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Lincoln Electric RANGER 250 Service Manual Download Page 120

ELECTRICAL DIAGRAMS

G-2

RANGER 250

WIRING DIAGRAM - RANGER 250 KOHLER

CONTACTOR

CONTROL

SHOWN IN

"WELDING ON"

POSITION

WIRE FEED POWER

       WINDING

42 VAC

+

+

C2

C1

25 w

at

ts

250 oh

m

s

J50

42 VAC

 FIELD WINDING

CENTER GND. SCREW ON

INSIDE OF CASE FRONT

WHITE

211A

D3

ARC CONTROL

10K

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

42

W3

CB7

25A

S1

9

7

W1

STATOR

WELD

WINDINGS

W3

W2

75

R1

76

77

277

278

CCW

OUTPUT CONT. POT

S3

2

GND-G

GND-D

GND-E

300 AMP

MODULE

SHUNT

50MV=400 AMPS

3

NEG. BRUSH

POS.BRUSH

ROTOR

5A

3D

3A

5A

5B

5C

3

6

3E

6F

BLACK

35A

35A

20A

20A

WHITE

BLACK

WH

IT

E

WH

IT

E

BLACK

GREE

N

BLACK

WHITE

BLACK

BLACK

SILVER

SILVER

STATOR AUX. WINDING

CONNECTORS VIEWED FROM INSERTION END

ELECTRICAL SYMBOLS PER E1537

FRAME GND.

5C

3A

3

6B

6

6B

CB1

CB2

CB5

CB6

6B

5B

J101

J102

J100

3E

6E

115/230V

10K

210

210A

212A

9

7

41

206B

206A

200A 200

201

201A

200B

212

211

209

209

32

3A

5C

+

HOUR METER

224B

5

GND E

5

5H

5H

5G

HEATSINK

208

4

279

BOTTOM GND. SCREW ON

INSIDE OF CASE FRONT

PCB 1

D1 - THREE PHASE BRIDGE RECTIFIER

D2 DIODE

MODULE

W4

W5

W6

R3

6

3

6

3

W10

W7

16

8

1

9

5

1

4

8

J1

P1-J2

6

1

5

10

J4

J5

2

1

P6-J6

3

1

2

4

P7-J7

P10-J10

3

1

2

4

J8

3

1

2

4

P9-J9

1

3

4

6

P11-J11

16

8

1

9

P12-J12

6

1

5

10

P42-J42

9

1

16

P43-J43

3

1

2

4

P41-J41

PCB4 BATTERY PC BOARD

PCB2 ANALOG POWER PC BOARD

PCB3 WELD  CONTROL  PC  BOARD

Programing

Mode

Selection

Meter

Meter

6

1

5

10

Shunt

Output

Control

Hot Start

Pinch/

Arc Force

14 Pin

Ampenol

Thermal

Sense/

Idler/

PWM

204S

206S

75

76
77

279

277

278

77A

76A

75A

208B

251

250

260A

215

25

23

222

214

220

218

S6 MODE SELECTOR SWITCH

2A

4A

P34-J34

PCB7 Battery Display

P33-J33

PCB6 Thermal Display

P13-J13

POWER

5F

1

3

4

6

4

2

13

252

253

13

14

11

12

115A

118A

101A

105A

105A

115A

101A

116A

IDLE SOLENOID

5F

5G

206S 204S

14

TS1

206A

208B

C1

4

3

2

1

222

TIG

CC

PIPE

CV

220

218

214

8

228

229

229

228

200

224B

CCW

R2

211

230

231

230

231

232

233

233

232

210B

210B

5K

210D

1

4

5

8

261A

210D

B7

B3

B2

B1

P50

210C

210C

215

116A

118A

PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE

(VIEWED FROM LEAD SIDE OF RECEPTACLE)

9 PIN

J50

1

2

3
6 5 4
9 8 7

3

2

1
4 5 6
7 8 9

9 PIN

P50

9

8

7

6

5

4

1 2 3

11

12

23

25

L1  CHOKE

W9

W8

3

6

261

260

WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH

TOROID

3

6

7

8

9

4

5

6

3 2 1

RANGER 250 KOHLER - WIRING DIAGRAM

4-14-2000

G3667

IDLER CONTROL

SHOWN IN

"AUTO" POSITION

S4

250

251

S2

START

BUTTON

C3

800uf

150vdc

POSITIVE BRUSH CONNECTED

TO SLIP RING NEAREST

TO THE LAMINATION

WHITE

TERM.

