View Safety Info SVM 110-A TM RANGER 9 January, 1996 For use with machine code numbers 9975 and 9976 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN INDEX 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.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Installation Section Table of Contents ........................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Location and Ventilation ........................................................................................................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 9 INPUT - GASOLINE ENGINE Manufacturer Description Onan P218® 2 cyl., 4 cycle air-cooled gasoline 18 HP @ 3600 RPM Speed Displacement Ignition Capacities 3500 RPM Full load 47.7 cu. in. (782 cc) Electric Fuel: 9 gal. (34 l) Manual choke Oil: 1.8 qt. (1.
Return to Master TOC Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ENGINE EXHAUST can kill. Return to Master TOC Return to Section TOC • Use in open, well ventilated areas or vent exhaust to the outside. • Do not stack anything on or near the engine.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-4 A-4 INSTALLATION STACKING WARNING RANGER 9 machines CANNOT be stacked. • Keep hands away from the engine muffler or HOT engine parts. TILTING • Stop the engine when fueling. Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. • Do not smoke when fueling.
Return to Master TOC Return to Section TOC A-5 A-5 INSTALLATION FIGURE A.1 - RANGER 9 OUTPUT CONNECTIONS 3 2 4 6 5 7 4 8 3 2 1 90 RANGE 70 DC+ 9 125 DC- AC 1 175 10 max 50 5 225 AC 210 DC 16 to 25 WARNING LINCOLN ELECTRIC RANGER 9 CHOKE 7 AUTO Return to Master TOC Return to Section TOC IDLER START RUN STOP HIGH 1. 2. 3. 4. 5. 6. 7. 8. 9.
Return to Master TOC Return to Section TOC A-6 A-6 INSTALLATION WELDING CABLE CONNECTIONS CABLE SIZE AND LENGTH Be sure to use welding cables that are large enough. The correct size and length becomes especially important when you are welding at a distance from the welder. Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder.
Return to Master TOC Return to Section TOC A-7 A-7 INSTALLATION When the RANGER 9 is mounted on a truck or a trailer, the machine generator ground stud MUST be securely connected to the metal frame of the vehicle. See Figure A.1. The ground stud is marked with the ground symbol. If the RANGER 9 is connected to premises wiring such as a home or shop, it must be properly connected to the system earth ground. See the PREMISES WIRING section of this manual for details.
Return to Master TOC Return to Section TOC A-8 A-8 INSTALLATION FIGURE A.2 - CONNECTION OF RANGER 9 TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 115 VOLT 115 VOLT NEUTRAL BUS DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operating your RANGER 9. SAFETY INSTRUCTIONS WARNING ARC RAYS can burn. • Wear eye, ear, and body protection. WARNING Return to Master TOC Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine.
Return to Master TOC Return to Section TOC B-3 OPERATION RECOMMENDED APPLICATIONS WELDER The RANGER 9 provides excellent constant current AC/DC welding output for stick (SMAW) welding and for TIG welding, and it offers constant voltage output for DC semiautomatic wire feed welding. For more details on using the machine as a welder, see WELDING OPERATION in the Operation section of this manual.
Return to Master TOC Return to Section TOC B-4 OPERATION • Quiet engine muffler with reversible exhaust feature for right or left side. • All copper alternator windings and high quality insulation for dependable long life. • Automatic engine shutdown protection for low oil pressure. • Automatic engine idler goes to low idle 10 to 14 seconds after welding for greater fuel economy; includes high idle switch.
Return to Master TOC Return to Section TOC B-5 B-5 OPERATION FIGURE B.1 – OUTPUT PANEL CONTROLS 4 2 5 6 6 5 7 4 8 3 2 1 90 RANGE 70 DC+ 9 125 175 DC- AC 1 10 max 50 3 225 AC 210 DC 16 to 25 WARNING LINCOLN 1. 2. 3. 4. 5. RANGER 9 ELECTRIC CHOKE 7 AUTO IDLER START RUN STOP Return to Master TOC Return to Section TOC HIGH 8 6 7. 8. 9. 10. 11. 12. 13. 11 9 12 13 10 Return to Master TOC Return to Section TOC WELDER/GENERATOR CONTROLS See Figure B.
