOLENOID ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR SPARK olL REGULATOR PRESSURE RC ELA m B PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE SWITCH n d IGNITION oc oooo VIEWED FROM LEAD SIDE OF RECEPTACLE CONTROL FLYWHEEL ALTERNATOR h P43 J43 ONAN ENGINE COMPONENTS CAPACITOR 1 oj o Ae So 1 PCB6 Thermal Display PCB4 BATTERY PC BOARD 4 14 2000 G3675 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN RANGER 250 SE ELECTRICAL DIAGRAMS Ge CONTROL INTER CONNECTION DIAGRAM RANGER 250 CONTROL INTER CONNECTION DIAGRAM 25 1 12toPIN7of P50 CHOPPER PWMSIGNAL SE EE 23 2 12 5 PIN 9 cf P50 CHOPPER PWM SIGNAL gt ENERGIZES KOHLER FUEL SOLENOID 251 7 12 SA IDLER CONTROL SWITCH LH gt ENERGIZES FUEL SOLENOID WHEN STARTING ENGINE 250 8 12 0 SA IDLER CONTROL SWITCH 229 4 43102134 BATTERY DISPLAY PC BOARDS To
10. 2 0 US qt 1 7 Imp qt 1 9 liter Kohler 1 8 US qt 1 5 Imp qt 1 7 liter Onan Use 4 cycle motor oil that meets or exceeds the requirements for API service classification SG or SH Always check the API SERVICE label on the oil con tainer to be sure it includes the letters SG or SH SAE 10W 30 is recommended for general all temper ature use 5 F to 104 F 20 C to 40 C For the Onan engine it is recommended that SAE 30 oil be used above 82 F 27 C See the engine Owner s Manual for more specific information on oil viscosity recom mendations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service sta tion or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain OIL FILTER CHANGE 1 Drain the engine oil 2 Remove the oil filter and drain the oil into a suit able container Discard the used oil filter 3 Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil 4 Screw on the new oil filter by hand until the gasket contacts the filter mounting base Then use an oil filter socket tool to tighten the filter an additional 1 2 to 7 8 turn 5 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap Start the eng
11. 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 AUXILIARY POWER RECEPTACLES The auxiliary power of the Ranger 250 consists of two 20 amp 120 VAC 5 20R duplex receptacles and one 50 amp 120 240 VAC 14 50R receptacle The 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 8 000 watts of 60 Hz single phase power The auxiliary power capacity rat ing in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 33 amps The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 33 amps per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity The 120 VAC auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 VAC receptacle has two 120 VAC cir cuits but they are of opposite polarities and cannot be paralleled STANDBY POWER CONNECTIONS The Ranger 250 is suit
12. F 33 Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 34 F 34 TROUBLESHOOTING amp REPAIR ANALOG POWER PC BOARD VOLTAGE TEST continued FIGURE F 14 ANALOG POWER PC BOARD RESISTOR R3 ON BLOWER SIDE OF BAFFLER o CONTROL CIRCUIT n PCB2 TT ANALOG POWER PC BOARD 3 1 41 to POS TERMINAL ON C2 85V SUPPLY f PC BOARD a INPUT POWER e14 241 to WEG TERMINAL ON C2 85V SUPPLY if ja EH ER S ES LI d pl Sese 9 DO eooooe H Ze S E EE GE fooooooP Iona Rs o e GNDK O MENN wv GNDL o o o o J42 BLOWER BAFFLE SIDE OPPOSITE BLOWER TEST PROCEDURE 1 Turn the engine off If the reading is not correct the stator output may 2 Perform the Case Cover Removal proce be incorrect the rectifier output may be incorrect dura the capacitors may be faulty or the Power Module PC board may be faulty Perform the 3 Locate plugs J41 and J42 from the Analog Voltage Test the Output Rectifier Bridge Test Power PC board See Figure F 14 and the Power Module PC Board Test The 4 Start the engine and run it at high idle 3700 EE EE STEM RPM with no load P y 6 Check for the correct outpu
13. Air Filter Paper Element Service 1 Loosen the cover retaining knob and remove the cover 2 Remove the pre cleaner from the paper element 3 Remove the element cover nut element cover and paper element 4 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a new ele ment Handle new elements carefully do not use if the sealing surfaces are bent or damaged 5 When servicing the air cleaner check the air cleaner base Make sure it is secured and not bent or damaged Also check the element cover for damaged or improper fit Replace all damaged air cleaner components NOTE Before the air cleaner is reassembled make sure rubber seal is in position around the stud Inspect making sure it is not damaged and seals with the ele ment cover 6 Reinstall the paper element pre cleaner element cover element cover nut and air cleaner cover Secure the cover with the cover retaining knob SPARK PLUG SERVICE To ensure proper engine operation the spark plugs must be properly gapped and free of deposits A WARNING The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot 1 Remove the spark plug cap 2 Clean any dirt from around the spark plug base 3 Use a plug wrench to remove the spark plugs 4 Visually inspect the spark plugs Disca
14. CHOKE CABLE Frequency Counter Method 1 Plug the frequency counter into one of the 120 VAC auxiliary receptacles 2 Start the engine and check the frequency counter At HIGH IDLE 3700 RPM the counter should read between 61 and 63 Hz At LOW IDLE 2400 RPM the counter should read between 39 and 40 Hz Note that these are median measurements hertz readings may vary slightly above or below 3 If either of the readings is incorrect adjust the throttle as follows RANGER 250 LINCOLN P 7 16 LOW IDLE ADJ USTMENT NUT SOLENOID HOUSING in DAS MUFFLER Adjust HIGH IDLE Use the 3 8 wrench to loosen the spring loaded adjustment nut See Figure F 5 for location of the adjustment nut Turn the nut clockwise to increase the HIGH IDLE speed Adjust the speed until the fre quency reads between 61 and 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 7 16 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure F 6 for the location of the adjustment nut Adjust the nut until the frequency reads between 39 and 40 Hz Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g a 2 8 E e Retum to Master TOC
15. DIODE A W ee ee oe 1 2 CURRENT WITH SWITCH CLOSED When the switch is closed current is applied through the inductor to the arc When the switch opens current stored in the inductor sustains flow in the arc and through the diode The repetition rate of switch closure is 20Khz which allows ultra fast control of the arc By varying the ratio of on time versus off time of the switch Duty Cycle the current applied to the arc is con trolled This is the basis for Chopper Technology Controlling the switch in such a way as to produce superior welding RANGER 250 LINCOLN B E 8 o d x E I ai O zE Z as DOL z t Q UNY DOL z t Q UNY DJOL ASew OF UY DJOL ASew OF UY E 8 JOL uono2es OF UM Y DOL uORn 29S Q uiros DOL uono es o3 MEY DOL uot2ee o UMY Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION g Troubleshooting amp Repair Section ccccecccceeeeceeeeeeeecaee teense etaeeeseaeeseeeeesaaeeeenes Section F g How to Use Troubleshooting Guide eene nnns F 2 E PC Board Troubleshooting Procedures sse ene F 3 Prd Troubleshooting QUIO eossiondeintikas hdi RU riduce atto oia F 4 F 12 Idae F 13 Case Cover Removal and Replacement Procedure sss F 13 Power Module Capacitor Discharge Procedure
16. Retum to Master TOC Retum to Master TOC g a 2 8 E e Retum to Master TOC F 30 F 30 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS continued FIGURE EI LOCATION OF LEADS 7 AND 9 AT FIELD DIODE RECTIFIER BRIDGE 201 201A 7 200A 200B FIELD NU 200A RECTIFIER AM K 200B BRIDGE RETAINING TAB CAPACITOR To test the field winding ken 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 1 Connect the volt ohmmeter probes to leads 7 and 9 where they connect to the field diode rectifier bridge See Figure F 11 2r Mari he engine Amatu i at hgh idie 3 00 If the voltage readings are within specifications RENY then the windings are good and functioning prop 3 Check the AC voltage reading It should be erly betwen 40 and SD VAC 4 If finished testing perform the If any one or more of the readings are missing or Replacement procedure not within specifications check for loose or bro RANGER 250 LINCOLN 5 Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g 1 2 8 E e Retum to Master TOC F 31 F 31 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS
17. nection diagram explain in general how to make the proper connections 6 Set the VOLTMETER switch to or depend 1 Shut the welder off ing on the polarity chosen 2 Connect the electrode cable from the wire feederto 7 Setthe ARC control to 0 initially and adjust to suit the terminal of the welder Connect the work i Adjust wire feed speed at the wire feeder cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application Retum to Master TOC S F u 8 FIGURE C 1 RANGER 250 K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM 14 PIN AMPHENOL A 81 o 82 o NOT USED ON RANGER POWER SOURCES SPARE o K867 UNIVERSAL 2 o CONNECTTOGETHERFOR ADAPTER PLUG 4 o J WELDING OUTPUT 41 mE 42 VAC 31 o A nsvac GND o POWER SOURCE FRAME CONNECTION 21 O WIRE FEEDER VOLTMETER CONNECTION TO WORK CONNECTS TO WORK TERMINAL OF POWER SOURCE 7 10K ELECTRODE CABLE 76 H REMOTE OUTPUT CONTROL TO WIRE FEED UNIT 75 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN Retum to Section TOC Retum to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 25 TO THE RANGER 250 ACROSS THE ARC SEE FIGURE C 2 1 Shut the w
18. o d x E I ai O zE Z as DOL z t Q UNY DOL z t Q UNY DJOL ASew OF UY DJOL ASew OF UY C 10 DOL uono2es o uiros DOL uORn 29S OF uiros DOL uono es o3 MEY DOL UOS o WIMPY Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE UE CSIE UT APRI Section D Safety Preca tighS ceres tet rer n gu eR Du t ger x uuu erdeelt D 2 E Routine and Periodic Maintenance essen nennen nnne nnne nnne D 2 d Engine Malntenarce tent ione e ista EEN RA A a CERS ee D 2 Engine Oil Change EE D 4 OIL Filter CHANGES E D 4 Air Cleaner Service mrri iranin iieii aeaaaee ense nnns snnt rte tenis senten D 4 Spark le BET D 5 Fuel Filter Service tiv iiie van die d o dede eile ended D 5 Engine PISS FIL eenegen aaeeea aeai YETENE edge AEREE D 5 H Battery Mamenang eieaa aer A een tnne nena A trn enean tnter santet nnne nenas D 6 d Optional Spark ArreStor eege D 6 Welder Generator Maintenance D 7 E irre M A D 7 d erbe D 7 PROCS AGIOS EE D 7 Cable Connections 2 8 etii iie etre tee ste e eee cides anes D 7 Brush Removal and Replacement scies eesse R ARRARAS D 7 B F 8 E D B F 8 i ux RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC Retum to Master TOC Retum to Master TOC MAINTENANCE SAFETY PRECAUTIONS A WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off
19. 20 to 250 Amps 25 Volts at 250 Amps 14 to 28 Volts OUTPUT GENERATOR Auxiliary Power 8 000 Watts 60 Hz 120 240 Volts 100 Duty Cycle PHYSICAL DIMENSIONS Width Depth 21 50 in 42 25 in 546 0 mm 1073 0 mm High Idle 3700 12 VDC Battery amp Starter Group 58 435 cold Full Load 3500 crank amps Battery Charger 20 A regulated K1725 1 15 A regulated K1725 2 Low Idle 24 ow Idle 2400 Push Button Start 100 Top of enclosure add 6 0 152 mm for exhaust Lubrication Full Pressure with Full Flow Filter Air Cleaner Duel Element Receptacles Two 120 VAC Duplex 5 20R One 120 240 VAC Dual Voltage Full KVA 14 50R available auxiliary power will be reduced Valve Lifters Solid Onan Hydraulic Kohler Engine Idler Automatic Idler ENGINE COMPONENTS Fuel System Vacuum Pulse Pump Onan Mechanical Fuel Pump Kohler Muffler Low noise muffler Top outlet can be rotated Made from long life aluminized steel Auxiliary Power Circuit Breaker Two 20 Amp for Two Duplex Receptacle Two 35 Amp for Dual Voltage Circuit Power RANGER 250 LINCOLN OCV Fuel 12 gal 45 4 L Oil 1 8 Qts 1 7 L Onan Oil 2 0 Qts 1 9 L Kohler Cooling System Air Cooled 3700 RPM 80 Volts Weight 452 Ibs 205 kg K1725 1 434 Ibs 197 kg K1725 2 Governor Mechanical Governor 5 Regulation Engine Protection Shutdown on low oil
20. 45VTO CIRCUIT GROUND 5L 442 0GND SCREWS PRAVE GROUND TIC 121621 6 PINAMPHENOL PINA 215A 5p 42101113 VELD BOARD POWER SUPPLY 15V TO CIRCUIT GROUND 12 42 1B PINT FPSO gt CHOPPER POWER SUPPLY 20V 25031 CIRCUIT GROUND 216A 9 4214 13 pope WELD BOARD POWER SUPPLY 15VTO CIRCUIT GROUND LBA 10 42 1073 5 WELD BOARDPOWER SUPPLY H5VTO CASE GROUND O Ojo ojo E E Sls o t olse KAES SIB E E s p Bie o o IG CASE FRONT REAR VIEW BLOWER BAFLE SIDE OPPOSITE BLOWER GROUND 210 TO 12 NEG Ved ahead IGNITION GROUND CHOPPER POWER SUPPLY 212A TOBATTERY STAR SE NI A 120V AC FOR WRE FEDER SWITCH 1 34 gt L4 2216 TO START gt TOSTOP ENGINE 2 4 CHARGER CIRCUIT BUTTON SWTCH BREAKER el 225 TO BATTERY PC BOARD T CONNECTOR UNPLUGGED 224 TO HOUR METER POS 42V AC FOR WRE FEDER 22an 23 NEG TWSTEDPAIR PWM SIGNAL WELDER HARNESS SIDE WELDER HARNESS SIDE 12 DC MEASURED WITH LEAD ENTRY VIEW LEAD ENTRY VIEW CONNECTOR UNPLUGGED ENGINE CONECTOR BLOCK ENGINE CONECTOR BLOCK ONAN P216 ENGINE KOHLER CH20 ENGINE FRONT MEW OF AMPHENOLS Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOL RANGER 250 G 5 ELECTRICAL DIAGRAMS
21. E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 list ed 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 four main categories Output Problems Function Problems Engine Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case cover Step 3 PERFORM COMPONENT TESTS The last
22. E E Q stor LE 4 d S oem en BX 5 cic wey esce 3 EE En E ve DEE 250 EG peurat onouno ro raame Kees 2 7 Dwar MODE SSES CIRCUIT BREAKERS di xx Retum to Master TOC B E 9 D u 8 a NANT VU AADAAADDADDD AADADADDDDD han ENGINE CONTROLS receptacles approximately 100 watts mini LL mum the engine accelerates and operates 1 RUN STOP SWITCH RUN position energizes the j Yiy l i Se at high speed g g engine prior to starting STOP position stops the ar engine The oil pressure interlock switch prevents c When welding ceases or the AC power load battery drain if the switch is left in the RUN position is turned off a fixed time delay of approxi d g and the engine is not operating mately 12 seconds starts If the welding or v l AC power load is not restarted before the 8 2 CHOKE When pulled out it closes the choke valve end of the time delay the idler reduces the F E on the engine carburetor for quick starting engine speed to low idle speed cic 3 START PUSHBUTTON Energizes the starter d The engine will automatically return to high motor to crank the engine idle speed when the welding load or AC 4 IDLER SWITCH Has two positions as follows power load is reapplied A In the HIGH positi
23. F 22 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued Oscilloscope Method 1 Connect the oscilloscope to the 120 VAC receptacle according to the manufacturer s instructions At HIGH IDLE 3700 RPM the waveform should exhibit a period of 16 2 milliseconds At LOW IDLE 2400 RPM the waveform should exhibit a peri od of 25 0 milliseconds Refer to thel AOR FORM 120 VAC SUPPLY HIGH IDLE NO LOADiin this section of the manual 2 If either of these waveform periods is incor rect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to loosen the spring loaded adjustment nut See Figure F 5 for location of the adjustment nut Turn the nut clockwise to increase the HIGH IDLE speed Adjust the speed until the period is 16 2 milliseconds Adjust LOW IDLE First make sure there is no load on the machine Set the IDLER switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure Ee for the location of the adjustment nut Adjust the nut until the period is 25 0 milliseconds RANGER 250 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 2 Start the engine and observe the whip han dle of the vibratach At HIGH IDLE 3700
24. GE 1 OF 5 NSERTED ADDITIONAL COMPONENTS NOT INSERTED ON 6366 ANALOG WELD CONTROL PCB FPGA MEMORY amp INTERFACE SUP S 0 G G3661 200 1 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 250 Eros ELECTRICAL DIAGRAMS Ere SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 2 MAIN WELDING CONTROL W AUTOMATIC REMOTE LOCAL SETPOINT CIRCUIT MIN CURREN HOT_SETPOINT Return to Section TOC Return to Master TOC C AMPHENOL V PIPE ENABLE fpga D CVwithout PINCH POT STICK PIPE Tit XED_MIN ENABLE fpga REFZ
25. K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc K1737 1 FOUR WHEEL ALL TERRAIN UNDERCAR RIAGE For moving by hand K1770 1 UNDERCARRIAGE FACTORY For mov ing by hand on a smooth surface One or two gas cylinders can be mounted on the rear of the undercar riage with the installation of K1745 1 Cylinder Holder s K1739 1 CABLE CARRIER KIT For use on K1737 1 and K1770 1 Undercarriages K1745 1 SINGLE GAS CYLINDER HOLDER For use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protec tion K886 2 CANVAS COVER Protects machine when not in use 24647 SPARK ARRESTER Mounts inside exhaust pipe K702 ACCESSORY KIT Accessory set includes 35 ft 10 7 meters 2 AWG electrode cable 30 ft 9 1 meters 2 AWG work cable headshield with No 12 fil ter GC300 work clamp and Cooltong 300 electrode holder Cables are rated at 250 amps 40 duty cycle K857 28 ft 8 5m or K857 1 100 ft 30 4m REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120 volt ground fault circuit interrupter duplex type receptacle wit
26. LINCOLN P Return to Section TOC Return to Section TOC F u 8 Retum to Master TOC Retum to Master TOC g a 2 8 E e F 61 F 61 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 26 BATTERY AND CASE BACK REMOVAL REMOVAL PROCEDURE Engine Preparation and Lead Disconnection 1 Turn the engine off ACCESS PANEL fe l S sS 5 d 355 S S5 S With the 1 2 wrench loosen the bolt on the negative battery cable clamp Remove the clamp and cable from the post 2 Perform the Case Cover Removal proce Using the 3 8 socket wrench remove the dure eight screws holding the case back to the machine base four on each side Remove 3 Disconnect the spark plug wires from the the case back spark plugs Using the 1 2 wrench remove the engine 4 Perform the Power Module Capacitor ground strap where it connects to the engine Discharge procedure mounting foot on the left side 5 Using the 3 8 socket wrench remove the Note the position of the choke cable for oio screws holding the battery access panel to reassembly purposes Using the 5 16 nut H 0 the case back Slide the panel with the bat driver remove the clamp holding the engine 5 5 tery attached out of the machine far enough choke cable to the choke control lever Flex HE to access the battery cables See Figure the cable outward to free it from the lever MES F
27. Maximum Allowable Cord Length in Ft m for Conductor Size 10 AWG 8 AWG 6 AWG Conductor size is based on maximum 2 0 voltage drop RANGER 250 LINCOLN B Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES g LTE Section C 8 le C 2 E Field Installed ee ue EE C 2 e TIG Welding EE C 2 Semiautomatic FCAW and MIG Welding Accessories seseseseeesse esee eeee eene erneennnernesn na C 2 Connection of Lincoln Electric Wire Feeders seseeeesssieesirresrnssrssrnesrrsnrnssrnnesrnnssrnesrnn C 3 Connection of the K867 Universal Adapter cceccececeeeeeeeeeeeeeeeeaeeseeeeeesnaeeeseneees C 3 Connection of the LN 25 Across the Ac C 4 Connection of the LN 25 with 42V Remote Output Control Module C 5 Connection of the LN 25 with K857 Remote Control C 6 8 Connection of the LN 7 Using the K584 Control Cape C 7 g Connection of the LN 8 Using the K595 Control Cable ssssssess C 8 8 epes eebe C 9 i Ki B d 8 i Ki B Vd 8 i ux RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES OPTIONS ACCESSORIES FIELD INSTALLED OPTIONS The following options accessories are available for your Ranger 250 from your local Lincoln distributor
28. USED CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A 400V UNLESS OTHERWISE SPECIFIED FILENAME M19462_1BA THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A scALE NONE _ LE DATE 3 26 99 CHK A SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT NM COMMON CONNECTION 7 7 FRAME CONNECTION a EARTH GROUND CONNECTION EQUIP VBE CHOPPER 300 AMP 9 SCHEMATIC SHT SUP S G No M 19462 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 250 oe ELECTRICAL DIAGRAMS G 10 SCHEMATIC DISPLAY PRINTED CIRCUIT BOARD 099728 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HO ojo E E SIS o lk SIS wl SIS SIE s p w o o THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A NOTES LABELS LAST NO USED GENERAL INFORMATION A N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED 177 FRAME CONNECTION CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 SUPPLY EECHER CAPACITORS MFD UNLESS OTHERWISE SPECIFIED THE INTERCHANGEABILITY OF A C
29. continued FIGURE F 12 14 PIN AMPHENOL PIN ASSIGNMENTS To test the feeder winding 1 Connect the volt ohmmeter probes to leads 31 and 32 where they connect to circuit 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 probe pins at pin A for lead 32 and pin J for lead 31 See Figure F 12 However if you use this method and you 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 32 and the other probe at amphenol pin J 2 Start the engine and run it at high idle 3700 RPM 3 Check the AC voltage reading It should be between 118 and 126 VAC RANGER 250 LINCOLN P 4 Connect the volt ohmmeter probes to leads 141A and 42A where they connect to circuit breaker CB8 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 probe pins at pin K for lead 242A and pin for lead 41A See Figure F 12 However if you use this method and you 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 f