31

5K

5L

5L

L2

L3

TWISTED  PAIR

TWISTED  PAIR

+

+

D4

3

1

2

4

3

1

2

4

W6

W11

PC BOARD TO

HEAT SINK CONN.

PC BOARD TO

HEAT SINK CONN.

POS

KOHLER ENGINE COMPONENTS

12 VOLT

BATTERY

-

B-

AC

AC

B

+

GND-H

GROUNDING THIS CIRCUIT

STOPS THE ENGINE

IGNITION

MODULE

STARTER

1 2 3

P51

J51

OIL

PRESSURE

SWITCH

V

WHITE

R

FRAME

GROUND

ENGINE

GROUND

FUEL

SHUTOFF

SOLENOID

ENGINE TERMINAL

BLOCK

4

224

210

REGULATOR

FLYWHEEL ALTERNATOR

221

212A

GND J

+

STARTER

CR1

SOLENOID

R

U

225

211A

224

221

5J

5J

260A

261A

225

NEG

NEG

W11

(LOCATED BELOW
TERMINAL 1)

S1RUN-STOP

SWITCH

(SHOWN IN

RUN POS.)

12

7

6

1

1

2

1 2

3

4

1

3

1

4

6

5

8

6

10

L2, L3: RF CHOKES

16

9

8

1

CB8

JUMPER

PLUG

P3

4

1

3

6

J3

Machine

Selection

4

1

3

6

5

8

4

1

6

4

3

1

12

7

6

1

31

GND-B

42A

GND-A

21

41A

AMPHENOL 1

75B

77B

76B

2B

4B

32

B

K

I

G

F

E

H

C

D

A

J

GROUND

42VAC

REMOTE

CONTROL

WORK

CONTACTOR

115AC

GND. SCREW ON

CENTER BAFFLE

4C

GND-B

2C

AMPHENOL 2

75C

77C
76C

F

E

D

C

B

A

GROUND

CONTACTOR

CONTROL

REMOTE

TOP GND. SCREW ON

INSIDE OF CASE FRONT

P61

J61

  BYPASS

PC  BOARD

206B 208

2A

4A

2B

4B

2C

4C

75A

75B

75C

76A

76B

76C

77A

77B 77C

P60

J60

P62

J62

GND-K

GND-L

GND-A

FRAME GND.

GREE

N

GND M

LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)

GND-J

FRAME GND.

GREEN

GREE

N

GREE

N

CND-C

4

5

1

GND-K

41A

42A

15A

208A

21

S5

VOLTMETER

POLARITY

SWITCH

206A

SHOWN IN
POSITIVE (+)
POSITION

G-2

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.

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Summary of Contents for RANGER 250

Page 1: ...HOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machines having Code Numbers 10654 Ranger 250 TM Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info RETURN TO MAIN INDEX Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1...

Page 2: ...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 Compan...

Page 3: ...lectrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level us...

Page 4: ...ng 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 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 an...

Page 5: ... 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 ou le...

Page 6: ...ervice A 4 Electrical Output Connections A 5 Operation Section B Safety Instructions B 2 General Description B 2 Design Features B 3 Controls and Settings B 3 Engine Operation B 5 Welder Operation B 7 Auxiliary Power B 9 Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P 358 RETURN TO MAIN INDE...

Page 7: ...ure Operation A 4 Towing A 4 Pre Operation Engine Service A 4 Oil A 4 Fuel A 4 Engine Cooling System A 4 Battery Connections A 5 Muffler Outlet Pipe A 5 Spark Arrester A 5 High Frequency Generators for TIG Applications A 5 Remote Control A 5 Welding Terminals A 5 Electrical Output Connections A 5 Machine Grounding A 5 Welding Output Cables A 6 Cable Installation A 7 Auxiliary Power Receptacles A 7...

Page 8: ... Volts CV WIRE DC Output 25 Volts at 250 Amps 100 CV WIRE Output Range 14 to 28 Volts OUTPUT GENERATOR Auxiliary Power1 8 000 Watts 60 Hz 120 240 Volts 100 Duty Cycle PHYSICAL DIMENSIONS Height Width Depth Weight 30 00 in 21 50 in 42 25 in 452 lbs 205 kg K1725 1 762 0 mm 546 0 mm 1073 0 mm 434 lbs 197 kg K1725 2 Top of enclosure add 6 0 152 mm for exhaust ENGINE COMPONENTS Lubrication Valve Lifter...

Page 9: ...d 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 th...

