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Lincoln Electric RANGER 225 GXT Service Manual Download Page 1

SVM201-A

July, 2010

Safety Depends on You

Lincoln  arc  welding  and  cutting
equipment  is  designed  and  built
with  safety  in  mind.    However,
your  overall  safety  can  be
increased  by  proper  installation
.  .  .  and  thoughtful  operation  on
your  part.   

DO NOT  INSTALL,

OPERATE  OR  REPAIR  THIS
EQUIPMENT  WITHOUT  READ-
ING  THIS  MANUAL  AND  THE
SAFETY  PRECAUTIONS  CON-
TAINED  THROUGHOUT.

And,

most importantly, think before you
act and be careful.

SERVICE MANUAL

For use with machine code number: 

11522

RANGER

®

225 GXT

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199  U.S.A.   TEL: 888.935.3877   FAX: 216.486.1751   WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © Lincoln Global Inc.

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Summary of Contents for RANGER 225 GXT

Page 1: ...HROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machine code number 11522 RANGER 225 GXT Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products Copyright Lincoln Global Inc Return to Master TOC Re...

Page 2: ...THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric ...

Page 3: ...pen arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal ELECTRIC ...

Page 4: ...near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode circuit is touching the work or gr...

Page 5: ...uttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloigner les matériaux inflammables ...

Page 6: ...ance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The w...

Page 7: ...ld be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electr...

Page 8: ...NS I I RANGER 225 GXT Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P 581 ...

Page 9: ...A 5 Angle of Operation A 5 High Altitude Operation A 5 Location Ventilation A 6 Connection of Wire Feeders A 6 Additional Safety Precautions A 6 Welder Operation A 6 Auxiliary Power A 7 120V Duplex Receptacles A 7 Motor Starting A 7 Electrical Devices used w Ranger 225 GXT A 8 Auxiliary Power While Welding A 9 Stand by Power Connections A 9 Connection of Ranger 225 GXT to Premises Wiring A 10 Retu...

Page 10: ...ds up to rated capacity When welding available auxiliary power will be reduced RECEPTACLES 2 120VAC Duplex 5 20R 1 120 240VAC Dual Voltage Full KVA 14 50R BATTERY CHARGING CIRCUIT BREAKER 20AMP for Engine Battery Charging Circuit AUXILIARY POWER CIRCUIT BREAKER Two 20AMP for Two Duplex Receptacle 1 40AMP for Dual Voltage 2 pole RECEPTACLES AND CIRCUIT BREAKERS HEIGHT WIDTH DEPTH WEIGHT 30 00 in 21...

Page 11: ...engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local reg ulations the K1898 1 spark arrester must be installed and properly maintained An incorrect arrester may lead to damage to the engine or adversely ...

Page 12: ... speed rough ness of surface on which the trailer will be operat ed environmental conditions 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding spe cific requirements for use on public highways PRE OPERATION SERVICE READ the engine operating and maintenance instructions supplied with this machine CAUTION LUBRICATION SYSTEM CAPACITY INCLUDI...

Page 13: ...er altitudes Welder output de rating may be necessary For maximum rating de rate the welder output 3 5 for every 1000 ft 305m above 3000 ft 914m If operation will consistently be at altitudes above 5 000 ft 1525m a carburetor jet designed for high altitudes should be installed This will result in bet ter fuel economy cleaner exhaust and longer spark plug life It will not give increased power Conta...

Page 14: ...25 GXT WARNING Position the RANGE switch to the WIRE FEED CV position Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carries no welding current Place the engine switch in the AUTO IDLE posi tion When welding with MIG wire instead of self shield ed core wire weld starts can be improved by set ting the idle mode to HIGH Adjust wire feed ...

Page 15: ...le is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period Duty Cycle for the RANGER 225 GXT is 100 AUXILIARY POWER The RANGER 225 GXT can provide up to 9 000 watts of 120 240 volts AC single phase 60Hz power for continuous use and up to 10 500 watts of 120 240 volts AC single ...