30. haust in the desired direction Tighten using a socket or wrench SPARK ARRESTER Some federal state or local laws may require spark arresters in locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester such as the S24647 must be installed and properly maintained See the Accessories section for more information A CAUTION An incorrect spark arrester may lead to engine damage or may adversely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K930 2 TIG Module is suitable for use with the Ranger 250 The Ranger 250 and any high frequency generating equipment must be properly grounded See the K930 2 operating manual for complete instruc tions on installation operation and maintenance REMOTE CONTROL The Ranger 250 is equipped with a 6 pin and a 14 pin Amphenol connector The 6 pin connector is for con necting the K857 or K857 1 Remote Control optional or for TIG welding the K870 foot Amptrol or the K963 2 hand Amptrol When in the CC STICK PIPE and CV WIRE modes and when a remote control is connected to the Amphenol the auto sensing circuit in the Ranger 250 automatically switches the OUTPUT control from con trol at the welder to remote control The 14 pin connector is used to directly connect a wire feeder In the CV WIRE mode the Ran
31. i007 10027 100 AN 01 dl 20v 20v D sov s SE gt e e e MNs LA ER P EC c ER d 20V SW HIN 7 VS 121K a Sc e TZ GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD UNLESS OTHERWISE SPECIFIED RESISTORS Ohms UNLESS OTHERWISE SPECIFIED NOTES DIODES UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET ER ki W gt Cc is i 2 be hi l M A G Y zm E ELE EE THIS DIAGRAM MAY Q POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING amp COMMON CODE V COMMON CONNECTION NUMBER M19422 1BA TT FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CONNECTION AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE Ich ge ShtNow _ EQUIP ON HOLES SIZES PER E 2056 C COI ELECTRIC CO TYPE Multi System ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002_ ELAND OHIO U S A suggect Analog Control Power Su ON ALL ANGLES IS 5 OF DEGREE MATERIAL TOLERANCE t TO AGREE TI E STEE SHT WITH PUBLISHED STANDARDS 7 DATE 09 02 99 SUP S D G NO M 19577 Ojo ojo E E Sls o t olse KAES SIB E E s p Bie o o IG
32. of thermal joint compound Penetrax A 13 to the diode module base plate only under the plastic body of the mod ule Do not apply compound to the area under the mounting holes Press the module firmly against the heat sink aligning the mounting holes Place a spring washer then a flat washer over each outer mounting screw and insert them into the holes Insert the allen head screw into the center hole Tighten all three screws finger tight only Using the torque wrench and 7 16 socket tighten each outer screw between 5 0 and 10 in Ibs Using the torque wrench and 9 64 allen head socket tighten the center screw between 12 and 18 in lbs Now tighten the two outer screws between 30 and 40 in lbs o Replace the Power Module PC board as described above F 55 F 55 TROUBLESHOOTING amp REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT A 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 Retum to Section TOC Retum 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
33. pressure Other Circuit Breakers 25 Amp for Battery Charging 150 Amp for 42 Volt Wire Feeder Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturers manual supplied with your welder It includes 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 electrode with skin or e wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside e Do not stack anything near the engine MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts x AM See additional safety information at the front of this manual Only qualified personnel should install use or service this equipment LOCATION AND
34. 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 6 zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin 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
35. sss F 15 Idler Solenoid RE F 17 Engine Throttle Adjustment Test cccccceeeeeeeeeeeeeeeeeeeesecaeeeeaaeeseeeeessaaeeseeeeeesiaeeeneneees F 19 Rotor Resistance Test dui ierit ttc SEENEN EES SCR PIER GS F 23 Flashing and Rotor Voltage Test ssssssssssssseseeneeeenen nennen nens F 25 Stator e te EE F 28 Analog Power PC Board Voltage Test F 33 H Output Rectifier Bridge Test nennen F 36 S Power Module Test 1 reset ce ptt eiim t eee edge denatelelevenmnadl wenctds F 39 S Flywheel Alternator Test F 43 8 Oscilloscope WayVvelfortms u tette eta rer tenet e Rn ees abeunt F 45 E Normal Open Circuit Voltage Waveform 120 VAC Supply sess F 45 g Normal Open Circuit Voltage Waveform Stick ssssssseese F 46 z Normal Weld Voltage Waveform Stick CC F 47 Normal Open Circuit Voltage Waveform Wire CV Top F 48 Normal Weld Voltage Waveform Wire CN F 49 Replacement Procedures AANEREN F 50 Power Module Assembly Power Module PC Board Diode Module Removal and Heplacement F 50 Power Capacitor Removal and Replacement sse F 55 Output Rectifier Bridge and Choke Removal and Heplacement F 57 5 Engine Stator Rotor Removal and Replacement sssssseeesseeeseeeerteseennesrinesrnnsrenssrns F 60 Retest After Heng RC F 68 Vd 2 8 E Ki B Vd 8 f ux RANGER 250 LINCOLN Return to Section TOC Retum to Section TOC S E
36. BATTERY CHARGER TROUBLE LIGHT 261A 9 12 to CURRENT SENSING TOROID I A wi E gt 14V SUPPLY VOLTAGE FROM BATTERY 260A 10 12 to CURRENT SENSING TOROID TO BATTERY CHARGER TROUBLE LIGHT 2248 7 43to HOUR METER IDLER CLAMPING DIODE CIRCUIT E pe TUIS gt BATTERY VOLTAGE FROM OIL PRESSURE SWITCH FOR FLASHING CIRCUIT 215 15 12 to IDLE SOLENOID a gt GROUNDTO FRAME 2088 1 12 NEG UFSTUED OUTPUT TO IDLER SOLENOID PULLS TO LOW IDLE 200 11 43 to POSITIVE BRUSH HOLDER S ROTOR ELASHING cr gt ARC VOLTAGE FEEDBACK 201D 3 4310 14 12 PWM SIGNAL TWSTED PAIR araa IDLER CONTROL AC POWER SENSE FOR IDLER gt gt gt gt gt gt IDLER CLAMPING DIODE CIRCUIT Return to Section TOC Return to Master TOC ARC CONTROL 277 U9 tp R2 ARC CONTROL 10K 5 279 3919 R2 ARC CONTROL 1k P3 JUMPER PL PINS 1 AND ARE JUMPERED TOGETHER BGGOBOOB po oooood gt 204S _1 6to SHUNT POS WIOSIDE gt CURRENT LEVEL Lee 216 SHUNT NEG OUTPUT STUD SIDE FEEDBACK TWSTED PAIR START BUTTON SWITCH S2 221 KOHLER ONLY 5j KOHLER ONLY to 233 THERMAL DI 4 in THERMOSTAT ON HEAT SINK gt 230 11 to 33 THERMAL DISPLAY INDICATOR S MODE DOC ODROOCOO 214 1 2 to MODE SWTCH TERM 1 CV 218 2to MODE SWTCH TERM 2 PIPE 210 MODE SWITCH TERM 4TG 912 to MODE SWITCH CENTE
37. ENHANCED os SCHEMATIC COMPLETE MACHINE WIRING DIAGRAM Ojo o e ES i HE SUT ED GES pe Ho IS COMMON TO HEATSINK DE PC BOARD D4 n POSITIVE eg u 50MV 400 AMPS L1 CHOKE D1 THREE PHASE BRIDGE RECTIFIER g 8 OUTPUT Q o qo CH CH CH CH O Q O O 13 SIE TERMINAL 14 EIE 206S 2008 CURRENT LEVEL e E FEED BACK SIGNAL g 7 2068 206A Q 250 OHMS ipo 2400uf CAE D2 DIODE 25W 100vde t00vdc BY PASS WIREFEEDER MODULE Q Wi PC BOARD VOLTMETER 25 2 208 POLARITY PWM SIGNAL FROM SWITCH WELD CONTROL 208A PCBOARD_ LPL NEGATIVE od d Q OUTPUT TERMINAL w2 Ww TWO POLE 3600 RPM ALTERNATOR lt 3 O IO i olo AC 120VAC SLIP RINGS e E POWER 240VAC lt 5 ae eg 11 muar CNDE Lo Hi GE ENV Sc GR v z ARC VOLTAGE FEEDBACK 15V re ANALOG 150vdc gle WELD CONTROL OM rota POWER PC 42VOLTAC cle ny PC BOARD 15 1164 BOARD WIRE FEEDER 5 5 15V TO GND 118A POWER ROTOR FIELD B5 OUTPUT Lk 0 10 V m PENNE CONTROL 10K ec jo E O O7 IDLER SWITCH a TET 13 14 iov 42 VOLT AC urere 15V o0 WELD TERMINALS POWER FOR REMOTE 1 _ 15V WO POT SWITCH ROTOR FIELD CIRCUIT CONTROL 40K 0V ov eee EE o CV O PIPE MODE ips E EN 80V DC BUS VOLTAGE Olo TOROID o SENSES WELD a CURRENT AND el gi AC POWER TO THERMOSTAT ON 25A BATERY Blt ACTIVATE IDLER E 7 7leuoPeER MODULE CIRCUIT BREAKER BAT CHARGER 9 NORMALLY CLOSED 212 o o 209 D v zs T
38. Electric recommends that you install a new bearing Lincoln part M9300 85 and tolerance ring Lincoln part 4S18044 9 any time the stator and rotor are reassembled 1 Fitthe rotor into the stator being careful not to damage the rotor core against the stator Position the rotor so that the laminations are at top and bottom and air gap at the sides This will limit movement of the rotor IMPROPER HANDLING OF THE ROTOR CAN RESULT IN SHORTED WINDINGS AND OR LOST OUTPUT 2 Tap the rotor carefully with a mallet to fit the bearing all the way into the stator frame Clean the tapered engine crankshaft Using the hoist carefully fit the stator rotor assembly onto the engine crankshaft 5 Install the four bolts that mount the stator to the engine NOTE Apply Loctite 271 thread sealant to the two bottom bolts on the ONAN engine to prevent oil leakage from the crankcase With the 9 16 wrench draw the bolts up evenly in order to seat the rotor bearing properly Tighten moving diagonal ly from bolt to bolt RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e F 67 F 67 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued 9 10 11 12 13 14 15 16 17 18 Insert the rotor thru bolt and centering wash er With the torque wrench and socket tight en
39. For each door lift up on the stop pin and slide the door off the hinge It may be nec essary to lightly tap the door with a rubber mallet to free it from the hinge See Figure F 1 Using the 9 16 wrench remove the exhaust pipe extension Remove the cover seal from around the lift bail Using the 3 8 wrench remove the sheet metal and machine screws holding the case cover in place Using the 3 8 wrench remove the sheet metal screws from the right and left case sides Tilt each side back and lift up to free the bottom tabs from their slots RANGER 250 LINCOLN 5 8 ENGINE ACCESS DOOR HINGES Lift the case cover off the machine NOTE It is not necessary to remove the gas cap in order to take the case cover off the machine Leave the gas cap on when working on the Ranger 250 REPLACEMENT PROCEDURE 1 Install the right and left case sides and screw them in place Carefully set the case cover in place Replace the lift bail cover seal Install the exhaust pipe extension Install the screws that hold the case cover in place Install the doors by lifting the stop pins and sliding each door onto its hinges Close and latch the doors Retum to Section TOC Retum to Section TOC S E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 15 TROUBLESHOOTING amp REPAIR POWER MODULE CAPACITOR DISCHARGE PRO
40. 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 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing 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 strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment Aa ATTENTION frame RS S e f you don t have a wrist strap bis h inted grounded Handle only at touch an unpainted grou Static Safe part of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools
41. IDLER SWITCH 54 n 210A 211A 2108 210C OUTPUT CONTROL T 16 75 WELD TERMINALS DE E CONTACTOR SWITCH 53 WIRE FEEDER VOLTMETER l l SWTCH 55 a 4 2A 2 ARC CONTROL SWITCH S1 PCS Go 5 KOHLER ONLY T 12 Je drab 251 PM 25 FL Jai HOUR METER 2242248 5G 5 Dis PCB6 A THERMAL dB B DI 230 play EN 231 WELD MODE SWITCH 56 a GE POS 1 CV WIRE 28 POS 2 PIPE POS 3 CC STICK 25 POS 4 TOUCH START TIG NEGATIVE OUTPUT STUD GND LGND M 206A GND A GNDG 277 216 275 GND D GNBS 20AMP m at map A AN GOLD PA pos m 31 Yo i un o Is CB5 CB7 CBl EN A Oh 5A Tsuver _ 1 gd bo 3032 E NDG GA e 5 68 8E fa 2 EE GOLD CB6 Ca CB2 X7 ger L a p Jl o o ert e E Usuveg U SUAM Cu mp GNDD 5E 2045 2065 POSITIVE OUTPUT STUD CASE FRONT REAR VIEW Stator Lead Disconnection 5 Refer to Figure F 28 6 NOTE Use diagonal cutters to cut any cable ties necessary to free the leads as described below 1 With two 1 2 wrenches remove heavy flex leads W1 W2 and W3 and their bolts lock washers and flat washers from the straps on the left side of the output rectifier plates Figure F 25 2 Remove field winding leads 7 and 9 from the field rectifier bridge See Figure F 9 Disconnect lead 41 from its in line coupling Using a 3 8 deep socket o
42. Pans Manual v S Snn0Sn0 P 358 RANGER 250 LINCOLN Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION 8 b Installation BSE Ree c ese prec ner oie iens Bees oiu Meets dEcce indue ce eUs Ven eel DURER DUM ae ear Section A g Technical Specifications AANEREN A 2 8 s l gi ecin ip A 3 E Location and Ventilation eee enne nennen nnne ennt nennen nenas A 3 4 SIOFIridis EE A 3 iiec A 3 Peleo ec Ta a A 3 Ein O H A 3 Additional Safety Precautions ccccccceceeeeeneeeceneeeeeaeeeeceeeeseaaeseeeeeeseaeeeseneeeeaeeeseaeeeseeeeeeaeeneaes A 4 High Altitude Operation A 4 e High Temperature Operation seisis asinsi naniu panine aiiud enne enne nnn entren eene nnne en A 4 8 TOWN M H A 4 g Pre Operation Engine Service sssssssssssisssessseeeenne enne enne nnne nnne nen A 4 8 OU A 4 f eebe A 4 4 Engine Cooling Syste Mirisna ainai a a aE a iE Sa A 4 Battery Connections cs A 5 M ffler Outlet Pipes TEE A 5 Spark Arresten ite eegenen a e aE ARAE aa eiaa uad iea ieas A 5 High Frequency Generators for TIG Applications 0 c ccceececeeeeeeeseeeeeesecaeeeeeeeeeeaeeeteneeeees A 5 Remote Control csc ice nieto tei ree ete ie ised ndash T
43. Start the engine and direct the strobe tach light on the blower paddle Synchronize it to the rotating mark With the machine at HIGH IDLE the tach should read between 3700 and 3750 RPM With the machine at LOW IDLE the tach should read between 2350 and 2450 RPM MARK BLOWER PADDLE 4 f either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to loosen the spring loaded adjustment nut See Figure F 5 for location of the adjustment nut Turn the nut clockwise to increase the 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 IDLER switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure F6 for the location of the adjustment nut Adjust the nut until the tach reads between 2350 and 2450 RPM Return to Section TOC Retum to Master TOC RANGER 250 LINCOLN P Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 21 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE ER HIGH IDLE ADJUSTMENT FIGURE F 6 LOW IDLE ADJUSTMENT 3 8 HIGH IDLE ADJUSTMENT NUT
44. TOC TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine will not crank when the start button is pushed The engine cranks but will not start Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Check the circuit breaker CB7 Reset if tripped Make sure the Run Stop switch is in the RUN position Check for loose or faulty battery cable connections 4 The battery may be low or faulty 5 The Start button may be faulty Check for adequate fuel supply 2 Check for adequate oil level 3 The battery voltage may be too low The fuel filter may be clogged or the fuel contaminated Replace the fuel filter if necessary RECOMMENDED COURSE OF ACTION Ifthe battery is replaced or tests good then the charging circuit may be faulty Perform the Flywheel Alternator Test 2 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 oil pressure switch may be faulty See the Wiring Diagram The engine may be in need of mechanical repair Check for spark and fuel The engine will not develop full power The fuel filter may be clogged or the fuel contaminated Replace the fuel filter if necessary The air filter may be clogged Replace if necessary The spark plug s may b
45. This procedure should take approximately 15 minutes to perform Retum to Master TOC S E E u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN P Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 44 210 TO RUN STOP SWITCH 224 TO HOUR METER POS 2 WELDER HARNESS SIDE LEAD ENTRY VIEW F 44 TROUBLESHOOTING amp REPAIR FLYWHEEL ALTERNATOR TEST continued FIGURE F 20 PLUG J51 PIN LOCATION 221 TO 212A TO BATTERY CHARGER CIRCUIT BREAKER 24A BREAKER ENGINE SIDE LEAD ENTRY VIEW ENGINE CONNECTOR BLOCK J51 ONAN P216 ENGINE TEST PROCEDURE Turn the engine off Using the 3 8 wrench remove the three screws holding the battery access cover in place and slide the battery tray out enough to access the terminals Using the volt ohmme ter measure the voltage at the battery termi nals It should be approximately 12 volts DC Start the engine and run it at high idle for approximately 30 seconds Measure the voltage at the battery terminals It should be 13 7 to 14 2 volts DC If correct the test is over If not correct proceed to the next step Check circuit breaker CB7 on the front panel Reset if tripped Repeat Step 3 If circuit breaker is functioning properly proceed to Step 5 RUN STOP BATTE
46. 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 obtain replacements from a Lincoln Distributor See Operating Manual Parts List Read the Safety Precautions in the front of this manu al and in the Engine Owner s Manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the fans and all other moving parts when starting operating or repairing the equipment ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE A CAUTION To prevent the engine from accidentally starting dis connect the spark plug leads before servicing the engine See Table D 1 Kohler engine or D 2 Onan Engine for a summary of maintenance intervals for the items listed ial Table D 3 Follow either the hourly or the cal endar intervals whichever comes first More frequent servicing may be required depending on your specific application and operating conditions See Figure D 1 for major component locations At the end of each day s use refill the fuel tank to min imize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated TABLE D 1 KOHLER ENGINE MAINTENAN
47. 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 section 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 A 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 1 800 833 9353 RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can kill e
48. connections The oil pressure switch may be faulty Replace if necessary Check leads 210C and 215 for loose or faulty connections See the Wiring Diagram Perform the dler Solenoid 3 The Control Board may be faulty The engine will not go to high idle when using the auxiliary power Auxiliary power is normal when the IDLER switch is in the HIGH posi tion Automatic idle function works properly when the welding termi nals are loaded Make sure the auxiliary power leads are tight The automatic idler may not function if the auxiliary power is loaded to less than 100 watts Make sure leads 3 and 6 pass through the toroid twice in opposite directions See the Wiring Diagram A 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 1 800 833 9353 RANGER 250 LINCOLN B Retum to Section TOC Return to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine will not go to high idle when attempting to weld or when the auxiliary power is loaded Welding output and auxiliary power outputs are normal when IDL
49. factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the Power Module assembly Procedures for removal and replacement of the Power Module PC board and the diode module are included MATERIALS NEEDED 3 8 wrench or socket wrench 7 16 wrench 7 16 Socket wrench 1 2 Wrench 9 16 Wrench 3 16 Allen head wrench 9 64 Allen head wrench Torque wrench with 3 16 and 9 64 allen head sockets Phillips head screw driver Diagonal cutters Electrical thermal joint compound Penetrox A 13 This procedure should take approximately 1 hour to perform RANGER 250 LINCOLN P F 50 Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g a 2 8 E e Retum to Master TOC F 51 TEMPERATURE TO SWITCH Ws Wa POWER MODULE PC BOARD POSI
50. heavy leads W4 and W5 to the posi e large access holes on either side of the rec tive strap on the rectifier See Figure F 25 for S H tifier to place the wrench on these nuts placement p mi 3 g 11 Remove the output rectifier from the 4 Attach heavy leads W6 W11 and W7 to the gle machine negative strap of the rectifier See Figure E E 25 for placement F B ouput Choke 5 Attach the front panel to the machine base du 1 Remove the output rectifier as described with four 3 8 screws Replace any cable ties above cut during removal 2 Using the 1 2 wrenches remove the heav 6 Insert the engine choke cable through the y flex leads W8 W9 and W10 from the choke case front attach it with the 9 16 nut and A install the sleeve Fit the end of the cable into Bo EE ires the hole in the choke control lever then lang bells E Washers And nis holding attach the cable to the choke control lever in the choke to the mounting bracket in the th o geg e position noted at disassembly using its vlu machine base Note that the lower right 5 16 clamp g g corner of the choke has no bolt c 7 Perform the Case Cover Replacement pro 9 5 4 Carefully remove the choke 5 7 cedure iz 2 8 ali CAL RANGER 250 LINCOLN B F 60 F 60 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs perfo
51. in damage to the internal charger com ponents Follow the instructions of the battery charger manufac turer for proper charger settings and charging time OPTIONAL SPARK ARRESTOR A WARNING MUFFLER MAY BE HOT Allow the engine to cool before installing the spark arrestor Do not operate the engine while installing the spark arrestor Clean the spark arrestor after every 100 hours of use RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC D 7 MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store the Ranger 250 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in par ticularly dirty areas 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 out put terminals often Be sure that the connections are always firm BRUSH REMOVAL AND REPLACEMENT Its normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary A CAUTION Do not attempt to polish slip rings while the engine is running A WARNING Service and repair should only be perform