Page 10: ...l laws regarding specific requirements for use on public highways PRE OPERATION ENGINE SERVICE Read and understand the information about the gaso line engine in the Operation and Maintenance sec tions of this manual before you operate the Ranger 250 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 fue...

Page 11: ... 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 Amp...

Page 12: ...e 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 reduce voltage drops Avoid coiling long cables on the machine when welding INSTALL...

Page 13: ...y 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 suitable for temporary standby or emergency power using the engine manufacturer s rec ommended maintenance schedule The Ranger 250 can be...

Page 14: ...BLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 50 AMP 120 240 VOLT RECEPTACLE 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 electric...

Page 15: ...ng Controls B 5 Engine Operation B 5 Before Starting the Engine B 5 Starting the Engine B 6 Stopping the Engine B 6 Welder Operation B 7 General Operation B 7 Stick Welding B 8 Constant Current CC Stick Welding B 8 Pipe Welding B 8 TIG Welding B 9 Wire Welding CV B 9 Arc Gouging B 9 Auxiliary Power B 9 Simultaneous Welding and Auxiliary Power Loads B 10 Return to Master TOC Return to Master TOC Re...

Page 16: ...d areas or vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and...

Page 17: ... 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 ...

Page 18: ...idler reduces the engine speed to low idle speed d The engine will automatically return to high idle speed when the welding load or AC power load is reapplied 5 ENGINE ALTERNATOR TROUBLE LIGHT The yellow engine alternator light is off when the battery charging system is functioning normally If the light turns on the alternator or the voltage regulator may not be operating correctly The light may a...

Page 19: ... same as the 6 pin Amphenol See below 11 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 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 fron...

Page 20: ...ear 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...

Page 21: ... 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 Table A 1 in the Installation section Straighten out coiled cables before welding OPERATION B 7 B 7 RANGER 250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return t...

Page 22: ...Return to Master TOC Tungsten Electrode Diameter in mm 2 15 5 20 15 80 70 150 150 250 250 400 400 500 500 750 750 1000 3 3 3 10 20 15 30 25 40 40 55 55 80 180 125 3 8 2 4 5 10 3 5 5 10 3 5 5 10 3 5 13 17 6 8 15 23 7 11 21 25 10 12 23 27 11 13 28 32 13 15 3 8 2 4 5 10 3 5 5 10 3 5 9 13 4 6 11 15 5 7 11 15 5 7 13 17 6 8 18 22 8 10 23 27 11 13 TIG TORCH Nozzle Size 4 5 Approximate Argon Gas Flow Rate...

Page 23: ...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 1 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 ...

Page 24: ...120 VAC or 240 VAC supply not both at the same time OPERATION B 10 B 10 RANGER 250 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 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 4 RANGER ...

Page 25: ... K867 Universal Adapter C 3 Connection of the LN 25 Across the Arc 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 Connection of the LN 7 Using the K584 Control Cable C 7 Connection of the LN 8 Using the K595 Control Cable C 8 Connection of the LN 742 C 9 Section C 1 Section C 1 RANGER 250 Return to Master TOC Return to Mas...

Page 26: ...t 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 SEMIAU...

Page 27: ...fol lowing NOTES indicated on the figure A These leads are not used for the Ranger 250 Insulate each unused lead individually B For wire feeders that return a signal for welding output use an isolation relay to close leads 2 and 4 C Refer to the Operation section of this manual for maximum wire feeder auxiliary current draw 4 Set the MODE switch to the CV WIRE position 5 Place the IDLER switch in ...

Page 28: ...ol 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 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 ON position 8 Adjust wire feed speed at the ...

Page 29: ...ication 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 Any increase of the high idle engine RPM by changing the governor setti...

Page 30: ... switch in the AUTO or HIGH position as desired If you are using an LN 25 without an internal contactor the electrode will be HOT when the Ranger 250 is started 6 Set the MODE switch to CV WIRE 7 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 o...

Page 31: ...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 Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control cir cuit...

Page 32: ...he HIGH position 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 6 Set the VOLTMETER switch t...

Page 33: ...t 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 5 Set the MODE switch to the CV WIRE position 6 Place the IDLER switch in the AUTO or HIGH position as desired An increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will caus...

Page 34: ...C 10 NOTES RANGER 250 C 10 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: ...ions D 2 Routine and Periodic Maintenance D 2 Engine Maintenance D 2 Engine Oil Change D 4 Oil Filter Change D 4 Air Cleaner Service D 4 Spark Plug Service D 5 Fuel Filter Service D 5 Engine Adjustment D 5 Battery Maintenance D 6 Optional Spark Arrestor D 6 Welder Generator Maintenance D 7 Storage D 7 Cleaning D 7 Receptacles D 7 Cable Connections D 7 Brush Removal and Replacement D 7 ...