Page 16: ... devices require large drills well pumps grinders small current inrush for starting refrigerators weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV sets An inductive type line condition complicated electrical equipment er along with ...

Page 17: ...peres will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 3 Install a 50 amp 120 240V plug NEMA type 14 50 to the Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 120 240V plug is available in the optional plug kit 4 Plug this cable into the 50 amp 120 240V recepta cle on the RANGER ...

Page 18: ...nd must comply with the National Electrical Code and all other applicable electrical codes Figure 1 CONNECTION OF RANGER 225 GXT TO PREMISES WIRING WARNING Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 19: ...B 2 Engine Switch B 2 Range Switch B 3 Controls Dial B 3 Fuel Consumption B 3 Engine Operation B 4 Before Starting the Engine B 4 Starting the Engine B 4 Stopping the Engine B 4 Break in Period B 4 Welding Process Stick Tig B 5 Summary of Welding Processes B 6 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 20: ... is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK ...

Page 21: ... CAUTION CAUTION KOHLER 23 H P COMMAND CH23S 40 Gallons Hour 1 50 Liters Hour 7 Gallons Hour 2 8 Liters Hour 1 2 Gallons Hour 4 6 Liters Hour 1 3 Gallons Hour 4 9 Liters Hour 1 2 Gallons Hour 4 5 Liters Hour 1 4 Gallons Hour 5 3 Liters Hour Low Idle No Load 2400 RPM High Idle No Load 3700 RPM AC CC Weld Output 225 Amps 25 Volts DC CC Weld Output 210 Amps 25 Volts DC CV Weld Output 200 Amps 20 Volt...

Page 22: ...ne Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the RANGER 225 GXT because the fuel tank is mounted below the engine BREAK IN PERIOD It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in period approxi mately 50 running hours IMPORTANT IN ORDER TO...

Page 23: ...h range setting will be approximately 50 higher than those marked on the nameplate This is due to the special nature of the AC TIG welding arc Do not AC TIG weld on the 210DC 225AC Amp setting The output may exceed the rating of the RANGER 225 GXT WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The Innershield electrode recommended for use with the RANGER 225 GXT is NR 211 MP The elec trode sizes and...

Page 24: ... CONTACTOR contactor closes Welding starts immediately and engine goes to high idle Note Output Control must be set above 3 TIG TIG MODULE WITH Yes HIGH Cold Press Amptrol WITH CONTACTOR KIT contactor closes CONTROL CABLE welding starts immediately AMPTROL WIRE FEED LN 15 No AUTO Cold Press gun trigger ACROSS the ARC LN 15 contactor closes has internal contactor Welding starts immediately and engi...

Page 25: ...CTION C 1 C 1 RANGER 225 GXT Accessories Section C Optional Equipment C 2 Recommended Equipment C 3 Stick C 3 TIG C 3 Wirefeed C 3 Plasma Cutting C 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 26: ...dant mildew resistant and water repellent K802R Power Plug Kit provides four 120V plugs rated at 15 amps each and one dual voltage Full KVA plug rated at 120 240V 50 amps K802N Power Plug Kit Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps K704 Accessory Kit Includes 35 ft 10 7m 2 0 AWG elec trode cable 30 ft 9 1m 2 0 AWG work cable heads...

Page 27: ...2 TIG Module Provides high frequency and shielding gas control for AC and DC GTAW TIG welding applications Its compact case is designed foe easy carrying complete with a handle High frequency bypass is built in Requires K938 1 Contactor Kit K936 4 Control Cable and K814 Arc Start Switch K938 1 Contactor Kit For use with TIG Module Provides a cold electrode until the triggering device Arc Start Swi...

Page 28: ...NOTES C 4 C 4 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 29: ... Safety Precautions D 3 Routine Maintenance D 3 Engine Maintenance D 3 Change the Oil D 3 Engine Oil Refill Capacities D 3 Change the Oil Filter D 4 Engine Adjustments D 5 Slip Rings D 5 Hardware Battery D 5 Major Component Locations D 6 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 30: ...INTENANCE D 2 D 2 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 31: ...efer to the maintenance section of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the oil and oil fil ter are not changed according to the manufacturer s recommendation ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain valve and attach the...