52. phillips head screw driver remove the four screws holding the plug to the vertical baffle Cut any necessary cable ties Then pull the plug and leads away from the baffle 9 Using the 3 8 socket wrench remove the three screws holding the Power Module heat sink to its brackets on the vertical baf fle Remove the glastic fan guard if present on your machine 10 Remove the Power Module assembly from the machine Replacement Refer to Figures F 21 and F 22 1 Mount the heat sink to the brackets on the vertical baffle with the three 3 8 screws Mount the glastic fan guard if present 2 Mount plug J50 to the vertical baffle with four phillips head screws Connect the plug and screw it together 3 Install leads 232 and 233 to the tempera ture switch RANGER 250 LINCOLN B T Using the 7 16 wrench attach the negative strap from the power capacitors to the diode module with two bolts lock washers and flat washers Using the 7 16 wrench tighten the negative strap center nut Tighten all fasten ers to 30 40 in lbs Using the 7 16 wrench attach the positive straps from the power capacitors to the Power Module PC board Tighten the fasten ers at the positive terminals of the power capacitors to between 50 and 60 in lbs Mount heavy leads W8 and W9 to the Power Module PC board with the 7 16 nuts lock washers and flat washers Apply a thin coat ing of electrical thermal joint compound Penetrox A
53. 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 du 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 lect
54. tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN P
55. the 14 pin amphenol on the Ranger 250 5 Place the IDLER switch in the HIGH position A CAUTION An 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 lf 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 spec ifications listed in this manual 6 Set the VOLTMETER switch to or depend ing on the polarity chosen 7 Set the MODE switch to CV WIRE 8 Set the WELD TERMINALS switch to WELD TERMINALS REMOTELY CONTROLLED 9 Adjust wire feed speed and voltage at the LN 8 10 Adjust the ARC control to O initially and adjust to suit FIGURE C 6 RANGER 250 LN 8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM 14 P IN AMPHENOL z TO LN 8 INPUT CABLE PLUG K595 CONTROL CABLE Co o oo TO WORK ELECTRODE CABLE TO WIRE FEED UNIT RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 742 TO THE RANGER 250 SEE FIGURE C 7 1 Shut the welder off 2 Connect the electrode cable from the LN 742 to the terminal of the welder Connect th
56. the bolt to 50 ft lbs Then recheck all four engine stator mounting bolts for tightness Check the rotor stator air gap with a 017 feeler gauge The measurement is taken at the blower end of the rotor before the fan is reinstalled The rotor has two flat sides which are not measured for air gap Slide in the gauge Then rotate the shaft 180 degrees and measure again If the gauge does not clear loosen the rotor thru bolt and four engine stator bolts retighten the bolts and recheck the air gap Repeat until the proper 017 minimum air gap is achieved 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 Install the muffler to the engine Use new gaskets if necessary Position the vertical firewall as you install the muffler Then install the 1 2 bolt washers and nut that hold the muffler to the stator frame Install the side firewalls Reassemble the idler solenoid linkage Connect the engine ground strap to the engine mounting foot Attach the stator to its bottom support bracket and reinstall the engine mounting hardware Connect the engine starter solenoid leads Connect the engine choke cable and fuel line Install the brush holder assembly and leads Install the case back Install the battery Connect the positive bat tery cable first then the negative battery cable BE SURE TO CONNECT THE POS ITIVE BATTERY CABLE FIRST LEAD RECON
57. the cylinder and cylin der head fins and other exterior surfaces STACKING Ranger 250 machines CANNOT be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved The maximum angle of continuous operation is 15 degrees in any direction If the engine is to be operat ed at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 12 gallons 45 4 liters LIFTING The Ranger 250 weighs approximately 452 Ibs 205 kg with a full tank of gasoline A lift bail is mounted to the machine and should always be used when lifting it RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 z 8 E e Retum to Master TOC INSTALLATION ADDITIONAL SAFETY PRECAUTIONS A WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting HIGH ALTITUDE OPERATION At higher altitudes output de rating may be necessary For maximum rating de rate the
58. volts wire feeder control cir cuits may be damaged The engine governor setting is preset at the factory do not adjust above RPM spec ifications listed in this manual 7 Place the WELD TERMINALS switch in the REMOTELY CONTROLLED position Adjust wire feed speed and voltage at the LN 25 9 Setthe ARC control to 0 initially and adjust to suit Gei FIGURE C 3 RANGER 250 LN 25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM 14 PIN AMPHENOL TO WORK TO LN 25 INPUT CABLE PLUG K626 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 25 TO THE RANGER 250 ACROSS THE ARC WITH K857 REMOTE CONTROL SEE FIGURE C 4 1 Shut the welder off 2 Connect the electrode cable from the LN 25 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 4 shows the electrode connected for negative polarity To change polarity shut the welder off and reverse the electrode and work cables at the Ranger 250 output terminals 3 Connect the K857 Remote Control to the 6 pin amphenol on the Ranger 250
59. wn 8 E gt oO ec Return to Section TOC Return to Master TOC Return to Master TOC o o Ka Be g uo 8g E Li gt ES o ec G 9 SCHEMATIC CHOPPER PRINTED CIRCUIT BOARD KA ELECTRICAL DIAGRAMS C2 C3 C4 C5 GND Al MIC4451BN M16100 39 to cap X1 MIC4451BN to heatsink GND GND ES ca C4 CR M16100 39 15 to 32 Vac G5 EL Ei E3 E4 Es 1 4 7 10 13 O to cap O B1 O LINCOLN B 7 NOTES NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 O to heatsink LAST NO
60. 0 wn IDLER COIL PULLS TO 0 IV WHEN ON YY RUN STOP SWITCH e BATTERY o O o 230 4 THERMAL BATTERY 12VOLT 228 SIP LOW IDLE 69 a SHUTDOWN SHOWN IN RUN POS CHARGING BATTERY PC BOARD E E DISPLAY MODULE E 210C SIS IGNITION eem ele FRAME FLASHING MODULE GROUND 210B 5K START BUTTON PATCH 211 225 224B e o 210 pum ENGINE DIODES ENGINE OIL PRESSURE SWITCH P SOLENOID i OPENS ON LOW OIL PRESSURE KOHLER FUEL ENGINE SHUTOFF 224 STARTER SOLENOID oO 9 Y omg ek HOUR METER Ele IGNITION cls MODULE o LJ t olse 7 3 KAES SIB C c cle L11480 BIB d o Ou IG NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 250 G 6 ELECTRICAL DIAGRAMS G6 SCHEMATIC ANALOG CONTROL POWER SUPPLY CC Return to Section TOC Return to Master TOC gt D10 1A FR 1000V Return to Master TOC Return to Section TOC P e D2 OCT 3A CDS C199 C23 C10 1 CNY17 3 600V
61. 13 to the mating surfaces but not the threads Tighten the fasteners to between 12 and 18 in lbs Replace any cable ties cut at disassembly See the procedures below for removal and replacement of the power module PC board and diode module When procedures are complete perform the Case Cover Heplacement proce dure Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g a 2 8 E e Retum to Master TOC F 53 F 53 TROUBLESHOOTING amp REPAIR POWER MODULE PC BOARD REMOVAL AND REPLACEMENT FIGURE F 22 DIODE MODULE POWER MODULE ASSEMBLY DETAILS PLUG J 50 POWER MODULE PC BOARD ALLEN HEAD SCREWS 4 DIODE MODULE COPPER SPACERS HEAT SINK TEMPERATURE SWITCH Removal Replacement 1 Perform steps 1 through 6 and 8 from the 1 Make sure the mating surfaces between the Power Module Assembly Removal proce copper spacers and the heat sink are clean dure dry and free of grease 2 Using the 3 16 allen wrench remove the 2 Apply a thin coating of electrical thermal joint four screws and lock washers holding the compound Penetrox A 13 to the mating sur board to the heat sink Note the two copper faces between the copper spacers and the spacers for the center terminals for reassam heat sink bly Seg Figure Ese 3 Using the torque wrench and 3 16 allen head 3 Remove the PC boar
62. 25 WIRE FEEDER CLIP LEAD TO WORK RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 25 TO THE RANGER 250 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE SEE FIGURE C 3 1 Shut the welder off 2 Connect the electrode cable from the K626 XX Input Cable Assembly to the terminal of the welder and to the LN 25 Wire Feeder Connect the work cable to the terminal of the welder NOTE Figure C 3 shows the electrode connected for negative polarity To change polarity shut the welder off and reverse the electrode and work cables at the Ranger 250 output terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the input cable from the K626 XX Input Cable Assembly to the 14 pin amphenol on the Ranger 250 and the input cable plug on the LN 25 4 Set the VOLTMETER switch to or depend ing on the polarity chosen 5 Set the MODE switch to the CV WIRE position 6 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
63. 26 u 8 8 JE cc RANGER 250 LINCOLN B F 62 F 62 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 27 ENGINE STARTER SOLENOID LEADS ONAN ENGINE SHOWN Return to Section TOC Retum to Master TOC H d T ois 818 FF cuc STARTER PLASTIC COVER ON SOLENOID 10 Refer to Figure F 27 Label engine starter solenoid leads 211A and 209 211A attaches to the solenoid spade terminal and 209 attaches to the positive stud on the solenoid along with the positive battery cable Pull lead 211A off its spade terminal To remove lead 209 you will have to remove the plastic cover on the starter first To do this use the 1 2 socket wrench to remove the nut on the negative stud of the solenoid Then remove the plastic cover Next remove the 1 2 nut from the positive solenoid stud Now you can remove lead 209 and the positive battery cable from the starter solenoid le SB D HE gl E HE cic Return to Section TOC Retum to Master TOC RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC e E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 63 F 63 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 28 STATOR LEADS FRONT PANEL RUN STOP START BUTTON SWITCH S2 221 KOHLER ONLY
64. 50 FUEL CONSUMPTION Onan P216 16 hp 3600 rpm gal hr liters hr Low Idle No Load 2400 R P M Kohler CH20 12 gallons hours gal hr liters hr Running Time for 12 gallons hours Onan Kohler a 20 20 High Idle No Load 3700 R P M 15 15 DC Weld Output 250 Amps 25 Volts Auxiliary Power 8 000 Watts 1 8 6 8 7 0 8 6 4 5 3 6 4 8 6 RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC B 8 OPERATION STICK WELDING The Ranger 250 can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CONSTANT CURRENT CC STICK WELDING The CC STICK position of the MODE switch is designed for horizontal and vertical up welding with all types of electrodes especially low hydrogen The OUTPUT control adjusts the full output range for stick welding The ARC control sets the short circuit current during stick welding arc force Increasing the number from 10 to 10 increases the short circuit current and pre vents sticking of the electrode to the plate while weld ing This can also increase spatter It is recommended that the ARC control be set to the minimum number without electrode sticking Start with the dial set at 0 PIPE WELDING This slope controlled setting is intend
65. 8 8 JE cic TEST PROCEDURE 1 Turn the engine off 4 Using the resistor and jumper leads CAREFULLY discharge the capacitor ter 2 m the Case Cover Removal proce minals NEVER USE A SHORTING STRAP FOR THIS PURPOSE DO NOT NOTE It is not necessary to remove the gas TOUCH THE TERMINALS WITH YOUR cap in order to take the case cover off the BARE HANDS Repeat the procedure for S g machine Be sure the gas cap is ON when dis the second capacitor K a charging Ihe power modulexcapaciiars 5 Using the volt ohmmeter check the voltage 8 H 3 Locate the power module capacitors on the across the capacitor terminals It should d g left side of the inner machine baffle See be zero volts vi Figure F 2 D I j IE a RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC Retum to Section TOC Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 17 F 17 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST A 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 electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tes
66. 833 9353 RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC c F E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 6 F 6 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No auxiliary power at the recepta cles The welding output is normal and the engine operates normally POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS The circuit breakers may be tripped Reset if necessary Check for loose or faulty con nections at the auxiliary recep tacles RECOMMENDED COURSE OF ACTION 2 Check the wiring between the auxiliary receptacles the con nection studs and the main sta tor See the Wiring Diagram Perform the Stator Voltage The machine has welding output but no control of output in some or all modes The auxiliary power is normal If a remote control unit is con nected check the remote control and related cable Check the welding and work cables for loose or faulty con nections 4 Check the OUTPUT control potentiometer and related leads See the Wiring Diagram Check the shunt and associated feedback leads See the Wiring Diagram Check the voltage feedback leads for loose or faulty connec tions See the Wiring Diagram Perform the Po
67. ANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the 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 battery 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 petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge and early battery failure 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 cor rect Improper polarity can damage the charging cir cuit The Ranger 250 positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do so can result
68. BOARD POSITIVE BRUSH CONNECTED 2248 HOUR METER ro W WHITE TO SLIP RING NEAREST 224 G GREEN W YELLOW STRIPE TO THE LAMINATION 5J P13J13 1 2 3 POWER H 212 IDLE SOLENOID P11 J11 Thermal o o Ee Be 2 uo o z 8 e Li B eie o ec o o Ee E ES o c w 8g E i B v oo o o UT PCB3 WELD CONTROL PC BOARD 1 o o 5 o o g 212A 12VOLT 21 BATTERY ENGINE TERMINAL t i BLOCK Lie PCB7 Battery Display ELECTRICAL SYMBOLS PER E1537 een ENGNE CONNECTORS VIEWED FROM INSERTION END GROUND GROUNDING THIS CIRCUIT WHITE eo ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR STOPS TENNE N Y GND H 210 REGULATOR i rr FRANE 224B ol AL AC S GROUND EE SE PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE PRESSURE IGNITION E emer Diop 21084 SWITCH ads VIEWED FROM LEAD SIDE OF RECEPTACLE MODULE GND J 2 K 200229 n P43 J43 FLYWHEEL ALTERNATOR o o KOHLER ENGINE COMPONENTS RUE BH KA P33 J33 e 225 gt PCB6 Thermal Display PCB4 BATTERY PC BOARD 4 14 2000 G3667
69. CC 2 gt ZE TWISTED PAIR POSITION o E IDLER CONTROL eo 208A STATOR AUX WINDING FELD WINDING o 0 84 d o VOLTMETER o obh J5 251 POLARITY o 6 3 mT SWITCH 42 VAC 2 250 Meter sai 7 9 NBA TER o OO e ko 5 GND E TIGA SHOWN IN 2 i Ee AUTO POSITION P00 E EN p6 J6 1 SHOWN IN ee SE ino Shunt iul Return to Section TOC Return to Master TOC POSITIVE 4 105A 101 Gs POSITION 112 Lo De to e lt 76 ph 71 j PAI PCB2 ANALOG POWER PC BOARD ES i Ge J8 Hot Start 8 m E P9 J9 Pinch GND L Arc Force N GND SCREW ON CONTACTOR o CENTER BAFFLE WORK 209 P1040 BEGPURSETRONP 3 d m n 44 Pin REMOTIS 3 6 TOP GND SCREW ON d Ampenol INSIDE OF CASE FRONT so White 212A Di de GROUND B S1RUN STOP AMPHENOL 1 SHOWN IN UN POS 210C A gt FRAME GND WHITE 201 S1 2 REMOTE F B o 5H 2210 O START CONTROL Cx eL75C BUTTON 215 CONTACTOR C EST ree E NEG Ett ee N P12 J12 GROUND Fed GND B Sense LEAD COLOR CODE EE T VLA LA Idler B BLACK OR GRAY BYPASS ROTOR Fv R RED OR PINK PC
70. CE SCHEDULE FREQUENCY Daily or Before Starting Engine Fill fuel tank Check oil level MAINTENANCE REQUIRED Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary First Oil Change Service air pre cleaner Every 25 Hours Retum to Master TOC S E E u 8 Every 100 Hours Change engine oil Replace fuel filter element Clean or replace air filter element Clean spark arrestor Every 200 Hours Replace oil filter Check spark plug and gap Every 2 Years Check fuel lines and clamps Service more frequently when used in dusty areas and or at high ambient temperatures Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN B MAINTENANCE TABLE D 2 ONAN ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Fill fuel tank Starting Engine Check oil level Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Retum to Section TOC Retum to Master TOC 5 Hours First Oil Change Every 50 Hours Service air pre cleaner Change engine oil Every 100 Hours Replace oil filter Clean spark arrestor Every 200 Hours Clean or replace air filter element Replace fuel filter element Every 500 Hours Check spark plug and gap Every 2 Years Check fuel lines and clamps Service more frequently when used in dusty areas and or at high ambient temperatures Retu
71. CEDURE A 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 electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will insure that the large capacitors in the power module have been dis charged This procedure should be performed whenever work is to be attempted on or near the power module MATERIALS NEEDED 3 8 Wrench or socket wrench 9 16 Wrench Volt Ohmmeter Resistor 25 1000 ohms and 25 watts minimum Jumper leads This procedure should take approximately 20 minutes to perform RANGER 250 LINCOLN B F 15 F 16 F 16 TROUBLESHOOTING amp REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 2 POWER MODULE CAPACITOR TERMINAL DISCHARGE Return to Section TOC Retum to Master TOC SHORT ACROSS TERMINALS WITH RESISTOR POWER MODULE CAPACITORS Retum to Master TOC B E 9 D u 8 a Yiy dk E SI vi VER
72. ER switch is in the HIGH position Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Make sure the welding cables and auxiliary power lead con nections are tight RECOMMENDED COURSE OF ACTION Check the Current Sensing Toroid leads for loose or faulty connections See the Wiring Diagram The Current Sensing Toroid may be faulty The Control Board may be faulty The machine goes to low idle but does not stay at low idle Make sure there is NOT an external load auxiliary or weld connected to the Ranger 250 The idler solenoid linkage may be misadjusted or damaged The idler solenoid lead connec tions 210C and 215 may be loose or damaged 3 Perform the dler Solenoid 4 The Control Board may be faulty A 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 1 800 833 9353 RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTO
73. I MOLEX Wow NOMINAL POIN TOROID SENSE AUX Return to Section TOC Return to Master TOC TOROID CONNEC Mo CUR_SENSE INDICATES CURRENT ENGINE HERMAL SENSE CIRCU SENSE CIRC o o Ka Be g uo 8g E Li gt ES o ec o o FE E B ES o o wn 8g E 2 ES o ec THERMAL LIGHT ARC HOT S CONTROL POT
74. MS The welding arc is cold The engine runs normally The auxiliary power is normal 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 cables may be too long or coiled causing an excessive voltage drop Make sure the electrode wire gas voltage current etc is correct for the process being used TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check for the correct OCV at the welding output terminals If the correct voltage is present at the output terminals check for loose connections on the heavy current carrying leads inside the Ranger 250 See the Wiring Diagram 2 If the OCV is low at the welder output terminals perform the Engine Throttle Adjustment 3 Perform the Output Rectifier Bridge Test 4 Perform the Stator Voltage Perform the Power Module Test 6 The Control Board may be faulty A 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 1 800 833 9353 RANGER 250 LINCOLN B F 13 F 13 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE A WARNING Service and repair should be performed by only Lincoln Electric factor
75. N A ZN JN al JN J60 J60 J60 J60 J60 J60 J61 J61 J61 J62 J62 J62 J62 J62 J62 77A TIB JI AAA AKA 6 12 1 7 11 Pee Da De A J62 J62 J62 J62 THIS SHEET CONTAIN ETARY INFORMATION OWNED BYTHE LIN V ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITI THE EXPRESS PERMISSION LN ELECTRIC CO CLEVELAND OHIO U S A LAST NO USED GENERAL INFORMATION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING HE INTERCHANGEABILITY OF A COMPLETE BOARD ELECTRICAL SYMBOLS PER E1537 E CONNECTION CAPACITORS M TEE EARTH GROUND CONNECTION D SUPPLY VOLTAGE NE 7 UNLESS OTHERWISE SPECIFIED 1 THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms UNLESS OTHERWISE SPECIFIED OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMB THERWISE SPECIFIED d CONNECTION UNLESS OTHERWISE SPECIFIED TOI N FILENAME S24740_2BA ON HOLES SIZES PER E2056 ON 2 PLACE DECIMALS IS 02 on EQUIPMENT TYPE ENGINE WELDERS MATERIAL TOLERANCE Ct TO AGRE TE SUBJECT BYPASS PCB SCHEMATIC No S24740 WITH PUBLISHED STANDARDS SCALE THIS DRAW E 03 23 00 SCALE NONE NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN B G 8 RANGER 250 Return to Section TOC Return to Master TOC Return to Section TOC U o ke E 2 P o Ou