Page 36: ...e 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 ...

Page 37: ...Champion RC12YC 030 Gap 025 Gap Battery BCI Group 58 435 CCA BCI Group 58 435 CCA 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 5 Hours First Oil Change Every 50 Hours Service air pre cleaner Change engine oil1 Every 100 Hours Replace oil filter1 ...

Page 38: ...nd 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...

Page 39: ...sure the plug gap with a feeler gauge Correct as necessary by bending the side electrode 6 Check that 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 If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If...

Page 40: ...partment 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 rech...

Page 41: ...r the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary Do not attempt to polish slip rings while the engine is running Service and repair should only be performed 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 ...

Page 42: ...TOC MAINTENANCE D 8 D 8 RANGER 250 FIGURE D 1 MAJOR COMPONENT LOCATIONS 1 2 3 4 5 6 7 8 9 14 13 12 11 10 1 CASE COVER AND DOOR ASSEMBLY CASE BACK 2 ENGINE 3 IDLER SOLENOID 4 ROTOR STATOR 5 POWER MODULE ASSEMBLY 6 POWER CAPACITORS 7 PC BOARDS 8 FRONT PANEL OUTPUT ASSEMBLY 9 CONTROL PANEL 10 OUTPUT CHOKE 11 OUTPUT RECTIFIER BRIDGE 12 FUEL TANK 13 MACHINE BASE 14 BATTERY ...

Page 43: ...SECTION FIGURE E 1 RANGER 250 BLOCK LOGIC DIAGRAM ENGINE CONTROL BOARD ROTOR STATOR BATTERY BOARD BATTERY CHOKE IGBT MECHANICAL ROTATION STARTER I D L E R ARC CONTROL OUTPUT CONTROL MODE SELECTOR POWER MODULE THREE PHASE RECTIFIER WORK TERMINAL ELECTRODE TERMINAL 120VAC RECEPTACLE 240VAC RECEPTACLE SLIP RINGS TO CONTROL BOARD GAS OIL PRESSURE SWITCH RUN STOP SWITCH FLYWHEEL ALTERNATOR TO CONTROL B...

Page 44: ...es 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 the 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 lin...

Page 45: ...e 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 THEORY OF OPERATION E 3 E 3 RANGER 250 FIGURE E 3 WELD WINDINGS RECTIFIER POWER MODULE AND FEEDBACK NOTE ...

Page 46: ...itry 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 FIGURE E 4 ANALOG POWER BOARD AND CONTROL BOARD ENGINE CONTROL BOARD ROTOR STATOR BATTERY BOARD BATTERY CHOKE IGBT MECHANICAL ROTATION STARTER I D L E R ARC CONT...

Page 47: ...s 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 Drawing B shows the IGBT in an active mode ...

Page 48: ...cond 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 time during the 50 microsecond cycle the output is maxi mized The darkened area under the top curve can be compared to ...

Page 49: ...w in the system when the switch is open and 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 curre...

Page 50: ...E 8 NOTES RANGER 250 E 8 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 51: ...nalog Power PC Board Voltage Test F 33 Output Rectifier Bridge Test F 36 Power Module Test F 39 Flywheel Alternator Test F 43 Oscilloscope Waveforms F 45 Normal Open Circuit Voltage Waveform 120 VAC Supply F 45 Normal Open Circuit Voltage Waveform Stick F 46 Normal Weld Voltage Waveform Stick CC F 47 Normal Open Circuit Voltage Waveform Wire CV Tap F 48 Normal Weld Voltage Waveform Wire CV F 49 Re...

Page 52: ...BLE 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 column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also speci...

Page 53: ...tic 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 If the PC Board uses protective shorting jumpers don t remove them until installation is complete If you ...

Page 54: ...e external control cable if used leads 2 and 4 See the Wiring Diagram 2 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 3 If the correct OCV is present at the welding output terminals check the welding cables clamps and electrode holder for loose or fault...

Page 55: ...6 Perform the Output Rectifier Bridge Test 7 Perform the Power Module Test 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 1 Check the brushes for wear and proper contact to the rotor slip rings 2 Make ...