Page 32: ...l the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap 6 Start the engine and check for oil filter leaks 7 Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER AND OTHER MAINTENANCE Air Cleaner With normal operating conditions the maintenance schedule for cleaning and re oiling the foam pre filter i...

Page 33: ...emery paper Do not attempt to polish slip rings while engine is running BATTERY 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover 2 If the battery requires charging from an external charger di...

Page 34: ...Blower Baffle Assembly 6 Stator Rotor Assembly 7 Covers Case Back Assembly FIGURE D 1 MAJOR COMPONENT LOCATION 7 7 5 5 6 6 4 4 3 3 1 1 2 2 7 7 5 5 6 6 4 4 3 3 1 1 2 2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 35: ... SWITCH AC AC OUTPUT BRIDGE CHOKE POLARITY SWITCH ELECTRODE TERMINAL WORK TERMINAL CV TAP HOUR METER OIL PRESSURE SWITCH RUN START IGN SWITCH FUEL SOLENOID EXCITER AUX 115 VOLT AUX 230 VOLT AUX AUX WELD IDLE SENSE TORROID AUX BREAKERS WE LD PRINTED CIRCUIT BOARD ROTOR STATOR STATOR ENGINE STARTER FLYWHEEL ALTERNATOR BATTERY OUPUT CONTROL IDLER SOLENOID MECHANICAL ROTATION ROTOR SLIP RINGS FIELD CA...

Page 36: ...ler solenoid The idler solenoid is mechanically connected to the engine throttle linkage If no current is being drawn from the RANGER 225 GXT the printed circuit board activates the idler sole noid which then brings the engine to a low idle state When output current is sensed either weld or auxiliary the printed circuit board deactivates the idler solenoid and the engine returns to high RPM PRINTE...

Page 37: ...total of AC power NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRINTED CIRCUIT BOARD ROTOR STATOR STATOR ENGINE STARTER FLYWHEEL ALTERNATOR BATTERY OUPUT CONTROL IDLER SOLENOID MECHANICAL ROTATION ROTOR SLIP RINGS FIELD CAPACITOR REACTOR RANGE SWITCH AC AC OUTPUT BRIDGE CHOKE POLARITY SWITCH ELECTRODE TERMINAL WORK TERMINAL CV TAP HOUR METER OIL PRESSURE SWITCH RUN STAR...

Page 38: ...RTER FLYWHEEL ALTERNATOR BATTERY OUPUT CONTROL IDLER SOLENOID MECHANICAL ROTATION ROTOR SLIP RINGS FIELD CAPACITOR REACTOR RANGE SWITCH AC AC OUTPUT BRIDGE CHOKE POLARITY SWITCH ELECTRODE TERMINAL WORK TERMINAL CV TAP HOUR METER OIL PRESSURE SWITCH RUN START IGN SWITCH FUEL SOLENOID EXCITER AUX 115 VOLT AUX 230 VOLT AUX AUX WELD IDLE SENSE TORROID AUX BREAKERS WE LD PRINTED CIRCUIT BOARD ROTOR STA...

Page 39: ... Diagram are the subject of discussion FIGURE E 5 OUTPUT BRIDGE CHOKE POLARITY SWITCH AND OUTPUT TERMINALS PRINTED CIRCUIT BOARD ROTOR STATOR STATOR ENGINE STARTER FLYWHEEL ALTERNATOR BATTERY OUPUT CONTROL IDLER SOLENOID MECHANICAL ROTATION ROTOR SLIP RINGS FIELD CAPACITOR REACTOR RANGE SWITCH AC AC OUTPUT BRIDGE CHOKE POLARITY SWITCH ELECTRODE TERMINAL WORK TERMINAL CV TAP HOUR METER OIL PRESSURE...