76. NECTION CHECKLIST Engine O Plug J51 O Brush leads 201 and 5H and 200A and 200 at their proper brush holder connections Stator O Heavy leads W1 W2 and W3 to the output rectifier bridge O Field winding leads 7 and 9 to the field rec tifier bridge O Lead 41 to 441A at their in line coupling Front Panel O Small green engine ground lead to the top ground stud on the case front panel GND J g Lead 5 and GND E to bottom ground stud O Lead 6 to circuit breaker CB6 and lead 3 to circuit breaker CB5 through the toroid Note number of turns and direction See the Wiring Diagram CJ Lead 42 to circuit breaker CB8 GENERAL NOTES ON REASSEMBLY 1 Replace any cable ties cut during disassem bly 2 When installing the battery connect the pos itive battery cable then the negative battery cable BE SURE TO CONNECT THE POSI TIVE BATTERY CABLE FIRST Connect the spark plug wires 3 4 Perform the Case Cover Replacement pro cedure 5 Conduct the Retest after Repair procedure the following topic in this section of the man ual Return to Section TOC Retum to Master TOC RANGER 250 LINCOLN B F 68 F 68 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any e
77. ODULE TEST continued FIGURE F 17 POWER MODULE CONNECTIONS TEMPERATURE SWITCH pese POSITIVE 4 STRAP ws w9 POWER MODULE M PC BOARD POSITIVE STRAP Ke W TEST PROCEDURE 1 2 3 Turn the engine off Perform the Case Cover Removal proce dure Perform the Power Module Capacitor Discharge procedure Using the 7 16 wrench loosen the nuts on the positive terminals of the power capaci tors Then remove the nuts lock washers and flat washers from the terminals where the positive straps connect to the Power Module PC board Flip the straps out of the way See Figure F 17 Using the 7 16 wrench remove the flex leads W8 and W9 from the Power Module PC board terminals 6 Using the 7 16 wrench remove the two pos itive jumper straps attaching the capacitors to the Power Module PC board Note all lead placements for reassembly Note lead 253 13 W4 and W5 do not have to be removed from the circuit See the Wiring Diagram The small flex lead connected to D4 should be removed and electrically isolated 7 Using the 7 16 wrench remove the W6 lead strap from the power module two bolted con nections Suggestion First loosen the straps at the capacitor terminals and remove the nuts on the power module Then fold the straps back out of the way NOTE Make sure the bolts do not fall back against the heat sink RANGER 250 LINCOLN B F 41 F 41 TROUBLESHOOTING
78. OMPLETE BOARD O POWER SUPPLY SOURCE POINT EARTH GROUND CONNECTION DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms UNLESS OTHERWISE SPECIFIED RCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES UNLESS OTHERWISE SPECIFIED VV COMMON CONNECTION FILENAME S24660 1AC HERWISE SPECIFIED TOLERANCE aan S cke EQUIPMENT TYPE ENGINE WELDERS m E XA SUBJECT DISPLAY PCB SCHEMATIC REF PUBLISHED STANDARDS DRWG No S 24660 U RAWING DATE 03 23 00 SCALE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 250 SCH ELECTRICAL DIAGRAMS e SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 1 PS_SWITC TWO FQUR HERMAL SENSE Return to Section TOC Return to Master TOC MACH_SEL_2 41 03 VMETER_PSET MODE REMOTE_DETECT MACH_SE__4 04 059 AMETER PS MODE CE SENSE x RESE
79. ONTROL CIRCL 2 amp 4 CLOSURE FROM OL amp TERMIN COMP PRESET 8403ARU10 C INT PENSATION cnn SEH 8 LABELS A O 7 FROME CO c THE LINCOLN ELECTRIC CO SS ANALOG WELD CONTROL PCB CLEVELAND OHIO U S A pees DISPLAY AND IDLER 95 SCALE NONE FC Aen 03 23 00 cry AM NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 250 Retum to Master TOC Retum to Master TOC Y e 1 z 8 E e Retum to Master TOC SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional
80. PPLY PC BOARD SCHEMATIC 00 000055 G 6 BATTERY PO BOARD SCHEMATIC eech Ee cater wed obit qur rerne rrr G 7 BYPASS PC BOARD SCHEMATIC i igo un e ar ga ga aee ee oL wan G 8 CHOPPER PC BOARD SCHEMATIC edat sa ENEE dina qiia G 9 DISPLAY PC BOARD SCHEMATIC ik aaro ddr ar UR IEEE et odo US rE IERI sd ar G 10 WELD CONTROL PC BOARD SCHEMATIC SHEET 1 erar nha G 11 WELD CONTROL PC BOARD SCHEMATIC SHEET 3 G 12 WELD CONTROL PC BOARD SCHEMATIC SHEET 3 G 13 fel WELD CONTROL PC BOARD SCHEMATIC SHEET A G 14 WELD CONTROL PC BOARD SCHEMATIC SHEET 8 0 NEEN ph ER EEN G 15 1 8 f e b a g E 4 a g S RANGER 250 LINCOLN G ELECTRICAL DIAGRAMS Gg WIRING DIAGRAM RANGER 250 KOHLER RANGER 250 KOHLER WIRING DIAGRAM S6 MODE SELECTOR SWITCH TERMINAL 1 R1 OUTPUT CONT POT Programing CW KE D1 THREE PHASE BRIDGE RECTIFIER R2 ARC CONTROL t Return to Section TOC Return to Master TOC LOCATED BELOW d A CccW STATOR 7 HEATSINK Mus 277 279 WINDING 278 222 220 EN P1 J2 Bes cd nade TWISTED PAIR 214 19 9 Selection 2068 204S 6 LUCHOKE D2 DIODE wu B MODULE SHUNT WRAP TWO TURNS 3 amp eo e 7 m3 harm 6 LEADS IN DIRECTION OPC BOARD TO GOMV A00 AMPS 3 SHOWN THROUGH HEAT SINK CONN oF Machine TOROID P d Selection NTACTOR JA B A 300 AMP Ste MODULE 4A E
81. R Cl_ 5 77_1 7to RL OUTPUT CONTR 76_2 7to RL OUTPUT CONTR OUTPUT Z5 3 61 RI OUTPUT CONTROLS j CONTROL 215A J 13 to 5 42 15 VOLT POWER 101 2 13 7 42 CIRCUIT GROUND 305 3 13 52 42 5 VOLT POWER POWER INPUTS 1364 4 1305 9 42 5 VOLT POWER FROM ANALOG POWER PC BOARD WRE FEEDER POS 1 CV WRE l POS 2 PIPE usa 5 13 to 10 42 415 VOLTS MEA TO CASE GND VOLTMETER POS 3 CC STICK 5F_7 13 to CASE FRONT GND SCREW CASE GND S SWTCH S5 POS ATOUCHSTART TIG Return to Section TOC Return to Master TOC WELDTERMINALS CONTACTOR SWITCH S3 eter e JJ 41 to PGS TERMINAL ON C2 85V SUPPLY fo INPUT POMER p 2 41 to KEG TERMINAL ON C2 SSV SUPPLY 2068 3 60to POS OUTPUT STUD gt TRANSIENT PROTECTION GND K 5j 60to GND SCREW gt ANDHIGH FREQ BYPASS 208 8 60to NEG OUTPUT STUD X ONOUTPUT TERMNALS 2A 1 61 t0 WELDTERM SWITCH 2C 3161 to GPIN AVPHENOL PIN D 4A 4 61 to WELDTERM SWTCH IND 4C G G1 to G PINAMPHENOL PIN E 75B 3 62 to 14 PIN AVPHENOL PING 76A 4 G2 10 21 10 10K REMOTE ZA 5 6210 1 10 10K REMOTE 77B_G G2 to 14 PIN AMPHENOL PINE Z5C 8 62 to 6 PIN AMPHENOL PIN C 11 342 tcPIN 3of PSO 76B 9 G2 to 14 PIN AVPHENOL PIN F CHOPPER POWER SUPPLY 20V x 1054 2 203 13 Z6C 10 62 to 6 PINAVPHENOL PIN B gt VELD BOARD POWER SUPPLY
82. RD WORK TERMINAL THREE PHASE O RECTIFIER TO mm CONTROL BOARD ELECTRODE TERMINAL CHOKE POWER MODULE zo voommm Q i GAS x c ONERE CONTROL BOARD MECHANICAL STARTER ENGINE ROTATION 3 ROTOR BOARD Q FLYWHEEL d 2 H STATOR OIL PRESSURE SWITCH FIELD AUXILIARY WINDING WINDINGS WIRE FEED PWR WNDG BATTERY A RUN STOP E SWITCH R TO CONTROL BOARD BATTERY BOARD O gt r lt ws oe can O oe on 240VAC RECEPTACLE ANALOG POWER BOARD AND CONTROL BOARD The analog power board which is powered by the two filter capacitors on the power module supplies various regulated DC voltages to operate the control board cir cuitry It also supplies a regulated DC voltage to oper ate the chopper board The control board monitors the operator controls arc oe pe C AMPHENOL 120VAC RECEPTACLE control output and mode selector It compares these commands to the current and voltage feedback infor mation it receives from the shunt and output terminal circuits The circuitry on the control board determines how the output should be controlled to optimize weld ing results and it sends the correct PWM signals to the IGBT driver circuit NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 250 LINCOLN B Return to Section TOC Retum to Master TOC Retum to Section TOC F u 8 Return
83. RPM the whip handle should exhibit max imum oscillation At LOW IDLE 2400 RPM the whip handle should exhibit mini mum oscillation Note that these are medi an measurements vibratach readings may vary slightly above or below 3 If either of the vibratach indications is incor rect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See Figure E 5 for location of the adjustment nut Turn the nut clockwise to increase HIGH IDLE speed Adjust the speed until the vibratach whip han dle exhibits maximum oscillation at 3650 to 3750 RPM 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 7 16 wrench to adjust the solenoid nut which changes the amount of throw in the throttle lever arm See Figure Ee for location of the adjustment nut Adjust the speed until the vibratach whip handle exhibits minimum oscillation at 2350 to 2450 RPM When finished testing perform the Case Cover Replacement procedure F 23 F 23 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST A 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 electrical shock p
84. RY 3 14 001 mp PRESSURE 4 SWITCH CIRCUIT 412V 212A TO BATTERY SWITCH CHARGER CIRCUIT 6 8 RANGER 250 LINCOLN B 211A TO START b F eem am 225 TO BATTERY PC BOARD WELDER HARNESS SIDE LEAD ENTRY VIEW T IGNITION GROUND TO EUEL 1 ro STOP ENGINE SHUTOFF SOLENOID 2 BATTERY CHARGER ENGINE SIDE LEAD ENTRY VIEW ENGINE CONNECTOR BLOCK J51 KOHLER CH20 ENGINE Perform the Case Cover Removal proce dure Perform the Power Module Capacitor Discharge procedure Locate plug J51 leads 212A pin 3 or 2 or engine alternator lead pin 3 C1 See Figure F 20 Check from pin 3 to the negative bat tery terminal with the engine running at high idle speed 3700 RPM Normal voltage is 13 7 to 14 2 volts DC If not correct the fly wheel alternator may be faulty If correct check the wiring between the flywheel alter nator and the positive battery terminal See the Wiring Diagram If finished testing perform the Case Cover Replacement procedure F 45 F 45 TROUBLESHOOTING amp REPAIR 5 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 120VAC SUPPLY SI V HIGH IDLE NO LOAD n 8 8 EJE 16 2 ms A I H e 0 volts i giS de E 50V 5ms 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 re
85. 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 250 A WARNING Keep hands away from the engine muffler or HOT engine parts Stop the engine and allow it to cool before fueling Do not smoke when fueling Fill the fuel tank at a moderate rate and do not over fill Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank Remove the fuel cap slowly to release pressure OIL en The Ranger 250 is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE If it is not up to the FULL mark on the dipstick add oil as required Check the oil every four hours of running time during the first 25 running hours Refer to the engine operator s manual for specific oil recommenda tions and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine operator s manual for the proper service and maintenance intervals FUEL Use gasoline fuel only Fill the fuel tank with clean fresh fuel The capacity of the fuel tank is 12 gallons 45 4 liters NOTE The fuel tank is mounted below the engine so a fuel shutoff valve is not required ENGINE COOLING SYSTEM Air to cool the e
86. Retum to Master TOC Retum to Master TOC F u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN B F 36 F 36 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST A 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 electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum 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 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there are faulty diodes in the output rectifier bridge Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Volt Ohmmeter Analog 11 32 Nut driver 1 2 Wrench 3 8 Wrench or socket wrench 9 16 Wrench Wiring Diagram This procedure should take approximately 45 minutes to perform Retum to Master TOC S E E u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN B F 37 F 37 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST continue
87. Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN RANGER 250 G9 ELECTRICAL DIAGRAMS GH WIRING DIAGRAM RANGER 250 ONAN RANGER 250 ONAN WIRING DIAGRAM S6 MODE SELECTOR SWITCH Return to Section TOC Return to Master TOC STEEN A R1 T CONT POT Keier Programing D1 THREE PHASE BRIDGE RECTIFIER R2 ARC CONTROL 77 STATOR CCW gt 10K HEATSINK weto T i 1 Je 75 5 2 WINDING SC B2 OO 278 Cem P22 Mode TWISTED PAIR PC BOARD TO 2065 204S lo Lt CHOKE ee B Selection kii Ee e MODULE SHUNT WRAP TWO TURNS 3 amp eo 6 LEADS IN DIRECTION PC BOARD TO 3 SOMV 400 AMPS SHOWN THROUGH HEAT SINK CONN Machine 2068 6 CONTACTOR Selection 206A CONTROL 208B SC sa t leen 26 260 0 260A TA POSTON kd 208 H N s s E il PAtAJ41 IDLER CONTROL Fa w 5 138 3 19 0 VOLTMETER 209 STATOR AUX WINDING g FIELD WINDING SE oo bh J5 POLARITY 206A 3 DR E Sa n T42 VAC S4 251 o c SWITCH 7 250 o o Meter 5 GND E n i 15A o L3 SE a
88. SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce 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 que 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
89. SVM150 A September 2002 Ranger 250 For use with machines having Code Numbers 10654 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be in creased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info o 2 gt 2 D o KI gt EE SERVICE MANUAL o o ke is 7 P o s o 4 c 3 Eer oO tc View Safety Info LI NCOLN 9 Copyright 2002 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC SAFETY A WARNING H 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 S cer birth defects and other reproductive harm cancer birth defects or other reproductive harm H The Above For Diesel E
90. Section TOC Retum to Master TOC RANGER 250 LINCOLN P Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g 1 2 8 E e Retum to Master TOC F 58 F 58 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT continued FIGURE F 25 OUTPUT RECTIFIER BRIDGE DETAILS RECTIFIER CHOKE MOUNTING BRACKET ei TOP WI Z CENTER W3 gt 7 BOTTOM OUTPUT RECTIFIER ENGINE BASE REMOVAL PROCEDURE Refer to Figure F 25 4 Note the position of the engine choke cable for reassembly purposes Using the 5 16 nut Output Rectifier driver remove the clamp holding the engine choke cable to the choke control lever at the 1 Turn the engine off carburetor Flex the cable outward to free it 2 Perform the Case Cover Removal procedure from the lever 3 Perform the Power Module Capacitor Discharge procedure RANGER 250 LINCOLN 5 F 59 F 59 TROUBLESHOOTING amp REPAIR Q H F 8 OUTPUT RECTIFIER BRIDGE AND CHOKE E z REMOVAL AND REPLACEMENT continued nz 8 S 5 Using the 1 2 and 9 16 wrenches hold REPLACEMENT PROCEDURE F F and loosen the nut holding the engine choke cable to the back of the front panel slk Pull the cable through the front panel Save Output Chaka the sleeve and nut for reassembly 1 Place the choke into the machine so that the three mou
91. T ENAB GL F 1 0139 3 CS SETPOINTS AUX_CUR_SENSE 3 MAX_PRESET ENABLE E HLIDLE SENSE 5 1 SCALE Wu POT Qu EXPANSION REMOTE_SENSE Ku START_ENABLE ARC_FORCE_ENABLE FIXED HOT START AF POT ENAB FX_ARC_FRC_ENABLE MIN POT FIXED MIN MIN CUR DISABLE Return to Section TOC Return to Master TOC FPGA BOOT EEPROM MACHINE SPECIF o o Ka Be g uo 8g E Li gt ES o ec o o FE E B ES o o wn 8g E 2 ES o ec
92. TIVE STRAP EE F 51 TROUBLESHOOTING amp REPAIR POWER MODULE ASSEMBLY REMOVAL AND REPLACEMENT FIGURE F 21 POWER MODULE CONNECTIONS PROCEDURE Removal Refer to Figures F 21 and F 22 1 2 Turn the engine off Perform the Case Cover Removal proce dure Perform the Power Module Capacitor Discharge procedure Label heavy leads W8 and W9 and using the 7 16 wrench remove the nuts lock washers and flat washers holding them to the Power Module PC board POSITIVE STRAP W6 Using the 7 16 wrench loosen the nuts on the positive terminals of the power capaci tors Then remove the nuts lock washers and flat washers from the terminals where the positive straps connect to the Power Module PC board Flip the straps out of the way Using the 7 16 wrench loosen the center nut on the negative strap Using the 7 16 wrench remove the two bolts lock washers and flat washers from the diode module Remove the strap RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 52 F 52 TROUBLESHOOTING amp REPAIR POWER MODULE ASSEMBLY REMOVAL AND REPLACEMENT continued 7 Label and remove leads 232 and 233 from the temperature switch 8 Unscrew plug J50 from the vertical baffle Using the
93. TOC Retum to Master TOC RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 38 F 38 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST continued FIGURE F 16 OUTPUT RECTIFIER BRIDGE LEAD REMOVAL AND TEST POINTS e TOP OUTPUT w1 RECTIFIER w2 7 lt CENTER BRIDGE W3 gt 7 BOTTOM 6 Electrically isolate the output rectifier bridge When all tests are complete Using the 1 2 wrench remove stator leads W1 W2 and W3 from their bolted connec 1 EE joel leads M A ane their respective terminals Replace lead s tions on the left side of the bridge Note lead 252 or 253 previously removed See placement for reassembly Bend the leads Fiaure F 16 out into free air so that they do not touch g DEAN anything See Figure F 16 2 f finished testing perform the 7 Remove any load that may be connected to Replacemen procedure the weld output terminals 8 Check all diode assemblies individually for opens or shorts If any of the checks are not correct the output rectifier bridge may be faulty See the Output Rectifier Bridge Removal and Replacement procedure RANGER 250 LINCOLN B F 39 F 39 TROUBLESHOOTING amp REPAIR POWER MODULE TEST A WARNING Service and repair should be performed by only Lincoln Electric fac
94. VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area STORING 1 Store the machine in a cool dry place when it is 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 haz ards 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 gaso line with a stabilizer to prevent deterioration rather than drain the system Follow the stabilizer manu facturer s instructions Add the correct amount of stabilizer for the size of the 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 refill 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 cylin der Replace the spark plugs but do not connect the plug leads Crank the engine two or three times to distribute the oil 5 Clean any dirt or debris from
95. a nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles RANGER 250 LINCOLN 5 Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT control is first set to the desired cur rent and the tungsten is touched to the work During the time the tungsten is touching the work there is very lite voltage or current and in general no tungsten contamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc The ARC CONTROL is not active in the TIG mode The Ranger 250 can be used in a wide variety of DC TIG welding applications In general the Touch Start feature allows contamination free starting without the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the Ranger 250 The follow ing settings are for reference Ranger 250 settings when using the K930 2 TIG Module with an Amptrol or Arc Start Switch a Set the MODE Switch to the TOUCH START TIG setting b Set the IDLER Switch to the AUTO position c Set the WELD TERMINALS switch to the REMOTELY CONTROLLED position This will keep the solid state contactor open and provid
96. able for temporary standby or emergency power using the engine manufacturer s rec ommended maintenance schedule The Ranger 250 can be permanently installed as a standby power unit for 240 VAC three wire single phase 35 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications Refer to the connection diagram in Figure A 2 1 Install the double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises dis connect and service over current protection 2 Take necessary steps to assure load is limited to the capacity of the Ranger 250 by installing a 35 amp 240 VAC double pole circuit breaker Maximum rated load for each leg of the 240 VAC auxiliary is 33 amperes Loading above the rated output will reduce output voltage below the allow able 10 of rated voltage which may damage appliances or other motor driven equipment and may result in overheating of the Ranger 250 engine and or alternator windings 3 Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the double pole circuit breaker using No 6 4 conductor cable of the desired length The 50 amp 120 240 VAC plug is available in the
97. ad e ds ne tl ee A 5 S Welding Terminals rotten rr tee rege o Gegend ses a ever agg Eau A 5 5 Electrical Output Connections scence eee enne aaan iaaa A 5 g Machine Gro ndirg iioi oerte rete hat eevee iets tert den aibi de de redeo ape e SA et A 5 8 Welding Output Cables err tried b dene ret reb epe ete i cce baee x uacua A 6 E Gable E EN en tiri rete eite tee a e iaaiiai Lr edd eue ase aud A 7 ec Auxiliary Power Receptacles AAA A 7 Standby Power Connections nennen nennen netter ensis nnne A 7 B F 8 i ux RANGER 250 LINCOLN B Retum to Section TOC Return to Section TOC c F E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION A 2 TECHNICAL SPECIFICATIONS RANGER 250 K1725 1 K1725 2 INPUT GASOLINE ENGINE Make Model Description Speed RPM Displacement Starting Capacities cu in cu cm System 2 cylinder Onan P216 K1725 1 16 HP 3600 RPM Onan 20 HP 3600 RPM Kohler Kohler CH20 K1725 2 Welding Output CC STICK amp PIPE DC Output STICK PIPE Output Range TIG Output Range CV WIRE DC Output CV WIRE Output Range Height 30 00 in 762 0 mm 44 714 Onan 38 OA Kohler Bore x Stroke inch mm 3 25 x 2 625 83 x 67 Onan 3 03 x 2 64 77 x 67 Kohler RATED OUTPUT WELDER Volts at Rated Amps Duty Cycle Max 25 Volts at 250 Amps 10096 20 to 250 Amps