Page 56: ...ecessary 2 Check for loose or faulty con nections at the auxiliary recep tacles 1 Check the wiring between the auxiliary receptacles the con nection studs and the main sta tor See the Wiring Diagram 2 Perform the Stator Voltage Test The machine has welding output but no control of output in some or all modes The auxiliary power is normal 1 If a remote control unit is con nected check the remote co...

Page 57: ...Flashing and Rotor Voltage Test If the rotor voltage is low the field capaci tor or field bridge may be faulty Test and replace if necessary See the Wiring Diagram 4 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 CAUTION The machine control is still active when the remote control unit is connected 1 Th...

Page 58: ...te circuit breaker CB1 or CB8 Reset if tripped 2 The wire feeder control cable may be faulty 3 The wire feeder may be faulty 1 Check for the presence of appropriate source voltage at the 14 pin amphenol 2 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 3 Perform the Stator Voltage Test The battery doe...

Page 59: ...lty See the Wiring Diagram 2 The engine may be in need of mechanical repair Check for spark and fuel The engine will not develop full power 1 The fuel filter may be clogged or the fuel contaminated Replace the fuel filter 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 need major repair The engine ...

Page 60: ...ssure switch may be faulty Replace if necessary The engine will not idle down to low speed The machine has normal weld output and auxiliary power 1 Make sure the IDLER switch is in the AUTO position 2 Make sure there is NOT an external load on the weld termi nals or the auxiliary power receptacles 3 Check for mechanical restric tions in the idler solenoid link age 1 Check leads 210C and 215 for lo...

Page 61: ...ON ENGINE PROBLEMS 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 IDLER switch is in the HIGH position 1 Make sure the welding cables and auxiliary power lead con nections are tight 1 Check the Current Sensing Toroid leads for loose or faulty connections See the Wiring Diagram 2 The Curren...

Page 62: ...Check for loose or faulty con nections at the weld output ter minals and welding cable con nections 2 The welding cables may be too long or coiled causing an excessive voltage drop 3 Make sure the electrode wire gas voltage current etc is correct for the process being used 1 Check for the correct OCV at the welding output terminals If the correct voltage is present at the output terminals check fo...

Page 63: ...d 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 ...

Page 64: ... Remove the cover seal from around the lift bail 6 Using the 3 8 wrench remove the sheet metal and machine screws holding the case cover in place 7 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 8 Lift the case cover off the machine NOTE It is not necessary to remove the gas cap in order...

Page 65: ...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 ...

Page 66: ...erform the Case Cover Removal proce dure NOTE It is not necessary to remove the gas cap in order to take the case cover off the machine Be sure the gas cap is ON when dis charging the power module capacitors 3 Locate the power module capacitors on the left side of the inner machine baffle See Figure F 2 4 Using the resistor and jumper leads CAREFULLY discharge the capacitor ter minals NEVER USE A ...

Page 67: ...or 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...

Page 68: ...resistance is approximately 15 ohms If the coil resistance is not correct the solenoid may be faulty Replace 6 Using the external 12VDC supply apply 12VDC to the solenoid leads Push the solenoid plunger in this simulates the action that takes place when the engine is running and there is less resistance to solenoid movement and check that it holds by itself The solenoid should deac tivate when the...

Page 69: ...hroughout 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 R...

Page 70: ...nize 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 4 If 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 cloc...

Page 71: ... 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 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...

Page 72: ...ttle lever arm See Figure F 6 for the location of the adjustment nut Adjust the nut until the period is 25 0 milliseconds 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 RPM the whip handle should exhibit max ...

Page 73: ...actory 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 DESCRIPTI...

Page 74: ...s remove the leads See Figure F 7 This will electrically isolate the rotor windings 4 Using the ohmmeter check the rotor winding resistance across the slip rings See Figure F 7 Normal resistance is approximately 4 7 ohms 5 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 leas...

Page 75: ... 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 correct DC voltage is being applied to the rotor at the maxi mum engine speed 3700 RPM This information wi...

Page 76: ...nd 224 See the Wiring Diagram This bypasses the oil pressure switch and 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 d Connect the negative meter probe to the other brush leads 201 and 5H e Measure the voltage It...

Page 77: ... speed 3700 RPM b Connect the positive meter probe to the brush nearest the rotor lamination leads 200A and 200 See Figure F 8 for 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 5 If the voltage reading is low or not present the generator field is not functioning prop erly Perform the Rotor Resi...

Page 78: ...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 DESCRIPT...

Page 79: ... See Figure F 10 and the Wiring Diagram Upper receptacle to leads 3D and 5A Lower receptacle to leads 6E and 5B 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 connection In this case before you start the engine insert two test pins into the receptacle Hold the test probes against these i...