Page 40: ...NOTES E 6 E 6 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 41: ...de Machine Loaded F 34 Typical DC Weld Output Waveform CC Mode Machine Loaded F 35 Typical AC Weld Output Waveform Machine Loaded F 36 Abnormal Open Circuit Weld Voltage Waveform CV Mode one diode open F 37 Abnormal Open Circuit DC Weld Voltage Waveform F 38 Normal Open Circuit Weld Voltage Waveform CV Mode F 39 Normal Open Circuit DC Weld Voltage Waveform F 40 Normal Open Circuit AC Weld Voltage ...

Page 42: ...mponents in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips et...

Page 43: ...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 shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er ...

Page 44: ... alternator stone or clean with fine grit sand paper 3 Check for presence of 12 VDC at the pc board from lead 224 to frame ground This is the supply voltage to the board and is present when the engine is running and the S3 switch is in the Run position If the 12 VDC is missing check the leads switches and connections associated with the lead 224 4 If the Rotor Voltage Test is normal then perform t...

Page 45: ...nd check for the presence of 80VAC from lead W1 to lead W2 on the main stator winding See Wiring Diagram If the AC voltage is NOT present the winding in the stator may be faulty Check the winding for continuity and the test to be sure it is NOT grounded to the stator iron Replace if necessary If the correct AC voltage is present proceed to step 2 2 Check the Reactor Range Switch S1 and associated ...

Page 46: ...ine operates normally 1 Check circuit breakers CB1 through CB4 Reset if tripped 2 Make sure the Output Control R1 is set at the maximum position 3 Check for loose or faulty plug s at the power receptacle s 1 Check the auxiliary power receptacles and associated wires for loose or faulty connections 2 Perform the Auxiliary and Field Winding Voltage Test 3 Check for faulty circuit breakers and loose ...

Page 47: ...he engine RPM may be low 1 If the engine HIGH IDLE RPM is low set to 3700 rpm then perform the Throttle Adjustment Test 2 Perform the Rotor Voltage Test 3 Check the Output Control Potentiometer Normal resistance is 10 000 ohms Also check associated wiring for loose or faulty connections 4 The Rotor may be faulty Perform the Rotor Resistance Test 5 The Printed Circuit Board may be faulty Replace 6 ...

Page 48: ...1 the Polarity switch S2 and associated wires for loose or faulty connections Check the choke winding for continuity and test to be sure it is NOT grounded with the choke iron No AC welding output DC welding output and auxiliary power is normal 1 Make sure the Polarity Switch S2 is in the proper position and is seated correctly 2 Make sure the electrode is correct for the process being used 3 Make...

Page 49: ...put Constant current CC and the auxiliary power are operating normally 1 Make sure the Range Switch S1 is in the proper position CV and seated correctly 2 Make sure the wire feeder is connected correctly 1 Check the operation of the Range Switch S1 and check the associated wires for loose or faulty connections See Wiring Diagram 2 Check for continuity from lead C1 to lead W1 located in the main st...

Page 50: ... 12VDC from lead 213 to ground lead 5 See Wiring Diagram If 12VDC is present then check lead 215 for continuity zero ohms from the Idler Solenoid to the Printed Circuit Board plug 1J9 If lead 215 is OK then the Printed Circuit Board may be faulty Replace 3 If there is NOT 12VDC from lead 213 to ground lead 5 then check the Idler Switch S4 for proper operation and associated wires for loose or faul...

Page 51: ...Switch S3 is in HIGH position 1 Make sure the welding cables and connections are tight 2 Automatic idler may not function if the auxiliary power is loaded to less than 150 Watts 1 Check for broken or faulty connections in the sensing leads 254 Make sure their connections are tight at the Electrode Terminal and also at the Polarity Switch See Wiring Diagram 2 Check lead 3 and 6 making sure they are...