98. amp REPAIR POWER MODULE TEST continued FIGURE F 18 IGBT TEST Retum to Section TOC Retum to Master TOC Q HEAT SINK EN H dE c i Bey j 2 HE 8 E E Ee ji 3 SU S POSITIVE CAPACITOR TERMINAL CONNECTIONS eig P 8 Check IGBT for Shorts 3 g 8 Using the analog ohmmeter connect the 9 Reverse the meter probe leads The resis 2 8 positive meter probe to the heat sink and the tance should be very high over 20 000 E negative meter probe to the positive capaci ohms It the resistance is low in either Step F B tor terminal on the power module chopper 8 or 9 the IGBT may be shorted or leaky cic PC board See Figure F 18 The resistance reading should be high over 20 000 ohms Retum to Master TOC 6 E z o D u 8 RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 42 DIODE MODULE TERMINALS TROUBLESHOOTING amp REPAIR Gs POWER MODULE TEST continued FIGURE F 19 DIODE MODULE TEST HEAT SINK Check Diode Module 10 Using the analog ohmmeter connect the negative meter probe to the terminal on the diode module See Figure F 19 Connect the positive meter probe to the heat sink The resistance should be very high over 20 000 ohms Using the analog ohmmeter co
99. anger 250 E H ELECTRIC SHOCK can kill Insulate each unused lead individually e Do not operate with panels open B For wire feeders that return a signal for welding e Disconnect NEGATIVE BATTERY output use an isolation relay to close leads 2 LEAD before servicing and 4 2 TO Do not touch electrically live parts 19 os eee gt T MOVING PARTS can injure wm Keep guards in place C Refer to the Operation section of this manual for maximum wire feeder auxiliary current draw Keep away from moving parts 4 Set the MODE switch to the CV WIRE position es e Only qualified personnel should install NR R DE use or service this equipment 5 Place the IDLER switch in the AUTO position A CAUTION CONNECTION OF THE RANGER 250 TO Any increase of the high idle engine RPM by changing WIRE FEEDERS USING K867 UNIVERSAL the governor setting or overriding the throttle linkage ADAPTER SEE FIGURE C 1 will cause an increase in the AC auxiliary voltage H 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 spec ifications listed in this manual Return to Section TOC Retum to Master TOC NOTE When you use the Ranger 250 with non Lincoln Electric wire feeders or with certain earlier models of Lincoln wire feeders you will require the K867 Universal Adapter The following discussion and con
100. ce voltage drops Avoid coiling long cables on the machine when welding FIGURE A 1 RANGER 250 OUTPUT CONNECTIONS a Q run NicHoke start nian deb a O oO Q stop n 1 120 VAC RECEPTACLES HO ourrur no 2 120 240 VAC uL RECEPTACLES 3 WELD OUTPUT amp TERMINALS 4 GROUND STUD RANGER 250 LINCOLN 5 Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION TABLE A 1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Cable Size for Length 250 Amps g 100 Duty Cycle 100 200 ft 30 46 meters 1 AWG 150 200 ft 46 61 meters 1 0 AWG 0 100 ft 0 30 meters 1 AWG CABLE INSTALLATION Install the welding cables to your Ranger 250 as fol lows 1 The engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 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 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
101. cealres 1 Connect the volt ohmmeter probes to leads 9 H Se 6F and 3E where they connect to the 3 3 To test the 120 VAC winding 240VAC receptacle 2 8 1 Connect the volt ohmmeter probes to either NOTE It is easier to insert the probes directly E 120 VAC receptacle as follows See Figure into the receptacle to perform this test However F H F 10 and the Wiring Diagram the probes may not reach in far enough to make oe Upper receptacle to leads 3D and 5A Or keep a good connection In this case before Lower receptacle to leads 6E and 5B you start the engine insert two test pins into the receptacle Hold the test probes against these NOTE It is easier to insert the probes directly inserts to measure voltage Step 3 into the receptacle to perform this test However mE the probes may not reach in far enough to make 2 Start the engine and run it at high idle 3700 or keep a good connection In this case before RPM you start the engine insert two test pins into the 3 Check the AC voltage reading It should read receptacle Hold the test probes against these between 236 and 252 VAC inserts to measure voltage Step 3 2 Start the engine and run it at high idle 3700 RPM 3 Checkthe AC voltage reading It should read between 118 and 126 VAC Return to Section TOC Retum to Master TOC RANGER 250 LINCOLN P Return to Section TOC Return to Section TOC F u 8 Retum to Section TOC
102. cidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control 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 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 from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistan
103. ction TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC B 2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Ranger 250 SAFETY INSTRUCTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read all the operating 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 such as output terminals or internal wiring H e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan gerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause r fire or explosion F ebe Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection 2 A WARNING ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside Do not stack anything on or near the engine a MOVING PARTS can injure ae Do not operate this equipment with any Y of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified pers
104. ctrode being used according to the ratings in Table B 3 TABLE B 3 CURRENT RANGE PER ELECTRODE DIAMETER Electrode Current Range Diameter DC Electrode Positive 30 60 Amps 5 32 90 150 Amps 150 200 Amps 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 Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings as long as no welding current is being drawn The auxiliary power of the Ranger 250 consists of two 20 amp 120 VAC 5 20R duplex receptacles and one 50 amp 120 240 VAC 14 50R receptacle The 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 8 000 watts of 60 Hz single phase power The auxiliary power capacity rat ing in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 33 amps RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION The 240 VAC output can be split to provide two sepa rate 120 VAC outputs with a maximum permissible cur rent of 33 amps per output to two separate 20 amp branch circuits These c
105. d FIGURE F 15 PLUG J41 AND RESISTOR R3 LOCATIONS Retum to Master TOC 8 E E o D u 8 F 4 RESISTOR R3 ON BLOWER SIDE OF BAFFLER d aS f V S 5 o PCB2 ol CONTROL CIRCUIT E 1 41 to POS TERMINAL ON C2 85V SUPPLY e IO H 018 FE ke 5 INPUTPOWER 1 14 2 41 to WEG TERMINAL ON C2 85V SUPPLY 93 KA 8 8 EIE dk dc S Ja e 5 GND K 6 1 te 7 2 11 142 toPIN 3ofP5 CHOPPER POWER SUPPLY 20V SE 105A 2 42103 13 WELD BOARD POWER SUPPLY 45V TO CIRCUIT GROUND GNDL i813 5L 442 to GND SCREW S FRAME GROUND 115A 5142 to 1113 5 WELD BOARD POWER SUPPLY 15V TO CIRCUIT GROUND H2 6142 to PIN Lof P50 5 CHOPPER POWER SUPPLY 20V 9 4 ns E B CIRCUIT GROUND BURIED WELD BOARD POWER SUPPLY 15V TO CIRCUIT GROUND 10 5 Ulu WELD BOARD POWER SUPPLY 15V TO CASE GROUND g 0 o O o o J42 5 H BLOWER BAFFLE SIDE OPPOSITE BLOWER 93 KA E E g TEST PROCEDURE du 1 Turn the engine off 4 Disconnect plug J41 with leads 13 and 14 from the Analog Power PC board See 2 Perform the Case Cover Removal proce 9 Figure F 15 dure 7 5 f your machine has resistor R3 with the 3 Perform the Power Module Capacitor y i i Bischareelorocedure 11 32 nut driver disconnect one end of gep resistor R3 either lead 4252 or 4253 See Figure F 15 Return to Section
106. d Socket install the four set screws and lock washers Note the two copper spacers required for the center terminals Tighten the screws finger tight then to between 24 and 28 in Ibs then again to between 40 and 48 in lbs RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 54 F 54 TROUBLESHOOTING amp REPAIR DIODE MODULE REMOVAL AND REPLACEMENT FIGURE F 23 DIODE MODULE MOUNTING DETAILS 0 2 TO 3 kW TURNS EACH 12 18 IN LBS oco Removal Refer to Figure F 23 1 Remove the Power Module PC Board as described above 2 Using the 7 16 wrench remove the two outer screws spring washers and large flat washers from the diode module 3 Using the 9 64 allen wrench remove the set screw from the center of the diode module 4 Remove the diode module from the heat sink Replacement Refer to Figure F 23 A CAUTION The proper tightening sequence is required to mount the diode module to the heat sink in order to avoid warping the base plate Apply the prop er torque to all fasteners 1 Be sure the heat sink mounting surface is clean dry and free of grease RANGER 250 LINCOLN B FINGER TIGHT 5 0 10 IN LBS 5 0 10 IN LBS Apply a thin even coat 1 to 25mm or 004 to 010 in
107. d speed at the LN 7 and adjust the welding voltage with the optional remote control if used 9 Set the ARC control at 0 initially and adjust to suit FIGURE C 5 RANGER 250 LN 7 WITH 584 CONTROL CABLE CONNECTION DIAGRAM 14 PIN AMPHENOL 6 PIN AMPHENOL TO WORK TO LN 7 INPUT CABLE PLUG OPTIONAL K857 REMOTE CONTROL K584 XX CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 8 TO THE RANGER 250 USING K595 CONTROL CABLE SEE FIGURE C 6 NOTE If your LN 8 comes equipped with a K291 or K404 input cable refer to CONNECTION OF THE LN 7 Using K867 UNIVERSAL ADAPTER rather than this discussion to connect your Ranger 250 for wire feed welding 1 Shut the welder off 2 Connect the electrode cable from the LN 8 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 6 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the Ranger 250 output terminals 3 Connect the K595 XX Control Cable to the LN 8 4 Connect the K595 XX to
108. e a cold electrode until the Amptrol or Arc Start switch is pressed When using the TIG Module the OUTPUT control on the Ranger 250 is used to set the maximum range of the CURRENT WIRE WELDING CV Connect a wire feeder to the Ranger 250 according to the instructions in the Accessories section In the CV WIRE mode the Ranger 250 can be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG weld ing gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance control The proper setting depends on the procedure and operator prefer ence Start with the dial set at 0 Some recommended Innershield electrodes are NR 311 NS 3M NR 207 NR 203 Ni 196 NR 204 H Recommended Outershield electrodes are 0S 70 0S 71M Some recommended solid wires for MIG welding are 035 0 9 mm and 045 1 1 mm L 50 and L 56 035 0 9 mm and 045 1 1 mm Blue Max MIG 308 LS For any electrodes including those above the proce dures should be kept within the rating of the machine ARC GOUGING The Ranger 250 can be used for limited arc gouging For optimal performance set the MODE switch to CC STICK and the ARC CONTROL to 10 Set the OUTPUT CONTROL to adjust output current to the desired level for the gouging ele
109. e engine will shut down and the bat tery PC board will disable the rotor flashing current The idler solenoid is mechanically connected to the engine s throttle linkage If no welding or auxiliary cur rent is being drawn from the Ranger 250 the control board activates the idler solenoid which then brings the engine to a low idle state When either welding or auxiliary current is detected at the toroid current sen sor the control board deactivates the idler solenoid and the engine returns to high RPM NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC e E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 WELD WINDINGS RECTIFIER POWER MODULE AND FEEDBACK WORK TERMINAL THREE PHASE RECTIFIER TO CONTROL E CHOKE POWER MODULE ELECTRODE TERMINAL o vommm O GAS ENGINE MECHANICAL STARTER ROTATION FLYWHEEL ALTERNATOR OIL PRESSURE FIELD SWITCH WINDING TO CONTROL BOARD BATTERY BOARD 240VAC RECEPTACLE WELD WINDINGS RECTIFIER POWER MODULE AND FEEDBACK The three phase stator weld windings are connected to a three phase rectifier bridge The resultant DC vol
110. e faulty Replace if necessary Due to wear the engine may need major repair A 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 1 800 833 9353 RANGER 250 LINCOLN B Retum to Section TOC Return to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine shuts down shortly after starting The engine will not idle down to low speed The machine has normal weld output and auxiliary power POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Check for adequate fuel supply and a clean fuel filter Low oil level Fill to proper level Start engine and look for leaks Check the battery cables for loose or faulty connections Make sure the IDLER switch is in the AUTO position Make sure there is NOT an external load on the weld termi nals or the auxiliary power receptacles Check for mechanical restric tions in the idler solenoid link age TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the RUN STOP switch and associated leads for loose or faulty
111. e maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE BATTERY MAINTENANCE To access the battery remove the screws from the rear battery tray using a screwdriver or a 3 8 socket Slide the battery tray out only far enough to access the bat tery terminals A WARNING GASES FROM BATTERY can explode e 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 bat tery 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 CLE
112. e the generator is linked to the premises Check your state and local requirements Adouble pole double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter RANGER 250 LINCOLN Section B 1 Section B 1 TABLE OF CONTENTS Q E OPERATION SECTION 2 Operation enini ee EE Section B B dusel nen E B 2 Sra E B 2 General Heen pont a aaa ea a aaa aE aiaa aAa AEEA a B 2 Alle B 3 Controls and er pep B 3 Engine Controls ceder idee per teuer ta Feet dear awa e le TOOL ad ce dde adie B 4 Welding Controls yvsissdiuriiasisnu oinaan aanta aat e aaoo nave brennan eed B 5 0 Engine ODperatlODi iaceo dod t erred epus doceat helene aaia eege dedu bun a eats B 5 H Before Starting the Engine ssesssssssssssssesessss essen enne nennen sinn B 5 3 Starting the Engine CEPS B 6 Stopping the Ge UE B 6 B Welder Operation EE B 7 Eo icikSs Jc B 7 Stick UL Te TEE B 8 Constant Current CC Stick Welding sse B 8 Pipe Welding EE B 8 UU ER E a E B 9 T Wire Welding EE B 9 H tele T lee DEE B 9 H ale nie E B 9 Simultaneous Welding and Auxiliary Power Loads sss B 10 8 E D B F 8 i ux RANGER 250 LINCOLN B Retum to Section TOC Return to Section TOC c F E u 8 Retum to Se
113. e work cable to the terminal of the welder NOTE Figure C 7 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the out put terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K619 Control Cable to the 14 pin amphenol on the Ranger 250 and the input cable plug on the LN 742 4 Set the VOLTMETER switch to or depend ing on the polarity chosen Set the MODE switch to the CV WIRE position 6 Place the IDLER switch in the AUTO or HIGH position as desired A CAUTION An 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 cir cuits may be damaged The engine governor setting is preset at the factory do not adjust above RPM spec ifications listed in this manual 7T Place the WELD TERMINALS switch in the REMOTELY CONTROLLED position Adjust wire feed speed and voltage at the LN 742 9 Set the ARC control to 0 initially and adjust to suit Gei FIGURE C 7 RANGER 250 LN 742 CONNECTION DIAGRAM 14 PIN AMPHENOL TO WORK TO LN 742 INPUT CABLE PLUG Ki K619 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT RANGER 250 LINCOLN B C 10
114. ed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in dan ger 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 RANGER 250 LINCOLN B MAINTENANCE FIGURE D 1 MAJOR COMPONENT LOCATIONS CASE COVER AND DOOR ASSEMBLY CASE BACK ENGINE IDLER SOLENOID ROTOR STATOR POWER MODULE ASSEMBLY POWER CAPACITORS PC BOARDS FRONT PANEL OUTPUT ASSEMBLY CONTROL PANEL OUTPUT CHOKE OUTPUT RECTIFIER BRIDGE FUEL TANK MACHINE BASE BATTERY Return to Section TOC Retum to Master TOC Q eco gus cm mmn ABAom o Return to Section TOC Retum to Master TOC le S D HE g 8 E HE cic Return to Section TOC Retum to Master TOC RANGER 250 LINCOLN B Section E 1 Section E 1 TABLE OF CONTENTS LINCOLN B P THEORY OF OPERATION SECTION g Theory Of Operation eere eter eti eter keine iiec eese ster catapasseucetsseadvence Section E 8 General Description ccccccccssecssecsseecsecesesesseceseccseeccssecsssecsueccseecssescsseceseseseeeesessesesseeaeees E 2 E Battery Engine Rotor Stator and Engine Protection cccccccccseesseceeseeseeeeeseeeeeesssseaeees E 2 e Weld Windings Rectifier Power Module and Feedback cccccccccsseceeeesssteeeeeessnee
115. ed for out of position and downhill pipe welding where the opera tor would like to control the current level by changing the arc length The OUTPUT control dial adjusts the full output range for pipe welding The ARC control is not active in the PIPE mode TABLE B 2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES DCEN DCEP 4 Tungsten Electrode Diameter in mm 196 296 Thoriated Tungsten 196 296 Thoriated Tungsten 2 15 5 20 15 80 70 150 150 250 250 400 400 500 500 750 750 1000 180 125 Approximate Argon Gas Flow Rate C F H I min Stainless Steel TIG TORCH Nozzle Size 5 4 5 6 5 6 6 7 8 8 10 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shield ing gases Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 196 Thoriated EWTh 1 296 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications DCEP is not commonly used in these sizes TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 in 11 mm 8 1 2 in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lav
116. eder with the appropriate control cable Smart machine Remote operation and Magnum spool gun 42VAC for LN 742 and Cobramatic wire feeders Wire feed voltmeter switch matches polarity of wire feeder voltmeter to polarity of electrode 12 gallon fuel capacity allows you to run an extend ed day Easily check fuel level during operation and refu elling with highly visible fuel gauge located next to the fuel cap on case top side Longer engine life reduced noise emissions and greater fuel economy with the automatic engine idler Conveniently located engine maintenance label under top engine door Engine hour meter for scheduled maintenance Automatic engine shutdown protection for low oil pressure Electric start Reduce abnormal charging thanks to a backlit battery charger system light indicator Oil drain valve no tools required 8 000 watts of continuous duty AC generator power Up to 33 amps at 240V from the 120V 240V recep tacle Circuit breaker protection Two 120V 20A duplex receptacles Circuit breaker protection Will operate up to a 9 grinder CONTROLS AND SETTINGS The gasoline engine stop start and idler controls are located on the case front panel The welder controls are also located here See Figure B 1 RANGER 250 LINCOLN OPERATION 5 8 FIGURE B 1 CASE FRONT PANEL CONTROLS FIF c db 3 gt S run N cHoke jsranT Sy uen 2 B 6 p E3 IDLER
117. eeder does not work when connected to the welder amphenol POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check the appropriate circuit breaker CB1 or CB8 Reset if tripped The wire feeder control cable may be faulty The wire feeder may be faulty RECOMMENDED COURSE OF ACTION 3 Check for the presence of appropriate source voltage at the 14 pin amphenol If the appropriate voltage 42 VAC or 115 VAC is NOT pre sent at the 14 pin amphenol check for loose or faulty con nections See the Wiring Diagram Perform the Stator Voltage The battery does not stay charged Check for loose or faulty con nections at the battery and engine charging system The battery may be faulty Check or replace 2 If the yellow engine alternator light is on perform the Flywheel Alternator Test If the battery is not charging and the yellow engine alternator light is not lit The battery board may be faulty A 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 1 800 833 9353 RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master
118. eeesees E 3 Analog Power Board and Control Board E 4 Insulated Gate Bipolar Transistor IGBT Operation sse E 5 Pulse Width Modulation 5 rennen ree nnno Ya xn nenne Rae ek ER Yo na XR AR E 6 Chopper Technology Fundamental E 7 d E FIGURE EI RANGER 250 BLOCK LOGIC DIAGRAM i e TERMINAL uer i ELECTRODE TERMINAL e meus Ste i POWER MODULE S 5 e s 5 d d 2 GAS ANALOG CONTROL 8 Ke POWER BOARD E m ENGINE ROTATION ROTOR BOARD Cx d Aenor O SSS E E REGULATED VOLTAGES ehn Note LG STATOR T i gt AMPHENOL 8 BATTERY j j BOARD C C Vd 2 8 i ux RANGER 250 Return to Section TOC F u 8 Retum to Master TOC Retum to Master TOC E 2 E 2 THEORY OF OPERATION 5 FIGURE E 2 BATTERY STARTER ENGINE ROTOR STATOR AND ENGINE PROTECTION EIE 5 TERMINAL y g RECTIFIER O u TO 8 8 Vu EJE Se i EUN STRE gu CHOKE Bound POWER MODULE F E TO E 1 FROM D 0 TOROID 5 0 CURRENT w A SENSOR c v K D S GAS ANALOG CONTROL es POWER BOARD ENGINE MECHANICAL ROTOR BOARD STARTER ROTATION SLIP CX RINGS priiis m QOL REGULATED VOLTAGES Onur Note STATO R CONTROL CONTROL SELECTOR OIL PRESSURE FIELD AUXILIARY WIRE FEED SWITCH WINDING WINDINGS PWR WNDG I 4 2 D 2 BATTERY H v ps SE daba SWITCH R c 4 2 e 0 0 AMPHENOL v v A A e c TO CONTROL BOARD BATTERY BOARD GENERAL DESCRIPTION The Rang