Page 80: ... 7 and 9 where they connect to the field diode rectifier bridge See Figure F 11 2 Start the engine and run it at high idle 3700 RPM 3 Check the AC voltage reading It should be between 40 and 50 VAC If any one or more of the readings are missing or not within specifications check for loose or bro ken wires between the test points and the stator windings See the Wiring Diagram Make sure that the win...

Page 81: ... 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 4 Connect the volt ohmmeter probes to leads 41A and 42A where they connect to circuit breaker CB8 and the 14 pin amphenol S...

Page 82: ...ter 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 If 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...

Page 83: ...ate 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...

Page 84: ... Removal proce dure 3 Locate plugs J41 and J42 from the Analog Power PC board See Figure F 14 4 Start the engine and run it at high idle 3700 RPM with no load 5 Check for the correct Analog Power PC board input voltage a Set the volt ohmmeter to the Volts DC 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 If the rea...

Page 85: ...ection TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ANALOG POWER PC BOARD VOLTAGE TEST continued 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 sensiti...

Page 86: ...our 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 DESC...

Page 87: ...R POWER SUPPLY 20V WELD BOARD POWER SUPPLY 5V TO CIRCUIT GROUND CIRCUIT GROUND FRAME GROUND WELD BOARD POWER SUPPLY 15V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY 15V TO CASE GROUND WELD BOARD POWER SUPPLY 5V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY 5V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY 5V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY 15V TO CIRCUIT GROUND CONTROL CIRCUIT INPUT POWER C1 C2 RESI...

Page 88: ...W3 from their bolted connec tions on the left side of the bridge Note lead placement for reassembly Bend the leads out into free air so that they do not touch anything See Figure F 16 7 Remove any load that may be connected to 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 th...

Page 89: ... 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 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 s...

Page 90: ...e terminals where the positive straps connect to the Power Module PC board Flip the straps out of the way See Figure F 17 5 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 ...

Page 91: ...POSITIVE CAPACITOR TERMINAL CONNECTIONS Check IGBT for Shorts 8 Using the analog ohmmeter connect the positive meter probe to the heat sink and the negative meter probe to the positive capaci tor terminal on the power module chopper PC board See Figure F 18 The resistance reading should be high over 20 000 ohms 9 Reverse the meter probe leads The resis tance should be very high over 20 000 ohms It...

Page 92: ...nal 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 11 Using the analog ohmmeter connect 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 th...

Page 93: ...d 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 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 2...

Page 94: ...crews 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 3 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 ...

Page 95: ...l auxiliary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time NOTE Scope probes are connected at machine 120 VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 120VAC SUPPLY HIGH I...

Page 96: ...C 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 Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX CONTROL POT...

Page 97: ...rom 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 NOTE Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div Coupling DC Trigger Internal NORMAL WELD VOLTAGE WAVEF...

Page 98: ... 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 Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV TAP MAX CONTRO...

Page 99: ... 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 NOTE Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div Coupling DC Trigger Internal NORMAL WELD VOLTAGE WAVEFORM...

Page 100: ...s 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 ...

Page 101: ...Case Cover Removal proce dure 3 Perform the Power Module Capacitor Discharge procedure 4 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 5 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 th...

Page 102: ...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 4 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 T...

Page 103: ... 3 16 allen wrench remove the four screws and lock washers holding the board to the heat sink Note the two copper spacers for the center terminals for reassam bly See Figure F 22 3 Remove the PC board Replacement 1 Make sure the mating surfaces between the copper spacers and the heat sink are clean dry and free of grease 2 Apply a thin coating of electrical thermal joint compound Penetrox A 13 to ...

Page 104: ...urface is clean dry and free of grease 2 Apply a thin even coat 1 to 25mm or 004 to 010 in 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 3 Press the module firmly against the heat sink aligning the mounting holes 4 Place a spring washer then a flat washer over each outer m...

Page 105: ...idate your factory warranty For your safety and to avoid elec trical 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800...

Page 106: ...rench remove the nuts lock washers and flat washers holding the leads and straps to the power capacitor terminals 5 With the slot headed screw driver loosen the clamps holding the capacitors to the vertical baffle 6 Slip the capacitors out of the vertical baffle To reassemble slide the capacitors into the verti cal baffle observe capacitor polarity and lead ori entation and tighten the holding cla...

Page 107: ...ry warranty For your safety and to avoid elec trical 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 troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD D...