Page 52: ...eplace if necessary 2 The fuel shut off solenoid may be faulty Kohler engines only Engine does not develop full power 1 The fuel filter may be clogged Replace if necessary 2 The air filter may be clogged Replace if necessary 3 The spark plug s may be faulty Replace if necessary 1 Due to wear the engine may be in need of repair TROUBLESHOOTING AND REPAIR F 12 F 12 RANGER 225 GXT Engine tries to sta...

Page 53: ...t off when S3 is placed OFF position 1 Fuel shutoff solenoid may be faulty or stuck open 2 Start switch S3 may be faulty 1 Feel solenoid for clicking open or closed Replace if necessary 2 Check start switch S3 Replace if necessary Engine continues to crank when S3 is switched to RUN position 1 Engine shutdown solenoid diodes may be shorted 1 Check diodes Replace Engine Diodes Engine Mfg Part if ne...

Page 54: ...ns 2 The welding cable may be too long or coiled causing an excessive voltage drop 1 Check for correct open circuit voltage OCV at the welder output terminals 80VAC Max 72VDC Max If the correct voltage is present at the output terminals then check for loose connections on the heavy current carrying leads inside the RANGER 8 See Wiring Diagram 2 If the OCV is low at the welder output terminals then...

Page 55: ...act the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct DC voltage is being applied to the rotor at maximum engine speed 3700 RPM This information will aid the technician in determining if the generator field is operating properly MATERIALS NEEDED Volt Ohmmeter 5 16 Nut dr...

Page 56: ...d run it at high idle Set the output control to the MAXIMUM position posi tion 10 11 Check the voltage reading on the voltmeter It should read between 32 and 45 VDC 12 If the voltage reading is low or not present the generator field is not functioning properly Perform the Rotor Resistance Test 13 If the voltage reading is normal the field circuit is functioning properly Install the right case side...

Page 57: ...rocedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there is a shorted winding in the rotor or if the rotor is grounded MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram ROTOR RESISTANCE TEST TROUBLESHOOTIN...

Page 58: ...ental engine kickback or starting 9 Isolate the rotor electrically by removing the generator brush leads Refer to Figure F 2 as you perform the remaining steps 10 Remove lead 219 from the negative brush 11 Remove lead 200A from the positive brush 12 Measure the resistance across the rotor slip rings A Set the ohmmeter on the low scale X1 B Place one meter probe on one of the rotor slip rings Place...

Page 59: ... speci fications then the rotor may be faulty Replace the rotor If the test does meet the resistance specifica tions the rotor is okay 14 Connect lead 200A to the positive brush which is the one nearest the rotor lamination Connect lead 219 to the negative brush 15 Reinstall the case side case top fuel cap lift bail gasket and spark plug wires TROUBLESHOOTING AND REPAIR F 19 F 19 RANGER 225 GXT Re...

Page 60: ...NOTES F 20 F 20 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 61: ...res or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct AC voltages are being generated from the stator windings MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram AUXILIARY AND FIELD WINDING TEST TROUBLES...

Page 62: ...onnect the volt ohmmeter probes to leads 6 and 3 where they connect to the 230 VAC receptacle NOTE It is easier to insert the probes directly into the receptacle to perform this test However the probes may not reach in far enough to make or keep a good connec tion In this case before you start the gasoline engine insert two test probes into the receptacle Hold the test probes firmly in place to me...

Page 63: ... 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 the windings are NOT grounded internally to the stator iron If the leads are intact then the stator may be faulty Replace the stator If the voltage readings are within specifications then the windings are good and func...

Page 64: ...NOTES F 24 F 24 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 65: ...o perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there are faulty diodes in the Output Rectifier Bridge MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver 7 16 wrench or 7 16 socket wrench and 6 socket extension Wiring Diagram OUTPUT RECTIFIER ...

Page 66: ...d 6 extension remove the nuts and washers hold ing the diode bridge pigtails and the heavy cur rent carrying leads to the studs located in the middle of the rectifier assembly Note their locations and the order of fasteners for reassembly 11 Electrically isolate the diode connectors by slightly bending them back into free air 12 With an ohmmeter or diode tester check each of the four diodes from t...