119. elder off 2 Connect the electrode cable from the LN 25 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Figure C 2 shows the electrode connected for negative polarity To change polarity shut the welder off and reverse the electrode and work cables at the Ranger 250 output terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Set the VOLTMETER switch to or depend ing on the polarity chosen 4 Set the MODE switch to the CV WIRE position 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 6 Place the IDLER switch in the AUTO or HIGH position as desired A CAUTION If you are using an LN 25 without an internal contactor the electrode will be HOT when the Ranger 250 is started 7 Place the WELD TERMINALS switch in the WELD TERMINALS ONT position 8 Adjust wire feed speed at the LN 25 and adjust the welding voltage with the output CONTROL at the LN 25 if optional remote control kit is used 9 Setthe ARC control to 0 initially and adjust to suit FIGURE C 2 RANGER 250 LN 25 ACROSS THE ARC CONNECTION DIAGRAM 6 PIN 14 PIN AMPHENOL TO WORK AMPHENOL ELECTRODE CABLE OPTIONAL K444 1 REMOTE CONTROL LN
120. electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the power capacitors MATERIALS NEEDED 3 8 Wrench or socket wrench 7 16 Wrench 9 16 Wrench Slot headed screw driver Retum to Section TOC Retum to Master TOC This procedure should take approximately 30 minutes to perform Retum to Master TOC F u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN P F 56 F 56 TROUBLESHOOTING amp REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 24 POWER CAPACITOR MOUNTING DETAILS Retum to Master TOC 8 E E o D u 8 F 4 CLAMPS Q dE E d j z Vv 8 8 E E POWER HE CAPACITORS cic VERTICAL BAFFLE gig PP 8 PROCEDURE 3 g 1 Perform the Case Cover Removal proce 5 With the slot headed screw driver loosen the 818 dure clamps holding the capacitors to the vertical F E 2 Perform the Power Module Capacitor pame y Discharge procedure 6 Slip the capacitors out of the vertical baffle Label all leads for reassembly To reassemble slide the capacitors into the verti cal baffle observe capacitor polarity and lead ori entation and tighten the holding clamps Replace the leads and straps as labeled and tighten the fasteners to between 50 and 60 in Ibs Perform the Case Cover Rep
121. ely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct DC voltage is being applied to the rotor at the maxi mum engine speed 3700 RPM This information will aid the technician in determining if the generator field is operating properly Tests can be conducted with the engine stopped static test and running dynamic test These procedures also allow you to test the oil pressure switch for proper functioning MATERIALS NEEDED 3 8 Wrench or socket wrench 9 16 Wrench Test pins Jumper lead Volt Ohmmeter Wiring Diagram This procedure should take approximately 35 minutes to perform RANGER 250 LINCOLN P F 25 Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 26 F 26 TROUBLESHOOTING amp REPAIR FLASHING AND ROTOR VOLTAGE TEST continued FIGURE F 8 ROTOR BRUSH LEADS SLIP RINGS BRUSHES TEST PROCEDURE 1 Perform the Case Cover Removal proce dure Set the volt ohmmeter to the DC volts posi tion Test rotor voltage static engine stopped but running condition simulated a Connect a jumper between P51 leads 210 and 224 See the Wiring Diagram This bypasses the oil pressure switch and
122. er 250 is a gasoline engine driven welding power source capable of producing 250 amps at 25VDC at a 100 duty cycle The engine is coupled to a brush type alternating current generator This AC output is rectified and controlled by Chopper Technology to produce DC current for multi purpose welding applications The Ranger 250 is also capable of producing 8 000 watts of AC auxiliary power at 10096 duty cycle 240VAC RECEPTACLE BATTERY ENGINE ROTOR STA TOR AND ENGINE PROTECTION The 12VDC battery powers the engine starter motor and also supplies power to the battery PC board and associated circuitry When the engine which is mechanically coupled to the rotor is started and run ning the 12 VDC battery voltage is fed through the bat tery board to the rotor field coil via a brush and slip ring configuration This excitation or flashing voltage mag 120VAC RECEPTACLE netizes the rotor lamination This rotating magnet induces a voltage in the stationary windings of the main alternator stator The stator houses a three phase weld winding a 120 240VAC single phase auxiliary winding a 42VAC wire feeder power winding and a separate 42VAC field feedback winding that is rectified and serves as a feedback supply for the rotor field winding The engine flywheel alternator supplies charging cur rent for the battery circuit The oil pressure switch mon itors engine oil pressure If a low oil pressure condition should develop th
123. ger 250 auto sensing circuit automatically makes the Ranger 250 OUTPUT control inactive and the wire feeder voltage control active when the control cable is connected to the 14 pin connector NOTE When a wire feeder with a built in welding volt age control is connected to the 14 pin connector do NOT connect anything to the 6 pin connector WELDING TERMINALS The Ranger 250 is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ONT position or cold welding terminals when in the REMOTELY CONTROLLED position ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the 120 and 240 volt receptacles weld output terminals and ground stud MACHINE GROUNDING QD Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is con nected to premises wiring home shop etc RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC A 6 A 6 INSTALLATION To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must a Be grounded to the frame of the welder using a grounded type plug b Be double insulated A WARNING Do not ground the machine to a pipe that carries e
124. h cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 amps The maximum total current from the GFCI Duplex is limited to 20 amps Two kits are required K802 N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps K802 R POWER PLUG KIT Provides four 120 volt plugs rated at 15 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps T12153 9 50 AMP 120 240V POWER PLUG Provides one dual voltage plug for full KVA power TIG WELDING ACCESSORIES K1783 9 TIG TORCH For TIG welding with shielding gas Includes 25 feet of cable K963 2 Hand Amptrol K870 Foot Amptrol NOTE TIG welding requires a Magnum TIG Gun appropriate Magnum Parts Kit and argon gas SEMIAUTOMATIC FCAW AND MIG WELDING ACCESSORIES LN 25 WIRE FEEDER K449 This portable unit pro vides 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 operation with no control cable The LN 25 provides a cold electrode until the gun trigger is pressed For voltage control at the feeder a K444 1 Remote Voltage Control Kit or K857 Remote Control is required Refer to connection instructions later in this section LN 7 OR LN 8 WIRE FEEDER Semiautomatic con stant speed wi
125. iled throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION If the machine output is low or high this test will determine whether the engine is operat ing at the correct speed RPM during both HIGH and LOW idle conditions You can check RPM using a strobe tach a frequency counter an oscilloscope or a vibratach Directions for adjusting the throttle to the correct RPM are given MATERIALS NEEDED 3 8 Wrench or socket wrench 9 16 Wrench White or red marking pencil Stobe tach frequency counter oscilloscope or vibratach This procedure should take approximately 35 minutes to perform RANGER 250 LINCOLN P Return to Section TOC Return to Section TOC E E u 8 Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e F 20 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 4 STROBE MARK LOCATION TEST PROCEDURE 1 Turn the engine off 2 Perform the Case Cover Hemoval proce dure Strobe Tach Method 1 With a white or red marking pencil place a mark on one of the blower paddles See Figure F 4 for location 2 Connect the strobe tach according to the manufacturer s instructions 3
126. inders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame 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 PL Precautions for Safe Handling of Compressed Gases in Cylinders 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 the U S National Electrical Code and the manufacturer s recommendations RANGER 250 LINCOLN B Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC SAFETY PRECAUTIONS DE
127. ine and check for oil filter leaks Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when oper ating the engine in extremely dusty areas A WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result A CAUTION Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine Air Pre Cleaner Service 1 Loosen the cover retaining knob and remove the cover Remove the pre cleaner from the paper element Wash the pre cleaner in warm water with deter gent Rinse the pre cleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the pre cleaner to air dry 4 Saturate the pre cleaner with new engine oil Squeeze out all excess oil Reinstall the pre cleaner over the paper element 6 Reinstall the air cleaner cover Secure the cover with the cover retaining knob RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC S E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC d e 1 2 8 E e Retum to Master TOC MAINTENANCE
128. input cable refer to CONNECTION OF THE LN 7 Using K867 UNIVERSAL ADAPTER rather than this discussion to connect your Ranger 250 for wire feed welding 1 Shut the welder off 2 Connect the electrode cable from the K584 XX Control Cable to the terminal of the welder and to the LN 7 wire feeder Connect the work cable to the terminal of the welder NOTE Figure C 5 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the out put terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the input cable from the K584 XX Control Cable to the 14 pin amphenol on the Ranger 250 and the input cable plug on the LN 7 4 Set the VOLTMETER switch to or depend ing on the polarity chosen 5 Set the MODE switch to the CV WIRE position 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 in the AC auxiliary voltage lf 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 spec ifications listed in this manual 7T Place the WELD TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire fee
129. inued Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS RECOMMENDED COURSE OF ACTION 5 Perform the Stator Voltage 6 Perform the Output Rectifier Bridge Test 7 Perform the Power Module 8 Perform the Analog Power Board Test 9 Check the output control potentiometer and associated wiring 10 The Control Board may be faulty No welding output in all modes Also no auxiliary power The engine operates normally at approximately 3700 RPM Check the brushes for wear and proper contact to the rotor slip rings Make sure the engine is operat ing at the correct high idle speed 3700 RPM Check for loose or faulty con nections or leads at the auxiliary output receptacles and or the welder output terminals See the Wiring Diagram 1 Perform the Rotor Resistance 2 Perform the If the flashing voltage is not present the battery board or leads 201 or 4200 may be faulty See the Wiring Diagram Also make sure that lead 5H has continu ity zero ohms to ground Check the field diode and capacitor Replace if neces sary 4 Perform the Stator Voltage A 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 1 800
130. ion TOC Retum to Master TOC 20V ims This is the typical DC open circuit out put voltage generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division rep resents 1 millisecond in time The machine was loaded with a resis tance grid bank to 250 amps at 25 volts Retum to Master TOC F u 8 NOTE Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div ulu Horizontal Sweep 1 ms Div g 0 COUPE sese deberse DC c Trigger Internal SI 5 93 wn 8 8 Jt CAE RANGER 250 LINCOLN P F 48 F 48 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV TAP MAX CONTROL POT HIGH IDLE NO LOAD Retum to Section TOC Retum to Master TOC NANA H t HHH HEHEHE 0 volts Retum to Section TOC Retum to Master TOC 50V 5ms This is the typical DC open circuit out put 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 Scope probes are connected at weld output terminals Retum to Master TOC F u 8 SCOPE SETTINGS Volts Div 50V Div Horiz
131. ircuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity The 120 VAC auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle For extension cord lengths see Table B 5 NOTE The 240 VAC receptacle has two circuits each of which measures 120 VAC to neutral However they are of opposite polarity and cannot be paralleled SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS The auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in Table B 4 The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time TABLE B 4 RANGER 250 SIMULTANEOUS WELDING AND POWER LOADS Permissible Auxiliary Current in Amps 120 VAC 240 VAC 8000 Welding Output Amps Permissible Power Watts Unity Power Factor 5000 40 3000 Each duplex receptacle is limited to 20 amps Not to exceed 25 amps per 120 VAC branch circuit when splitting the 240 VAC output TABLE B 5 RANGER 250 EXTENSION CORD LENGTH RECOMMENDATIONS Use the shortest length extension cord possible sized per the following table Current Voltage Load Amps Volts Watts 14 AWG 12 AWG
132. lacement proce With the 7 16 wrench remove the nuts lock washers and flat washers holding the leads and straps to the power capacitor terminals dure Qio PIE i gis 8 8 JE cc RANGER 250 LINCOLN B F 57 F 57 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT A 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 Retum to Section TOC Retum 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing the output rectifier bridge and the choke from the Ranger 250 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 Wrench or socket wrench 1 2 Wrenches two 9 16 Wrench Diagonal cutters This procedure should take approximately 1 hour to perform Retum to Master TOC F u 8 Retum to
133. lease observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum 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 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there is an open winding in the rotor or if the rotor is grounded Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Ohmmeter 3 8 Wrench or socket wrench 7 16 wrench 9 16 Wrench Needle nose pliers Wiring Diagram This procedure should take approximately 30 minutes to perform Retum to Master TOC F u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN P Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 24 F 24 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST continued FIGURE F 7 ROTOR BRUSH LEADS SLIP RINGS BRUSHES an Ah LEADS T TEST PROCEDURE Turn the engine off Perform the Case Cover Removal proce dure Locate and label the four leads from the rotor brush holder assembly See Figure F 7 Using the needle nose pliers remove the leads See Figure F 7 This will electricall
134. lectrical components Retum to Section TOC Retum to Master TOC ENGINE OUTPUT No Load RPM Load RPM Low Idle 2350 2450 High Idle 3700 3750 3350 3580 WELDER DC STICK OUTPUT ARC control 10 Mode Selector Output Control Open Circuit Load Volts Load Amps Switch Volts Stick CC 74 79 25 30 245 265 Return to Section TOC Retum to Master TOC WELDER CV WIRE OUTPUT ARC Control 10 Mode Selector Output Control Open Circuit Load Volts Load Amps Switch Voltage 56 64 25 30 245 265 20 28 13 14 5 25 30 TOUCH START TIG ARC Control 10 Mode Selector Output Control Open Circuit Load Volts Load Amps Switch Voltage 16 19 25 30 245 265 TIG Minimum 16 19 Short Circuit 19 24 Retum to Master TOC e E E u 8 AUXILIARY POWER OUTPUT 120 Volt Recep Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 236 252 216 225 35 39 118 126 110 120 d 5 42 VOLT WIRE FEEDER POWER D TE dp ii AE RANGER 250 LINCOLN C G 1 ELECTRICAL DIAGRAMS 9 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION j ELECTRICAL DIAGRAMS setas ts Caserta aud nda aqua DURER RE not qr SECTION G g WIRING DIAGRAM RANGER 250 KOHLER 0 00 0000 e G 2 z WIRING DIAGRAM RANGER 250 ONAN sss ne G 3 5 CONTROL INTER CONNECTION DIAGRAM 0 0 000 0 I e G 4 COMPLETE MACHINE SCHEMATIC 4 2222 ax stiau dad rh He Cra beth Sav radi G 5 ANALOG CONTROL POWER SU
135. m to Section TOC Retum to Master TOC TABLE D 3 ENGINE MAINTENANCE COMPONENTS ITEM Oil Filter Air Filter Element Air Filter Pre Cleaner Onan 140 1496 Kohler 2408302 Fuel Filter Onan 149 2005 Fram G1 Kohler 2505002 Fram G1 Spark Plug Onan 167 0263 Champion RS14YC Champion RC12YC 030 Gap 025 Gap Battery BCI Group 58 435 CCA BCI Group 58 435 CCA Retum to Master TOC e E E u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE ENGINE OIL CHANGE TZ Drain the oil while the engine is warm to assure rapid and complete draining 1 Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine Push in and twist the drain valve counterclockwise Pull the valve out and drain the oil into a suitable container 2 Close the drain valve by pushing in and twisting clockwise Replace the yellow cap 3 Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely Engine Oil Refill Capacities Without oil filter replacement 1 7 US qt 1 4 Imp qt 1 6 liter Kohler 1 6 US qt 1 3 Imp qt 1 5 liter Onan With oil filter replacement
136. me during the 50 microsecond cycle the output is maxi mized The darkened area under the top curve can be compared to the area under the bottom curve The more darkened area under the curve the more power is present RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION CHOPPER TECHNOLOGY FUNDAMENTALS The new era of welding machines such as the Ranger 250 employ a technology whereby a DC source is turned on and off chopped up at high speed thensmoothed through an inductor to control an arc Hence the name Chopper The biggest advantage of chopper technology is the high speed control of the arc similar to the inverter machines A block diagram for this is as follows 3 PHASE DC RECTIFIER SOLID STATE INDUCTOR ARC ALTERNATOR AND FILTER SWITCH AND DIODE ARC CONTROL In this system the engine drives a three phase alter nator which generates power that is rectified and fil tered to produce about 85VDC The current is applied through a solid state switch to an inductor By turning the switch on and off current in the inductor and the arc can be controlled The following diagram depicts the current flow in the system when the switch is open and closed SWITCH
137. ngine is drawn in through the lower set of louvers on the case back It is important that the intake air is not restricted Allow a minimum clearance of 2 feet 0 6m from the case back to a vertical sur face RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC INSTALLATION BATTERY CONNECTIONS A WARNING BATTERY ACID CAN BURN EYES AND SKIN S Wear gloves and eye protection and be careful when working near a battery Follow the instructions printed on the battery Use caution as the electrolyte is a strong acid that can burn skin and damage eyes The Ranger 250 is shipped with the negative battery cable disconnected Make certain that the RUN STOP switch is in the STOP position Remove the screws from the rear battery tray using a screwdriver or a 3 8 Socket Attach the negative battery cable to the nega tive battery terminal and tighten using a socket or wrench NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity See the battery charging instructions in the Maintenance section MUFFLER OUTLET PIPE Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned to direct the ex
138. ngines The Above For Gasoline Engines uc ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 2 T FOR ENGINE 8 7 us 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AW ke 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 cm 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Retum to Master TOC ELECTRIC AND 3 MAGNETIC FIELDS Sa may be dangerous Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to preve
139. nnect the positive meter probe to the terminal on the diode module Connect the negative meter probe to the heat sink The resistance should be lower approximately 300 ohms Also check diode D4 for shorted or open condition See the Wiring Diagram When all tests are complete 1 2 3 RANGER 250 LINCOLN B Reconnect all leads previously removed Torque the capacitor nuts to 50 60 inch pounds If finished testing perform the Case Cover procedure F 43 F 43 TROUBLESHOOTING amp REPAIR FLYWHEEL ALTERNATOR TEST A 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 Retum to Section TOC Retum 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the flywheel alternator is properly charging the battery MATERIALS NEEDED Volt Ohmmeter 3 8 Wrench or socket wrench Retum to Section TOC Retum to Master TOC
140. nt spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers before welding 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 Y e 1 z 8 E e All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 e In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Do not put y