Page 108: ... the engine off 2 Perform the Case Cover Removal procedure 3 Perform the Power Module Capacitor Discharge procedure 4 Note the position of the engine choke cable for reassembly purposes Using the 5 16 nut driver remove the clamp holding the engine choke cable to the choke control lever at the carburetor Flex the cable outward to free it from the lever FIGURE F 25 OUTPUT RECTIFIER BRIDGE DETAILS EN...

Page 109: ...scribed above 2 Using the 1 2 wrenches remove the heavy flex leads W8 W9 and W10 from the choke 3 Using the 1 2 wrenches remove the three long bolts lock washers and nuts holding the choke to the mounting bracket in the machine base Note that the lower right corner of the choke has no bolt 4 Carefully remove the choke REPLACEMENT PROCEDURE Output Choke 1 Place the choke into the machine so that th...

Page 110: ...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 gasoline engine stator and rotor for repair or replacement This procedure is for Onan models only Some pro cedures may vary sli...

Page 111: ... 3 8 socket wrench remove the screws holding the battery access panel to the case back Slide the panel with the bat tery attached out of the machine far enough to access the battery cables See Figure F 26 6 With the 1 2 wrench loosen the bolt on the negative battery cable clamp Remove the clamp and cable from the post 7 Using the 3 8 socket wrench remove the eight screws holding the case back to t...

Page 112: ...igure 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 ...

Page 113: ...through the toroid for each lead See the Wiring Diagram 7 Separate and remove lead 5H 201 200A and 200 at their piggy back connections at the brush holder See the Wiring Diagram 8 Disconnect plug J51 Engine Connector Block 9 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 HOUR METER RUN STOP S...

Page 114: ... lift bail Secure the chains to the hoist and put enough tension on them to support the engine but without lifting the assembly 2 Using the 9 16 wrench remove the two bolts lock washers and nuts from the stator bottom support bracket and two bolts wash ers and nuts from the engine mountings 3 Remove the fuel line at the carburetor and plug it 4 Using the hoist you can now lift the engine stator as...

Page 115: ...shers and nut holding the muffler to the stator Onan engine machines Remove the bolts and washers holding the muffler to the engine and remove the muffler 3 Disconnect the idler solenoid linkage at its clip 4 Using the 7 16 wrench remove the two nuts lock washers and bolts holding the brush holder assembly to the stator frame Remove the brush holder assembly 5 Unscrew the fan to remove it from the...

Page 116: ...wrench remove the four bolts that hold the stator to the engine There is one lock washer per bolt 14 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...

Page 117: ...idler solenoid linkage 12 Connect the engine ground strap to the engine mounting foot 13 Attach the stator to its bottom support bracket and reinstall the engine mounting hardware 14 Connect the engine starter solenoid leads 15 Connect the engine choke cable and fuel line 16 Install the brush holder assembly and leads 17 Install the case back 18 Install the battery Connect the positive bat tery ca...

Page 118: ...ad Volts Load Amps Switch Voltage CV Maximum 56 64 25 30 245 265 CV Minimum 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 TIG Maximum 16 19 25 30 245 265 TIG Minimum 16 19 Short Circuit 19 24 AUXILIARY POWER OUTPUT 240 Volt Receptacle 120 Volt Receptacles Open Circuit Load Volts Load Amps Open Circuit Load Volts Loa...

Page 119: ... 3 CONTROL INTER CONNECTION DIAGRAM G 4 COMPLETE MACHINE SCHEMATIC G 5 ANALOG CONTROL POWER SUPPLY PC BOARD SCHEMATIC G 6 BATTERY PC BOARD SCHEMATIC G 7 BYPASS PC BOARD SCHEMATIC G 8 CHOPPER PC BOARD SCHEMATIC G 9 DISPLAY PC BOARD SCHEMATIC G 10 WELD CONTROL PC BOARD SCHEMATIC SHEET 1 G 11 WELD CONTROL PC BOARD SCHEMATIC SHEET 2 G 12 WELD CONTROL PC BOARD SCHEMATIC SHEET 3 G 13 WELD CONTROL PC BOA...