Page 67: ...s or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Flywheel Alternator Regulator and associated circuitry are functioning properly MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram CHARGING CIRCUIT TEST TROUBL...

Page 68: ...ading is correct then check the output of the voltage regulator to determine the charging voltage for the battery Run the engine at high idle 3650 RPM Set the volt meter for DC volts and place one meter probe on the middle lead and one probe on the green ground wire connected to the voltage regulator See Figure F 5 for location Check for 13 15 VDC 5 If the DC voltage reading is incorrect or not pr...

Page 69: ...lectrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION If the machine output is low this test will determine whether the gasoline engine is oper ating at the correct speed RPM during both HIGH and LOW idle conditions Directions for adjusting the throttle to the correct RPM are given MATERIALS NEEDED 5 16 Nut driver 3 8 open end or box wrench Strobe tach frequ...

Page 70: ...tal engine kickback or starting 7 With the black or red marking pencil place a mark on one of the blower paddles See Figure F 6 for location 8 Connect the strobe tach according the manu facturer s instructions 9 Reconnect the spark plug wires and start the engine Direct the strobe tach light on the blower paddle and synchronize it to the rotat ing mark 10 With the machine at HIGH IDLE the tach sho...

Page 71: ...tz readings may vary slightly above or below 3 If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 3 8 wrench to turn the spring loaded adjustment nut See Figure F 7 for location of the adjustment nut Turn the nut clockwise to increase HIGH IDLE speed Adjust the speed until the frequency reads between 60 8 and 62 5 Hz Adjust LOW IDLE First make sure there...

Page 72: ...op of the air cleaner is the best location 2 Start the engine and observe the whip handle of the vibratach At HIGH IDLE 3700 RPM the whip handle should exhibit maximum oscillation At LOW IDLE 2400 RPM the whip handle should exhibit minimum oscilla tion Note that these are median measurements vibratach readings may vary slightly above or below 3 If either of the vibratach indications is incor rect ...

Page 73: ...e that each vertical divi sion represents 50 volts and that each horizontal division represents 5 mil liseconds in time Note Scope probes connected at machine 115 VAC receptacle NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM 16 2 ms Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to...

Page 74: ...bes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPICAL DC WELD OUTPUT WAVEFORM CV MODE MACHINE LOADED TROUBLESHOOTING AND REPAIR F 34 F 34 RANGER 225 GXT CH1 0 volts 5 ms 20 volts MACHINE LOADED TO 200 AMPS AT 20 VDC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to M...

Page 75: ...bes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPICAL DC WELD OUTPUT WAVEFORM CC MODE MACHINE LOADED TROUBLESHOOTING AND REPAIR F 35 F 35 RANGER 225 GXT MACHINE LOADED TO 200 AMPS AT 26 VDC CH1 0 volts 5 ms 20 volts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to M...

Page 76: ... probes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPICAL AC WELD OUTPUT WAVEFORM MACHINE LOADED TROUBLESHOOTING AND REPAIR F 36 F 36 RANGER 225 GXT MACHINE LOADED TO 225 AMPS AT 25 VDC CH1 0 volts 5 ms 20 volts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Maste...

Page 77: ...Scope probes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM CV MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING TROUBLESHOOTING AND REPAIR F 37 F 37 RANGER 225 GXT CH1 0 volts 5 ms 20 volts Return to Section TOC Return to Section TOC Return to...

Page 78: ... Scope probes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TROUBLESHOOTING AND REPAIR F 38 F 38 RANGER 225 GXT ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING CH1 0 volts 5 ms 50 volts Return to Section TOC Return to Section TOC Return to Sec...

Page 79: ...5VAC receptacle SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TROUBLESHOOTING AND REPAIR F 39 F 39 RANGER 225 GXT NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM CV MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM CH1 0 volts 5 ms 20 volts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Maste...

Page 80: ...VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODE HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM TROUBLESHOOTING AND REPAIR F 40 F 40 RANGER 225 GXT CH1 0 volts 5 ms 50 volts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mas...