141. nting holes line up with the 9 UAE ae Socks Wrench remove the mounting holes in the machine mounting four screws holding the front panel to the bracket machine base Tilt the front panel as far for ward as the attached leads will permit Cut 2 Insert the three long bolts through the choke any necessary cable ties and the mounting bracket Place a lock 8 9 7 With two 1 2 wrenches remove heavy aa pach potang tighten with FI leads W6 W11 and W7 and their bolt lock 5 8 washers and flat washers from the negative 3 Using the 1 2 wrenches attach the heavy 3 D strap on the right side of the output rectifier flex leads W8 WO and W10 to the appropri v s 8 With two 1 2 wrenches remove heavy S Pius EE EE MIRO 8 E leads W4 and W5 and their bolt lock wash giam E E ers and flat washers from the positive strap u 3 of the output rectifier Output Rectifier 9 With two 1 2 wrenches remove heavy 1 Place the output rectifier into the machine so leads W1 W2 and W3 and their bolts lock that its mounting studs fit into the holes in the washers and flat washers from the three bracket Attach the nuts and lock washers straps on the left side of the output rectifier using the 1 2 wrench 10 With the 1 2 wrench or socket wrench 2 m Mod erg W Ke ue e remove the nuts and lock washers holding deen er El the output rectifier to the machine mounting plates See Figure F 25 for placement 8 y bracket You will need to reach through the 3 Attach
142. o b SHOWNIN pem SEN AUTO POSITION AA o9 EOS Pese ST Shunt Return to Section TOC Return to Master TOC 21 SHOWN IN o ohh P4242 POSITIVE v POSITION CN P7 J7 Output Control Lo b 76 7 a o 7 PCB2 ANALOG POWER PC BOARD E LT amp J8 Hot Start 5L km BOTTOM GND SCREW ON M Poo INSIDE OF CASE FRONT Pinch 115AC d P60 m Arc Force CONTACTOR SR SN n m SCH REMOTE 3 TOP GND SCREW ON Out Gei 7 Ampenol Ovde c o anc E INSIDE OF CASE FRONT r 8 A me GROUND Bo 200A 200 spy IDLE SOLENOID 255 PIT AMPHENOL 1 ROUN Thermal REMOTE pA eT FRAME GND d Zi s CONTROL Gel75C oo 1 o z amp GREEN CONTACTOR Lore LH NEG BRUSH POS BRUS d N GROUND Fol GND B LEAD COLOR CODE AMPHENOL 2 224B N HOUR METER 5G d P12 J12 RCREDORPINK tpe pos W WHITE PC BOARD POSITIVE BRUSH CONNECTED 212A ang G GREEN W YELLOW STRIPE TO SLIP RING NEAREST TO THE LAMINATION Qjo ojo E E S o B olse wl SIS SIE s p w o o IG 12 VOLT PCB3 WELD CONTROL PC BOARD
143. older assembly 2 Using the 1 2 wrench remove the bolt 5 Unscrew the fan to remove it from the shaft washers and nut holding the muffler to the Turn the fan counterclockwise Be careful not stator Onan engine machines Remove the to lose the washer that fits between the blow bolts and washers holding the muffler to the er fan and the rotor engine and remove the muffler 3 Disconnect the idler solenoid linkage at its clip RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g 1 2 8 E e Retum to Master TOC F 66 F 66 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued 10 11 12 13 14 Double check that the spark plug wires are disconnected You will be turning the rotor during this procedure and this could cause engine kickback Hold the rotor shaft with locking pliers With the 5 8 wrench or an impact wrench remove the rotor thru bolt Hold the rotor with one hand and shock the wrench with a mallet to loosen the thru bolt The thru bolt has a centering washer tapered to conform to the rotor shaft Remove the thru bolt and washer from the end of the rotor Install the appropriate long thru bolt two are provided supplied with Lincoln Electric Rotor Puller Kit S20788 The slot head must face out Screw in the bolt with the
144. on the engine runs at the high 5 ENGINE ALTERNATOR TROUBLE LIGHT The idle speed controlled by the engine governor yellow engine alternator light is off when the battery m charging system is functioning normally If the light B In s AUTO position the idler operates as fol turns on the alternator or the voltage regulator may lows not be operating correctly The light may also come 5 a When switched from HIGH to AUTO or after on if the battery is not holding a charge It is normal K ke starting the engine the engine will operate for the light to come on while starting the engine E H at high speed for approximately 12 seconds 6 ENGINE HOUR METER Displays the total time y g and then go to low idle speed that the engine has been running This meter is g 2 b When the electrode touches the work or useful for scheduling prescribed maintenance E s power is drawn from the auxiliary power CAL RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION WELDING CONTROLS 7 10 11 OUTPUT CONTROL The OUTPUT dial provides continuous control of the welding current or weld ing voltage depending on the selected welding mode This control is not active in the CC STICK PIPE and CV WIRE modes when a remote con trol or wire feeder with remote control is connect ed to either
145. onnel should install use or ser vice this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place These provide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Ranger 250 is a gasoline engine powered DC multi process welding power source and 120 240 VAC power generator The engine drives a generator that supplies three phase power for the DC welding cir cuit and single phase power for the AC auxiliary out lets The DC welding control system uses state of the an Chopper Technology C Tw for superior welding performance RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g 1 2 8 E e Retum to Master TOC B 3 B 3 OPERATION DESIGN FEATURES Single full range output control dial 4 welding modes CC stick downhill stick welding on pipe CV wire welding and Touch Start TIG elimi nates high frequency and tungsten contamination Output at welding terminals controlled by electronic contactor Can be switched to On or to Remotely Controlled Contactor auto activated when con nected 6 pin connector for remote output Many wire feeder combinations 14 pin connector for Lincoln wire feeders LN 25 LN 23P LN 7 LN 8 operates when using a Lincoln wire fe
146. ontal Sweep 5 ms Div CGouplimg DC Ulu Trigger Internal FP c SI E wn 8 8 ili CAL RANGER 250 LINCOLN F 49 F 49 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM WIRE CV MACHINE LOADED TO 250 AMPS AT 28 VOLTS Retum to Section TOC Retum to Master TOC Hep tt 0 volts Return to Section TOC Retum to Master TOC 20V ims This is the typical DC voltage gener ated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 1 millisecond in time The machine was loaded with a resis tance grid bank to 250 amps at 28 volts Retum to Master TOC F u 8 NOTE Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div 5 g Couplimg DC Cr Trigger Internal eB 5 E wn 8 8 ili CAL RANGER 250 LINCOLN P Retum to Section TOC Retum to Section TOC S E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 50 TROUBLESHOOTING amp REPAIR POWER MODULE ASSEMBLY POWER MODULE PC BOARD DIODE MODULE REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric
147. optional K802R plug kit or as part number T12153 9 4 Plug this cable into the 50 amp 120 240 VAC receptacle on the Ranger 250 case front RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC S E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION FIGURE A 2 CONNECTION OF THE RANGER 250 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR on A DT mm x 60 Hz 3 Wire COMPANY E Service METER NEUTRAL BUS LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION C PREMISES DISCONNECT AND SERVICE 35AMP GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 N V 50 AMP 120 240 VOLT Y T NOTE No 8 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS A WARNING e Only a licensed certified trained electrician should install the machine to a premises or residential elec trical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated befor
148. or location c Connect the negative meter probe to the other brush leads 201 and 5H d Carefully measure the voltage It should read approximately 46 52 VDC RANGER 250 LINCOLN P FIGURE F 9 FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR If the voltage reading is low or not present the generator field is not functioning prop erly Perform the Rotor Resistance Test Also check the field diode rectifier bridge filter capacitor and associated leads and connections See Figure F 9 for location See the Wiring Diagram Check the rotor ground wire 5H for good connection See the Wiring Diagram If the rotor voltage readings are normal the field circuit is functioning properly If finished testing perform the Case Cover Replacement procedure Retum to Section TOC Retum to Section TOC S E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 28 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS A 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 electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand
149. or lead 42A and the other probe at amphenol pin I 5 Start the engine and run it at high idle 3700 RPM 6 Check the AC voltage reading It should be between 40 and 46 VAC Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 32 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS continued FIGURE F 13 OUTPUT RECTIFIER BRIDGE CONNECTIONS ei TOP OUTPUT w1 RECTIFIER w2 7 lt CENTER BRIDGE W3 E BOTTOM 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 sta tor windings See the Wiring Diagram Make sure that the windings are NOT grounded inter nally to the stator iron If the leads are intact then the stator may be faulty Replace the stator If the voltage readings are within specifications then the windings are good and functioning prop erly 7 f finished testing perform the Case Cover Replacement procedure To test the stator weld windings 1 Locate the weld winding leads connected to the three phase output rectifier bridge See Figure F 13 Check for approximately 58 65 VAC from W1 to W2 Also check for the same voltage from W2 to W3 and from W1 to W3 If any of these voltages are low or missing perform the Flashing and Rotor Voltage Tes
150. our hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 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 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Retum to Master TOC RANGER 250 LINCOLN Retum to Master TOC Retum to Master TOC Y e 1 z 8 E e Retum 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 wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or ac
151. present This is similar to turning ON a light switch RANGER 250 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q O He Ze o o o 2 x 3 E tc Return to Section TOC Return to Master TOC Q O ke E o p 7 o o B x 2 o cc THEORY OF OPERATION FIGURE E 6 TYPICAL IGBT OUTPUTS MINIMUM OUTPUT 2 usec 48 u sec 50 u sec Dwell or Off Time MAXIMUM OUTPUT 48 u sec PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle Changing the pulse width is known as MODU LATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing shows the minimum output sig nal possible over a 50 microsecond time period 50 usec Dwell or Off Ss The positive portion of the signal represents one IGBT group conducting for 2 microsecond The dwell time off time is 48 microseconds Since only 2 microseconds of the 50 microsecond time period is devoted to conduct ing the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 48 microseconds and allowing only 2 microseconds of dwell time off ti
152. r wrench remove leads 5 and GND E from the bottom ground stud on the case front See the Wiring Diagram RANGER 250 LINCOLN B Remove lead 42 from circuit breaker CB8 Remove stator auxiliary winding lead 6 from circuit breaker CB6 and lead 3 from circuit breaker CB5 These leads pass through the toroid For reassembly note the number of turns and direction through the toroid for each lead See the Wiring Diagram Separate and remove lead 5H 201 200A and 200 at their piggy back connections at the brush holder See the Wiring Diagram Disconnect plug J51 Block Engine Connector Using the 1 2 wrench disconnect the engine ground lead GND J at the engine foot This is the small lead that runs to the top ground stud on the case front Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 64 F 64 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 29 ENGINE STATOR ROTOR ASSEMBLY REMOVAL Engine Stator Rotor Assembly Removal Procedure Refer to Figure F 29 1 Attach chains to the lifting eyes on the top sides of the engine and the stator lift bail Secure the chains to the hoist and put enough tension on them to support the engine but without lifting the assembly Using the 9 16 wrench remove
153. rd them if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 5 Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode 6 Checkthat the spark plug washer is in good condi tion and thread the spark plug in by hand to pre vent cross threading 7 After the spark plug is seated tighten with a spark plug wrench to compress the washer e If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer Spark Plug Gap 030 in 0 76 mm Kohler 025 in 0 64 mm Onan Spark Plug Torque 20 ft Lb 27 N m Kohler 11 ft Lb 14 N m Onan A CAUTION The spark plug must be securely tightened An improp erly tightened spark plug can become very hot and may cause engine damage Use only the recommended spark plug or equivalent A spark plug which has an improper heat range may cause engine damage FUEL FILTER SERVICE 1 Check the fuel filter for water accumulation or sed iment 2 Replace the fuel filter if it is found with excessive water accumulation or sediment ENGINE ADJUSTMENT A WARNING OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase th
154. re 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 RANGER 250 LINCOLN B Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC 7 WELDING SPARKS can 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 overheating 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 The
155. re feeders NOTE Gas shielded welding requires a Magnum Gun Gasless welding requires an Innershield Gun LN 742 WIRE FEEDER A semiautomatic wire feeder with cold electrode Refer to connection instructions later in this section MAGNUM SPOOL GUN K487 25 A lightweight semiautomatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the handle Requires the K488 SG Control Module Refer to connection instructions later in this section SG CONTROL MODULE K488 Controls wire speed and gas flow Provides the required control interface between the Ranger 250 and the K487 25 Magnum Spool Gun Requires the K691 10 Input Cable K444 1 REMOTE VOLTAGE CONTROL Provides voltage adjustment control at the feeder Includes 25 feet of cable K126 2 INNERSHIELD GUN For gasless welding Includes 15 feet of cable K470 2 MAGNUM GUN CONNECTOR KIT For gas shielded welding K466 1 MAGNUM GUN CONNECTOR KIT For con necting the Magnum 300 MIG Gun to the feeder for gas shielded welding RANGER 250 LINCOLN C 3 C 3 ACCESSORIES 5 8 CONNECTION OF LINCOLN 3 Connect the K867 Universal Adapter to the 14 pin Fle amphenol of the Ranger 250 as shown in Figure 5 ELECTRIC WIRE FEEDERS C 1 Make the proper connections for local or d remote control according to Figure C 1 and the fol v A A WARNING lowing NOTES indicated on the figure d E f A These leads are not used for the R
156. re 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 250 LINCOLN B Retum to Section TOC Return to Section TOC c E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your Authorized Facility Lincoln Service local Field TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department at 1 800 833 9353 WELD No welding output in all modes The engine operates normally The auxiliary output is normal Place the Welding Terminals switch in the WELD TERMI NALS ON position If the prob lem is solved the fault may be in the external control cable if used leads 2 and 4 See the Wiring Diagram With the engine at high idle 3700RPM the machine in the Stick mode and the OUTPUT CONTROL at maximum check for the presence of approxi mately 80VDC open circuit voltage at the output terminals If the correct OCV is present at the
157. ricien 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 RANGER 250 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page SOA OEY i iv JE Fe EE Section A elle Ee Uer A 2 NIIS A 3 Location and Ventilatii Messaia acakan a aaa a aaa aiaa aa Ea aaa A 3 Pre Operation Engine Service essssssssssssssssseseeee eene nnne nennen tenete sinerent A 4 Electrical Output CGonpnechons nennen nennen nennen nennen ren A 5 iSi M eee Section B Safety IMStrUCthons ECT B 2 General Descriptio Meinaan ia B 2 Bini B 3 Controls and Seltihgs icri Fide etae cen ee Re gea Fe ce ut odd od erp ded deele i B 3 Engine Operation 2 eee e eret eire dut e Ais Te etude pd ees B 5 ilerum cee B 7 EU e E e EE B 9 AcCeSSOL GS neret Eo ER DR b nent EEEEER HERR REN X ERR Ek e Dine bx d Section C Maintenance i niente eee D ede ea pe eio i HELL E Ed Re dn baie Section D Theory of Operation eo a a N RE FERRDNIAR a PASSEN A DERE dese Section E Troubleshooting and Repair Section F Electrical Diagrams ee Lee od eee i ge t a t e RR te et AER eR a Rada Section G
158. ring break in subject the Ranger 250 to moderate loads Avoid long periods running at idle Before stop ping the engine remove all loads and allow the engine to cool several minutes RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC g 1 z 8 E e Retum to Master TOC B 7 OPERATION WELDER 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 weld ing from the breathing area C Keep flammable material away Wear eye ear and body protection The Ranger 250 can deliver from 40 to 250 amps of constant current for DC stick welding or from 20 to 250 amps of constant voltage current for DC semiautomat ic wire feed welding DC TIG welding is possible across the entire range from 20 to maximum rated out put Output can be adjusted by setting the OUTPUT control dial and the ARC control dial on the output con trol panel to the settings that are best for your selected welding process NOTE An unstable or unsatisfactory welding arc can result if welding cables are too long or are coiled on the machine when welding See in the Installation section Straighten out coiled cables before welding TABLE B 1 TYPICAL RANGER 2
159. rk Do not overfill Close engine door 4 See the Maintenance section for specific oil rec ommendations Check and fill the engine fuel tank WI A WARNING GASOLINE can cause fire or explosion Stop engine when fueling Do not smoke when fueling Do not overfill tank Avoid contact with skin or breathing of vapor Keep sparks and flame away from tank RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION 1 Remove the fuel tank cap 2 Fill the tank approximately 4 inches 100mm from the top of the filler neck to allow for fuel expansion Observe the fuel gauge while filling DO NOT FILL THE TANK TO THE POINT OF OVERFLOW Replace the fuel cap and tighten securely See the Maintenance section for specific fuel rec ommendations STARTING THE ENGINE 1 Remove all plugs connected to the AC power receptacles Set the IDLER switch to AUTO d lt D Set the RUN STOP switch to RUN Pull the choke to the full out position Press and hold the engine START button until the engine starts cR oO DN 6 Release the engine START button when the engine starts 7 Push the choke back in 8 The engine will run at high idle speed for approx imately 12 seconds and then go to low idle speed Allow the engine to warm up at low idle for
160. rmed 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 Retum 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD Q Ji 5 y DESCRIPTION 3 B The following procedure will aid the technician in removing and replacing the gasoline engine a stator and rotor for repair or replacement This procedure is for Onan models only Some pro d cedures may vary slightly for Kohler models JE MATERIALS NEEDED 5 16 Nut driver 3 8 Deep socket 3 8 Wrench or socket wrench Slot head screw driver 7 16 Wrench or socket wrench Phillips head screw driver 1 2 Wrench or socket wrench Gear puller small 3 4 Wrench Hoist chains straps 9 16 Wrench Feeler gauge for air gap check 1 2 Box end wrench Machine Wiring Diagram Diagonal cutters Rubber or wooden mallet Impact wrench Torque wrench with 1 2 socket Loctite 271 thread sealant Retum to Master TOC F u 8 This procedure should take approximately 3 hours to perform Retum to Section TOC Retum to Master TOC RANGER 250
161. rol unit is connected Machine seems to be locked into the CC mode of operation stick mode This is normal in TIG mode The remote control unit may be defective Check the amphenol connec tions and associated wiring Check the position of the Mode Selector switch It must be in the correct position for the process being used Check that jumper plug J3 is properly installed in the Control Board J3 has a jumper wire from pin 1 to pin 5 Make sure plug J2 is properly connected to the Control Board Check Plug J10 on the Control Board for loose or faulty con nections The bypass board may be faulty The Control Board may be faulty Check the Mode Selector switch and associated wiring See the Wiring Diagram The Control Board may be faulty A 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 1 800 833 9353 RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC c E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The wire f
162. sents 5 milliseconds in time NOTE Scope probes are connected at machine 120 VAC receptacle Retum to Master TOC F u 8 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div CGouplimg DC Ulu Trigger Internal dk c SI E wn 8 8 ili CAL RANGER 250 LINCOLN P Retum to Section TOC Return to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 46 F 46 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX CONTROL POT HIGH IDLE NO LOAD CH1 0 volts 50V 5ms This is the typical DC open circuit out put 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 Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div CGouplimg DC Trigger Internal RANGER 250 LINCOLN P F 47 F 47 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM STICK CC MACHINE LOADED TO 250 AMPS AT 25 VOLTS Retum to Section TOC Retum to Master TOC Trig 15V CH1 0 volts Return to Sect