Page 120: ...BERING SEQUENCE VIEWED FROM LEAD SIDE OF RECEPTACLE 9 PIN J50 1 2 3 6 5 4 9 8 7 3 2 1 4 5 6 7 8 9 9 PIN P50 9 8 7 6 5 4 1 2 3 11 12 23 25 L1 CHOKE W9 W8 3 6 261 260 WRAP TWO TURNS 3 6 LEADS IN DIRECTION SHOWN THROUGH TOROID 3 6 7 8 9 4 5 6 3 2 1 RANGER 250 KOHLER WIRING DIAGRAM 4 14 2000 G3667 IDLER CONTROL SHOWN IN AUTO POSITION S4 250 251 S2 START BUTTON C3 800uf 150vdc POSITIVE BRUSH CONNECTED ...

Page 121: ...ut Control Hot Start Pinch Arc Force 14 Pin Ampenol Thermal Sense Idler PWM 204S 206S 75 76 77 279 277 278 77A 76A 75A 208B 251 250 260A 215 25 23 222 214 220 218 S6 MODE SELECTOR SWITCH 2A 4A P34 J34 PCB7 Battery Display P33 J33 PCB6 Thermal Display P13 J13 POWER 5F 1 3 4 6 4 2 13 252 253 13 14 11 12 115A 118A 101A 105A 105A 115A 101A 116A IDLE SOLENOID 5F 5G 206S 204S 14 GND J TS1 206A 208B SHOW...

Page 122: ...WELD TERMINALS CONTACTOR SWITCH S3 208A 21 206A 4A 4 2 2A 250 251 224 224B 5G CASE FRONT REAR VIEW FRONT VIEW OF AMPHENOLS NEGATIVE OUTPUT STUD POSITIVE OUTPUT STID 204S 206S SHUNT 5C 3E GND C 6F J100 120 240 V AC GND G 5A 3D GND D 5B 6E 3 3A 3E 6 6B 6F CB5 CB6 3A 3D 32 6B 6E CB2 CB1 CB7 42A CB8 42 209 212A 212 BLOWER BAFLE SIDE OPPOSITE BLOWER R1 10K R2 10K J102 J101 5J 1 3 7 9 P50 LEAD END VIEW ...

Page 123: ...LS TO LOW IDLE 215 WELD CONTROL PC BOARD ANALOG POWER PC BOARD 42 VOLT AC POWER FOR ROTOR FIELD CIRCUIT 232 233 THERMOSTAT ON CHOPPER MODULE NORMALLY CLOSED 230 231 THERMAL SHUTDOWN DISPLAY 13 14 12 VOLT BATTERY 210B 105A 115A 101A 116A 118A 229 228 BATERY CHARGER TROUBLE LIGHT DISPLAY BATTERY PC BOARD 200 ROTOR FLASHING 5K KOHLER IGNITION MODULE BATTERY CHARGING MODULE KOHLER FUEL SHUTOFF SOLENOI...

Page 124: ... Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 6 RANGER 250 SCHEMATIC ANALOG CONTROL POWER SUPPLY G 6 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 125: ...Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 7 RANGER 250 SCHEMATIC BATTERY PRINTED CIRCUIT BOARD G 7 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 126: ... Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 8 RANGER 250 SCHEMATIC BYPASS PRINTED CIRCUIT BOARD G 8 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 127: ...h ge Sht No THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY UNLESS OTHERWISE SPECIFIED TOLERANCE MATERIAL TOLERANCE t TO AGREE ON 3 PLACE DECIMALS IS OO2 AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO OCI 1 15 50V 0 1 C1 1 0A 30V D7 10 0 R13 4 75K R22 1W 16V DZ3 10 0 R10 G1 C2 E4 C1 C3 G2 C4 E2 E5 C5 G3 E1 G5 G4 E3 A2 5 11 8 12 7 10 15 ...

Page 128: ...MPLETE N A UNLESS OTHERWISE SPECIFIED THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY SINCE COMPONENTS OR CIRCUITRY ON MAY CHANGE EARTH GROUND CONNECTION CIRCUIT BOARD ELECTRICAL SYMBOLS PER E1537 DIODES WITHOUT AFFECTING S THE INTERCHANGEABILITY SHOW THE EXACT COMPONENTS NOTES MFD VOLTAGE NET CAPACITORS GENERAL INFORMATION LABELS FRAME CONNECTION NO OR CIRCUITRY OF ON 3 PLACE DECIMALS IS OO2...

Page 129: ...EET 1 G 11 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 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 130: ... TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 12 RANGER 250 SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 2 G 12 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 131: ... TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 13 RANGER 250 SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 3 G 13 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 132: ... TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 14 RANGER 250 SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 4 G 14 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 133: ... TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 15 RANGER 250 SCHEMATIC WELD CONTROL PRINTED CIRCUIT BOARD SHEET 5 G 15 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

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