Return to Master TOC Return to Section TOC B-6 OPERATION B-6 7. 20 AMP, 115 VOLT DUPLEX RECEPTACLES: Connection point for supplying 115 volt power to operate one or two electrical devices. 8. 50 AMP, 230 VOLT RECEPTACLE: Connection point for supplying 230 volt power to operate one electrical device. 9. WELD OUTPUT TERMINAL (TO WORK) WITH FLANGE NUT: Provides the connection point for the work cable.
Return to Master TOC Return to Section TOC B-7 B-7 OPERATION FIGURE B.2 – GASOLINE ENGINE CONTROLS 6 5 7 4 8 3 2 90 RANGE 70 DC+ 9 125 175 10 max 50 225 AC 210 DC 16 to 25 1. 2. 3. 4. 5.
Return to Master TOC Return to Section TOC B-8 B-8 OPERATION BEFORE STARTING THE ENGINE Check and fill the engine oil level: 1. Be sure the machine is on a level surface. 2. Remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick. On the Onan engine, the oil fill cap and dipstick are a unit. See Figure D.1 in the Maintenance section of this manual. 3. Add oil (if necessary) to bring the level up to the full mark. Do not overfill. 2.
Return to Master TOC OPERATION B-9 TABLE B.1 TYPICAL RANGER 9 FUEL CONSUMPTION ONAN P218 PERFORMER Low Idle – No Load, 2150 RPM .40 Gallons/hour (1.5 liters/hour) High Idle – No Load, 3700 RPM .82 Gallons/hour (3.10 liters/hour) AC CC Weld Output, 250 Amps @ 25 Volts 1.7 Gallons/hour (6.5 liters/hour) DC CC Weld Output, 250 Amps @ 25 Volts 1.7 Gallons/hour (6.5 liters/hour) DC CV Weld Output, 250 Amps @ 25 Volts 1.7 Gallons/hour (6.5 liters/hour) Auxiliary Power, 9000 kVA 1.7 Gallons/hour (6.
Return to Master TOC Return to Section TOC B-10 OPERATION WELDING OPERATION To use the RANGER 9 for AC/DC Constant Current Stick Welding: GENERAL INFORMATION WARNING • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Do not breathe welding fumes or gases. Return to Section TOC Return to Master TOC Return to Master TOC • Use ventilation or exhaust to remove welding fumes from the breathing area. Return to Section TOC B-10 • Keep flammable material away.
Return to Master TOC Return to Section TOC B-11 B-11 OPERATION After you finish welding: To Use the RANGER 9 for AC/DC TIG (Constant Current) Welding: 1. Connect the K930-1 TIG Module to the RANGER 9. Follow the installation instructions provided with the kit. Also be sure to follow the special machine grounding instructions given in the manual. 1. Stop the gasoline engine. See ENGINE OPERATION in this section of the manual. 2. Allow the electrode and work to cool completely. 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-12 B-12 OPERATION To Use the RANGER 9 for DC Wire Feed Welding (Constant Voltage): 4. Set the OUTPUT RANGE dial to either HIGH, MED, or LOW depending on your wire size and speed. 1. Connect one of the following: the LN-25, LN-7, LN-8, or LN-742 Wire Feeder. Follow the installation instructions in the ACCESSORIES section of this manual. 5.
Return to Master TOC Return to Section TOC B-13 B-13 OPERATION SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS Table B.3 summarizes the requirements for various welding processes you can perform with the RANGER 9. Return to Master TOC Return to Master TOC Process Control Cable Used Idle Mode Output Control Switch Welding Terminals Switch Electrode State When Not Welding To Start Welding Stick – CC No Auto At Welder Always on Hot Touch electrode to work.
Return to Master TOC Return to Section TOC B-14 B-14 OPERATION AUXILIARY POWER Powering Motors WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation. You can start most 1.5 HP, single-phase electric motors if there is no load on the motor or other load connected to the RANGER 9. After starting, the motor may be run at full load.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-15 B-15 OPERATION TABLE B.5 - SIMULTANEOUS WELDING AND AUXILIARY POWER Output Selector Setting Welding Output Permissible Power in Watts (Unity Power Factor) 250 200 250 200 None 2500 — 22 — 11 160 120 160 120 3700 5000 32 44 16 22 90 45 90 45 6000 7500 52 65 26 32.5 CV Low 200 60 5000 7500 43 65 21.5 32.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-16 B-16 OPERATION TABLE B.
Return to Master TOC Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-2 TIG Welding..........................................................................................................................