163. sever al minutes before applying a load and or switch ing to high idle Allow a longer warm up time in cold weather A CAUTION Operating the starter motor for more than 5 seconds can damage the motor If the engine fails to start release the START button and wait 10 seconds before activating the starter again Do NOT push the START button while the engine is running because this can damage the ring gear and or the starter motor NOTE Starting a Ranger 250 for the first time or after an extended period of time of not operating will take longer than normal The fuel pump has to fill the fuel line and carburetor If the engine will not start see the Troubleshooting section of this manual STOPPING THE ENGINE 1 Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine 2 Stop the engine by placing the RUN STOP switch in the STOP position NOTE A fuel shut off valve is not required on the Ranger 250 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 250 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 A CAUTION Du
164. simulates the test with the engine running b Remove the spark plug wires then set the RUN STOP switch to RUN c Connect the positive meter probe to the brush nearest the rotor lamination leads 200A and 200 See Figure F 8 for location RANGER 250 LINCOLN C d Connect the negative meter probe to the other brush leads 201 and 5H e Measure the voltage It should read between 3 0 and 4 0 VDC f Set the RUN STOP switch to STOP Oil Pressure Switch Test The oil pressure switch is designed to open if it detects low or no oil pressure If you can con duct the test described here in Step 3 and obtain the 3 0 to 4 0 VDC voltage reading WITHOUT THE JUMPER then the oil pressure switch or the Battery PC board may be faulty Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 27 TROUBLESHOOTING amp REPAIR FLASHING AND ROTOR VOLTAGE TEST continued FIELD RECTIFIER BRIDGE RETAINING TAB CABLE CAPACITOR Test rotor voltage dynamic engine run ning a Remove the jumper used in the previous step Replace the spark plug wires set the RUN STOP switch to RUN start the engine and run it at high idle speed 3700 RPM b Connect the positive meter probe to the brush nearest the rotor lamination leads 200A and 200 See Figure F 8 f
165. slot head screw driver until the bolt bottoms out on the engine crankshaft about 3 4 Turning it counterclockwise screw in the left hand thread rotor removal tool from the kit into the rotor shaft Carefully prevent the rotor from turning use locking pliers Tighten the tool to approximately 50 ft lbs with the torque or impact wrench The rotor should pop off the engine crankshaft If the rotor does not pop off continue to carefully prevent the rotor shaft from turning and tighten the rotor removal tool an addi tional 5 ft Ibs until the rotor pops off the engine crankshaft With the 7 16 wrench remove the side fire walls With the 9 16 wrench remove the four bolts that hold the stator to the engine There is one lock washer per bolt Carefully remove the stator rotor assembly from the engine Once the assembly is sep arated from the engine be careful that the rotor does not fall out of the stator 15 Carefully remove the rotor from the stator You can tap carefully on the end of the rotor shaft with a rubber mallet Guide the rotor carefully to prevent damage to its core REASSEMBLY NOTES Reassemble the rotor and stator to the Ranger 250 by carefully retracing the disassembly proce dure steps in reverse order Keep the following special points in mind as you proceed A Lead Reconnection Checklist is provided here to aid in reassembly Rotor Stator Engine Reassembly Refer to Figure F 30 NOTE Lincoln
166. t 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 23 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 phosgene 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 insu
167. t age is applied to parallel capacitors incorporated with in the power module These capacitors function as fil ters and also as power supplies for the IGBT See IGBT Operation in this section The IGBT acts as a high speed switch operating at 20KHZ This device is switched on and off by the control board through pulsewidth modulation circuitry See Modulation in this section This chopped DC output STATOR AUXILIARY WINDINGS ANALOG POWER BOARD CONTROL BOARD REGULATED VOLTAGES ARG OUTPUT MODE CONTROL CONTROL SELECTOR WIRE FEED PWR WNDG AMPHENOL 120VAC RECEPTACLE is applied through a choke coil and shunt to the weld ing output terminals The choke functions as a current filter Free wheeling diodes are incorporated in the power module to provide a current path for the stored energy in the chokes when the IGBT is turned off See Chopper Technology in this section Output voltage and current feedback information is fed to the control board This information is sensed from the output terminal circuits and the shunt NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 250 LINCOLN B Retum to Section TOC Return to Section TOC c F E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 4 E 4 THEORY OF OPERATION FIGURE E 4 ANALOG POWER BOARD AND CONTROL BOA
168. t and also the Rotor Resistance Test If the tests in Step 2 are OK and the stator voltages are low or missing the stator may be faulty If finished testing perform the Case Cover Replacement procedure RANGER 250 LINCOLN B Retum to Section TOC Retum to Section TOC S E E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 33 TROUBLESHOOTING amp REPAIR ANALOG POWER PC BOARD VOLTAGE TEST A 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 electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the Analog Power PC board is receiving and passing the prop er signal voltages MATERIALS NEEDED Analog Volt Ohmmeter 3 8 Wrench or Socket Wrench 9 16 Wrench Wiring Diagram This procedure should take approximately 30 minutes to perform RANGER 250 LINCOLN B
169. t repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the idler solenoid is capable of functioning when it is energized with 12VDC MATERIALS NEEDED 3 8 Wrench or socket wrench 9 16 Wrench External 12VDC supply 30 amps Diagonal cutters Wiring Diagram Volt Ohmmeter This procedure should take approximately 30 minutes to perform RANGER 250 LINCOLN B Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 18 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST continued FIGURE F 3 IDLER SOLENOID LEADS SOLENOID HOUSING LEADS 4210C AND 215 TO CONNECTORS 4 STATOR TEST PROCEDURE Turn the engine off Perform the Case Cover Removal proce dure Locate the idler solenoid mounted on the stator beside the fuel tank filler neck Locate and remove the two in line connec tors that attach the idler solenoid leads to the wiring harness leads 4210C and 215 Cut any necessary cable ties See Figure F 3 and the Wiring Diagram Check the coil resistance The normal resistance is approximately 15 ohms If the coil resistance is not correct the solenoid may be faulty Replace Using the ex
170. t voltage readings 3 Sneck tar ane comect Anaad POWE EE per Table F 1 If any of the readings are not board input voltage correct the Analog Power PC board may be a Set the volt ohmmeter to the Volts DC faulty position b Place the negative probe on J41 pin 2 and the positive probe on J41 pin 1 c The reading should be between 75 and 85 VDC RANGER 250 LINCOLN B F 35 F 35 TROUBLESHOOTING amp REPAIR Q E P ANALOG POWER PC BOARD VOLTAGE TEST continued fa D 3 g TABLE F 1 ANALOG PC BOARD OUTPUT VOLTAGE TABLE 8 8 E F B TEST POINTS COMPONENT TESTED VOLTAGE READING a 1J42 to 6J42 Chopper Power Supply 20 VDC 2J42 to 7J42 Weld Control PC Board Power Supply 5 VDC 5J42 to 7J42 Weld Control PC Board Power Supply 15 VDC 9J42 to 7J42 Weld Control PC Board Power Supply 15 VDC 10J42 to 4J42 Weld Control PC Board Power Supply 15 VDC 7 If finished testing perform the Case Cover Replacement procedure NOTE ON THE BYPASS PC BOARD The purpose of the Bypass PC board circuitry is to provide a more attractive path to ground for transient spikes and high frequency signals that could damage sensitive circuit components The Ranger 250 Bypass PC board cannot be tested However a faulty Bypass PC may show visible physical damage As a general rule of practice if you have catastrophic damage to any other PC board on the machine the Bypass PC board should be replaced as well Retum to Section TOC
171. ternal 12VDC supply apply 12VDC to the solenoid leads Push the solenoid plunger in this simulates the action that takes place when the engine is RANGER 250 LINCOLN C 10 running and there is less resistance to solenoid movement and check that it holds by itself The solenoid should deac tivate when the 12VDC is removed If the solenoid does not operate properly check for a mechanical restriction in the linkage Also check for proper operation of the governor See the Engine Owner s Manual If the linkage is intact and the solenoid does not operate correctly when the 12VDC is applied the solenoid may be faulty Replace Replace leads 210C and 215 to the correct in line connectors See Figure F 3 and the Wiring Diagram Replace any previously removed cable ties If finished testing perform the Cover Replacement procedure Return to Section TOC Retum to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST A 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 electrical shock please observe all safety notes and precautions deta
172. the 6 pin or 14 pin Amphenol WELD MODE SELECTOR SWITCH This switch provides four selectable welding modes CV WIRE PIPE e CC STICK TOUCH START TIG ARC CONTROL The ARC CONTROL WIRE STICK dial is active in the CV WIRE and CC STICK modes and has different functions in these modes This control is not active in the TIG and PIPE modes CC STICK mode In this mode the ARC CON TROL sets the short circuit current during stick welding arc force Increasing the number from 10 to 10 increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode stick ing Start with a setting at O CV WIRE mode In this mode turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance control The proper setting depends on the procedure and operator preference Start with a setting at O 14 PIN AMPHENOL For attaching wire feeder control cables to the Ranger 250 Includes con tactor closure circuit auto sensing remote control circuit and 120V and 42V power The remote control circuit operates the same as the 6 pin Amphenol See below 6 PIN AMPHENOL For attaching optional remote control equipment When in the CC STICK PIPE and CV WIRE modes and when a remote control is connected to
173. the Amphenol the auto sensing circuit in the Ranger 250 automati cally switches the OUTPUT control from control at the welder to remote control When using the TOUCH START TIG mode the OUTPUT control on the front of the Ranger 250 sets the maximum current range 12 WELD TERMINALS CONTROL SWITCH In the WELD TERMINALS ON position the weld output is electrically hot all the time In the REMOTELY CONTROLLED position the weld output is con trolled by a wire feeder or amptrol device and is electrically off until a remote switch is depressed 13 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode ENGINE OPERATION A WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the Ranger 250 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 engine operator s manual that is shipped with your Ranger 250 BEFORE STARTING THE ENGINE TZ 1 Be sure the machine is on a level surface Check and fill the engine oil level 2 Open top engine door and remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dipstick 3 Add oil if necessary to bring the level up to the full ma
174. 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 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct AC voltages are being generated from the stator windings MATERIALS NEEDED 3 8 Wrench or socket wrench 9 16 Wrench 3 4 Wrench Test pins Volt Ohmmeter Wiring Diagram This procedure should take approximately 40 minutes to perform RANGER 250 LINCOLN P F 28 F 29 F 29 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS continued FIGURE F 10 RECEPTACLE LEAD LOCATIONS Return to Section TOC Retum to Master TOC 50 AMP 25 AMP 20 AMP m ees NDA eO B 2 N ces ce7 cat o e e bb 5 AMPHENOL 2 AMPHENOL 1 w 100 120 240 V AC 6 6B 6E Sc d f arb CB6 CB8 CB2 F Hoe E E3 ol o JI o o e o 6E T J d J 50 AMP 5 AMP 20 AMP wn Wan Caen UnZAIDCO eg 208 SHUN WZ yp Jma POSITIVE PUTPUT STID 208A 208B NEGATIVE PUTPUT STUD 2045 206S Retum to Master TOC E 9 B u 8 ec CASE FRONT REAR VIEW TEST PROCEDURE For all tests Perform the Case Cover Removal To test the 240 VAC winding gig Hp K n pro
175. the two bolts lock washers and nuts from the stator bottom support bracket and two bolts wash ers and nuts from the engine mountings LIFTING EYE 2 ENGINE MOUNTING FIREWALLS STATOR SUPPORT BRACKET FUEL LINE Remove the fuel line at the carburetor and plug it Using the hoist you can now lift the engine stator assembly free from the machine base Note that the firewall baffle assembly surrounding the muffler Onan engine machines and stator come with the engine stator rotor assembly It is not secured to the machine base Set the assembly carefully on a workbench or the floor Place a wooden block under the stator before removing support from the hoist RANGER 250 LINCOLN B Return to Section TOC Return to Section TOC S E E u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y e 1 2 8 E e Retum to Master TOC F 65 F 65 TROUBLESHOOTING amp REPAIR ENGINE STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 30 STATOR AND ROTOR REMOVAL STATOR BRUSH HOLDER ASSEMBLY ROTOR THRU BOLT BLOWER FAN TOLERANCE RING ROTOR BEARING IDLER SOLENOID ROTOR LIFTING EYE 00008o0w Stator Rotor Assembly Removal 4 Using the 7 16 wrench remove the two nuts lock washers and bolts holding the brush Rater te Figure 50 holder assembly to the stator frame 1 Support the stator with the hoist Remove the brush h
176. to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION FIGURE E 5 IGBT OPERATION BODY REGION DRAIN DRIFT REGION BUFFER LAYER lt INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semiconduc tors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned off like a light switch in the OFF position POSITIVE VOLTAGE WE GATE SOURCE BODY REGION DRAIN DRIFT REGION lt BUFFER LAYER n p INJECTING LAYER DRAIN B ACTIVE Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the posi tive gate signal is
177. tory 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 Retum to Section TOC Retum 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the power module is shorted This is a resistance test not a voltage test This test will only help diagnose a problem in the power section of the module Other PC board components could be faulty Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Volt Ohmmeter Analog 3 8 Wrench or socket wrench 9 16 Wrench 1 2 Wrench 7 16 Wrench This procedure should take approximately 45 minutes to perform Retum to Master TOC F u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN P Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g a 2 8 E e Retum to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR POWER M
178. welder output 3 5 for every 1000 ft 305m Contact an authorized engine service shop for modifications to operate above 5 000 ft 1525m HIGH TEMPERATURE OPERATION At temperatures above 30 C output de rating is nec essary For maximum output ratings de rate the welder output 5 for every 10 C above 30 C TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle is Lincoln s K957 1 If the user adapts a non Lincoln trail er he must assume responsibility that the method of attachment and usage does not result in a safety haz ard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated environmental conditions and likely maintenance 5 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways PRE OPERATION ENGINE SERVICE
179. welding output terminals check the welding cables clamps and electrode holder for loose or faulty connections Air flow may be blocked or restricted 1 Check for loose or faulty con nections on the heavy current carrying leads between the output bridge the power mod ule the choke the shunt and the output terminals Check thermostat TS1 and associated wiring See the Wiring Diagram Check the Welding Terminals switch and associated leads 2 and 4 See the Wiring Diagram If the correct OCV is present when the Welding Terminals switch is in the WELD TERMI NALS ON position the By pass Board may be faulty Also check associated wiring See the Wiring Diagram Check gate leads 423 and 25 for loose or faulty connec tions See the Wiring Diagram A 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 1 800 833 9353 RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC c F E u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No welding output in all modes The engine operates normally The auxiliary output is normal cont
180. wer Module The Control Board may be faulty A 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 1 800 833 9353 RANGER 250 LINCOLN Retum to Section TOC Return to Section TOC F u 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine has low welding out put and low auxiliary output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 The engine RPM may be low 2 Check the brushes for wear and proper contact to the slip rings RECOMMENDED COURSE OF ACTION If the engine high idle speed is low perform the Throttle Adjustment Test Perform the Rotor Resistance Perform the Flashing and Rotor Voltage Test lf the rotor voltage is low the field capaci tor or field bridge may be faulty Test and replace if necessary See the Wiring Diagram If the engine high idle RPM is OK but slows down excessively under load then the engine may have lost horsepower and be in need of major repair The machine control is still active when the remote cont
181. which come in contact with the PC Board must be either con ductive anti static or static dissi pative 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 e If the PC Board uses protective shorting jumpers don t remove them until installation is complete e 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 prop er failure analysis 4 Test the 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 tempera ture 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution 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 procedu
182. xplo sive or combustible material When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehicle When connected to premises wiring such as that in a home or shop the welder frame must be connected to the system earth ground See further connection instructions in the section entitled Power Connections as well as the article on ground ing in the latest U S National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the 4b ground symbol is provided on the front of the welder WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output terminals The welding process dictates the polarity of the electrode cable These con nections should be checked periodically and tightened with a wrench 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 redu
183. y isolate the rotor windings Using the ohmmeter check the rotor winding resistance across the slip rings See Figure F 7 Normal resistance is approximately 4 7 ohms RANGER 250 LINCOLN P Measure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpaint ed ground The resistance should be very high at least 500 000 ohms If the test does not meet the resistance spec ifications then the rotor may be faulty Replace Connect the leads previously removed from the brush assembly Make sure the leads are connected to the proper brushes See the Wiring Diagram If finished testing perform the Case Cover Replacement procedure Return to Section TOC Retum to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 25 TROUBLESHOOTING amp REPAIR FLASHING AND ROTOR VOLTAGE TEST A 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 electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs saf
184. y 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 SAFETY xa CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding 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 cyl
185. y trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum 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 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal cover and engine access doors Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 3 8 Wrench or socket wrench 9 16 Wrench This procedure should take approximately 15 minutes to perform Retum to Master TOC F u 8 Retum to Section TOC Retum to Master TOC RANGER 250 LINCOLN Return to Section TOC Return to Section TOC F u 8 Return to Section TOC Retum to Master TOC Retum to Master TOC g 1 2 8 E e Retum to Master TOC F 14 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 1 DOOR REMOVAL REMOVAL PROCEDURE Turn the engine off Unlatch and open the engine service access doors

Lincoln Electric SVM150-A User's Manual

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