Page 81: ...ine 115VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD OUTPUT CONTROL AT MAXIMUM TROUBLESHOOTING AND REPAIR F 41 F 41 RANGER 225 GXT CH1 0 volts 5 ms 50 volts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mast...

Page 82: ...NOTES F 42 F 42 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 83: ...st repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in accessing the generator brushes for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 5 16 open end wrench 7 16 wrench Slot head screw driver Needle nose pliers BRUSH REMOVAL...

Page 84: ... one way 13 Snap the plastic retainer back onto the brush holder The brushes may need some reposi tioning wiggle them slightly to help them seat properly on the slip rings 14 To reinstall the brushes depress the spring loaded brushes into the holder and slip a suit able non metallic fairly stiff retainer through the slots at the top and bottom of the holder A cable tie works well and will hold the...

Page 85: ...kening and wear of the slip rings and brushes is normal Brushes should be inspected when a general overhaul is necessary If brushes are to be replaced clean slip rings with a fine emery paper Do not attempt to polish slip rings while engine is running CAUTION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to ...

Page 86: ...NOTES F 46 F 46 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 87: ...t repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the printed circuit board for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver Phillips Head Screwdriver Diagonal cutters Wiring Diagram PRINTED CIRCUIT BOARD REMOVA...

Page 88: ...n reinstall the fuel cap 6 With the 5 16 nut driver remove the 5 screws holding the right case side 7 Remove the right case side by lifting up and out 8 Remove the 12 pin molex plug from the Printed circuit board 9 Remove 4 pin molex from the current sensing leads 254 and 254A see the Wiring Diagram These leads attach to the current sensor located on the printed circuit board 10 Remove leads from ...

Page 89: ...ted circuit board 13 Replace the old printed circuit board with a new one 14 Connect the 12 pin molex plug 15 Connect the 4 pin molex plug 16 Connect two 1 4 Q C wires to P C Board 17 Replace any cable ties that were cut during the removal procedure 18 Replace 4 self tapping screws previously removed 19 Reinstall the case side fuel cap lift bail gas ket case top and spark plug wires CAUTION Return...

Page 90: ...NOTES F 50 F 50 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 91: ...test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the output rectifier bridge for maintenance or replacement MATERIALS NEEDED 1 2 wrench 7 16 wrench 3 8 wrench Dow Corning 340 Wiring Diagram OUTPUT RECTIFIER BRIDGE REMOVAL ...

Page 92: ...fer to Figure F 11 8 With the 1 2 wrench remove the choke lead B 10 from rectifier lead 9 With the 1 2 wrench remove the heavy cable and the 8 lead White from the rectifier neg ative heat sink 10 WIth the 7 16 wrench remove the W1 lead and the heavy lead A5 going to the S2 Polarity switch 11 With the 7 16 wrench remove the S2 lead the heavy lead going to the S1 Range switch and 254 White lead to s...

Page 93: ...asteners flat washer at the bottom followed by pigtails heavy leads flat washer lock washer and nut 17 With the 7 16 socket wrench install the W1 lead and the heavy lead going to the S2 Polarity switch Note the order of fasteners flat washer at the bottom followed by pigtails heavy leads flat washer lock washer and nut 18 With the 1 2 socket wrench install the heavy cable and the 8 lead White to t...

Page 94: ...NOTES F 54 F 54 RANGER 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 95: ...described here are for a Kohler engine The same basic proce dures apply to the other engine although there may be a few slight wiring variations MATERIALS NEEDED Lincoln Electric Rotor Removal Kit S20788 FOR ROTOR REMOVAL ONLY 1 4 nut driver 5 16 nut driver Slot head screw driver 3 8 wrench 7 16 wrench 1 2 wrench 9 16 wrench 5 8 wrench Locking pliers Needle nose pliers Diagonal cutters Impact wren...