Return to Master TOC Return to Section TOC C-2 ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your RANGER 9 from your local Lincoln Distributor. Two-Wheel Trailer (K768-2) – For in-plant or yard towing of the RANGER 9. (Not intended for highway towing as equipped. For highway use of this trailer, consult applicable federal, state, and local laws about possible requirements for brakes, lights, fenders, etc.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-3 C-3 ACCESSORIES TIG WELDING SEMIAUTOMATIC FCAW AND MIG WELDING TIG Module (K930-1) - The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications. It provides contactor control of constant current welding power sources having an internal contactor. The K930-1 TIG Module is supplied without accessories.
Return to Master TOC Return to Section TOC C-4 C-4 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGATIVE (-) BATTERY LEAD before servicing. • Do not touch electrically live parts. NOTE: Welding cable must be sized for current and duty cycle of application. 3. Connect the K867 Universal Adapter to the 14 pin amphenol of the RANGER 9 as shown in Figure F.1.
Return to Master TOC Return to Section TOC C-5 ACCESSORIES 7. Place the WELDING TERMINALS switch in the “REMOTELY CONTROLLED” position. 8. Adjust wire feed speed at the wire feeder and set the welding voltage with the output “CONTROL” to a CV (constant voltage) position at the welder. NOTE: If optional remote control is used, place the output control switch in the “CONTROL REMOTE” position. CONNECTION OF THE LN-25 TO THE RANGER 9 “ACROSS THE ARC” (SEE FIGURE C.2.) C-5 6.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-6 C-6 ACCESSORIES CONNECTION OF THE LN-25 TO THE RANGER 9 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electrode cable from the K626-XX Input Cable Assembly to the “ELECTRODE” terminal of the welder and to the LN-25 wire feeder.
Return to Master TOC Return to Section TOC C-7 ACCESSORIES CONNECTION OF THE LN-7 TO THE RANGER 9 USING K584 INPUT CABLE ASSEMBLY (SEE FIGURE C.4.) NOTE: If your LN-7 comes equipped with a K291 or K404 Input able, refer to CONNECTION OF THE LN-7 Using K867 UNIVERSAL ADAPTER, rather than this discussion, to connect your RANGER 9 for wire feed welding. 1. Shut the welder off. 2.
Return to Master TOC Return to Section TOC C-8 C-8 ACCESSORIES CONNECTION OF THE LN-7 TO THE RANGER 9 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-7 to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder. CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage.
Return to Master TOC Return to Section TOC C-9 ACCESSORIES CONNECTION OF THE LN-8 TO THE RANGER 9 (SEE FIGURE C.6.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-8 to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder. Return to Master TOC NOTE: Welding cable must be sized for current and duty cycle of application. Return to Section TOC C-9 3.
Return to Master TOC Return to Section TOC C-10 ACCESSORIES CONNECTION OF THE LN-742 TO THE RANGER 9 (SEE FIGURE C.7.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-742 to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of hte welder. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC NOTE: Welding cable must be sized for current and duty cycle of application.
Return to Master TOC Return to Section TOC C-11 ACCESSORIES CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE RANGER 9 (SEE FIGURE C.8.) 5. Set the welder “polarity” switch to the desired polarity, either DC (-) or DC (+). 1. Shut the welder off. 7. Place the “IDLER” switch in the “HIGH” position. 2. Connect the electrode cable from the SG Control Module to the “ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder.
Return to Master TOC Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Routine and Periodic Maintenance ............................................................................................D-2 Engine Maintenance....
Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.
Return to Master TOC Return to Section TOC D-3 D-3 MAINTENANCE FIGURE D.1 – OIL DRAIN AND REFILL LOCATION 1 Return to Master TOC Return to Section TOC 3 2 1. DIPSTICK/OIL FILL 2. OIL DRAIN PLUG 3. OIL FILTER Return to Master TOC Return to Section TOC CHANGE THE OIL FILTER Change the oil filter the first time after 25 hours of operation. Then, under normal operating conditions, change the oil filter after every other oil change.
Return to Master TOC Return to Section TOC D-4 D-4 MAINTENANCE AIR CLEANER: Your air cleaner may have only the paper element, or it may have the cartridge and a foam precleaner. If it has the precleaner, service the element every 50 hours and the precleaner every 25 hours. If the air cleaner doesn’t have the precleaner, service the element every 25 hours. Under dusty conditions, service more often.