Page 96: ... Tolerance Ring 1B Rotor Thru Bolt 1C Blower Fan 2 Kohler Engine 3 Rotor 4 Rotor Shaft Bearing 5A Brush Bracket 5B Brush Holder 6 Engine Stator Mfg Bolts 7 Stator Lift Bale Stator 8 Idler Plunger 9 Pull Wire 10A Idle Spring 10B Idle Washer 10C Adjustment Nut FIGURE F 12 ENGINE ROTOR COMPONENT LOCATIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return t...

Page 97: ...rotor shaft 16 With the 1 4 nut driver disconnect the engine choke cable from the engine Mark the location of the retainer for reassembly The other end can remain connected 17 Disconnect the idle linkage by unsnapping the plastic clip at the engine end of the idler rod Snap the clip back onto the rod to avoid losing it remove the rod for reassembly 18 Disconnect the fuel line from the fuel tank Pl...

Page 98: ... driver until the bolt bottoms out on the engine crankshaft about 3 4 4 Turning it counterclockwise screw in the left hand thread rotor removal tool from the kit into the rotor shaft Support the rotor with one hand and tighten the tool to approximately 50 ft lbs with the torque or impact wrench 5 If the rotor does not pop off tighten the rotor removal tool an additional 5 ft lbs Hold the rotor wit...

Page 99: ...ieved 6 Fasten the ground lead to the right engine mounting bolt and install both bolts 7 Install the brush holder bracket back into the stator frame See the Brush Removal and Replacement Procedure in this section of the manual 8 Attach leads to the oil pressure switch refer to wiring diagram Replace any cut cable ties 9 Unplug the fuel tank connection and fuel hose and connect them 10 Connect the...

Page 100: ... Amps Volts Maximum Maximum 73 80 25 32 225 275 WELDER CV OUTPUT1 Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Wire Feed CV 29 33 19 23 200 220 AUXILIARY POWER RECEPTACLE OUTPUT1 230 Volt Receptacle 115 Volt Receptacle2 Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 246 264 216 250 34 41 5 123 132 115 130 17 5 21 FIELD AMPS AND VO...

Page 101: ...Machine L13820 G 3 Schematic Control PC Board L12197 1 G 4 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi lay ered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 102: ... A GROUNDING THIS TERMINAL STOPS THE ENGINE 210 CB5 20A R RED OR PINK B BLACK OR GRAY V VIOLET U BLUE W WHITE LEAD COLOR CODE 254 3 1 2 3 4 261 260 1 TURN 211 213 212 3A 6 LEADS 3 AND 6 2 TURNS THRU TOROID IN OPPOSITE DIRECTIONS 6 6 7 9 J2 P5 J5 S3 3D 6E 213A 213A 4 1 FUEL GAUGE FUEL SENDER 210A 230 5L 5M 5M GND J TOP GND SCREW ON INSIDE LEFT CASEFRONT ENGINE CROSS SUPPORT GROUND ENGINE BLOCK GROU...

Page 103: ... be accurately measured through diodes J51 Engine Connector If engine oi l press ure drops below safe operating p ressure the oi l press ure switch opensremoving 1 2 voltsfrom circuit 224 sh utting offfuel so lenoid to stop en gine Hourm eter will also stop running an d PCB1 will denergize idle solenoid 224C Fuel solenoid is mounted on engine carburetor Engine diodes are in engine wire harness C1 ...

Page 104: ...2uF C35 1K R39 68 1K R40 24 3K R18 332 R83 332 R84 332 R85 250V 0 047uF C3 5W 0 51 R21 100K R95 15 R96 15 R97 16V 5W DZ8 100K R98 50V 0 1uF C38 50V 0 1uF C41 50V 0 1uF C40 1 5K R48 400V 1A D2 100V 47pF C43 100V 47pF C42 100V 47pF C39 2K R99 221 R101 301 R100 100V 0 0033F C36 475 R102 FTP1 6 18 2009 01 A 12197 1C3 SCHEM IDLER FIELD CONTROL PCB 1 28 43 LC RANGER CRM41539 102 LC L12050 1 6 26 2009 SI...

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