Return to Master TOC Return to Section TOC D-5 D-5 MAINTENANCE CRANKCASE BREATHER: The Onan engine is equipped with a crankcase breather that prevents pressure from building up inside the crankcase, prevents moisture contamination from moisture, gasoline vapors, or combustion vapors. If the breather valve becomes sticky, it can cause oil leaks, oil consumption, rough idle, reduced power, and sludge and varnish buildup in the engine. Gap Specifications: 0.025 inch (.64 mm) FIGURE D.
Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-6 TABLE D.2 ONAN ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • • • • Fill fuel tank. Check oil level. Check air cleaner for dirty2, loose, or damaged parts. Check air intake and cooling areas, clean as necessary2. Every 25 Hours • Service precleaner element2. Every 50 Hours • Service air cleaner element2. • Change oil1. Every 100 Hours • Check spark plug condition and gap.
Return to Master TOC Return to Section TOC D-7 MAINTENANCE BATTERY MAINTENANCE WARNING GASES FROM BATTERY can explode. • Keep sparks, flame, and cigarettes away from battery. To prevent EXPLOSION when: Return to Master TOC Return to Section TOC • INSTALLING A NEW BATTERY - Disconnect the negative cable from the old battery first and connect to the new battery last.
Return to Master TOC Return to Section TOC D-8 MAINTENANCE To reinstall the brushes, press them upward and slide a cable tie or wooden stick through the brush holder tabs. See Figure D.4. Install the brush holder into position and secure with the screws previously removed. Remove the cable tie or wooden stick and the brushes will seat onto the slip rings. D-8 RECEPTACLES: Keep the electrical receptacles in good condition. Remove any dirt, oil, or other debris from their surfaces and holes.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC D-9 D-9 MAINTENANCE FIGURE D.6 - MAJOR COMPONENT LOCATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. OUTPUT TERMINALS (LOCATION) ENGINE CONTROLS AUXILIARY POWER RECEPTACLES OUTPUT PANEL CONTROL OUTPUT RECTIFIER/REACTOR/CHOKE FUEL TANK FILL GASOLINE ENGINE ROTOR/STATOR ASSEMBLY BATTERY MACHINE BASE P.C.
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E Battery, Starter, Engine, Rotor, Stator, and Idler Solenoid...................................................................................................E-2 Rotor Field Feedback, Auxiliary, and Wire Feeder Power.....................................................
Return to Master TOC E-2 THEORY OF OPERATION FIGURE E.
E-3 THEORY OF OPERATION Return to Master TOC FIGURE E.
E-4 THEORY OF OPERATION Return to Master TOC FIGURE E.
E-5 THEORY OF OPERATION FIGURE E.
Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshooting Guide ......................................................................................F-2 PC Board Troubleshooting Procedures .................................................................................F-3 Troubleshooting Guide .......................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Master TOC Return to Master TOC F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. 1. Contact your local Lincoln Authorized Field Service Facility. 1. Contact The Lincoln Electric Service Dept. (216) 383-2531 or 1-800-833-9353 (WELD).
Return to Master TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) Return to Master TOC 1. With the WELDING TERMINAL switch in the “ALWAYS ON” position, check the open circuit voltage (OCV) at the welder output terminals. Normal maximum is 73 to 80VAC. Normal DC maximum is 65 to 75VDC. If the OCV is OK, then proceed to Step #2.
Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. No auxiliary power at receptacles – welding output is normal – engine runs normally. Return to Section TOC F-6 1.
Return to Master TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has low welding output and low auxiliary output. 1. Make sure the REMOTE switch is in the proper position – “MACHINE CONTROL” if a remote control unit is NOT connected to the machine. 2. The brushes may be worn.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS No DC welding output. AC welding output and auxiliary power are normal. 1. Make sure the Polarity switch (S1) is in the proper position and is “seated” correctly. Return to Master TOC Return to Section TOC 2.
Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No constant voltage (CV) welding output. Constant current (CC) and the auxiliary power are operating normally.
Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) ENGINE PROBLEMS Engine will not idle down to low speed. Machine has normal weld output and auxiliary power. Return to Section TOC F-10 1.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure the welding cables and connections are tight. 2. If attempting to “scratch” start, the WELDING TERMINALS switch (S6) must be in the “ALWAYS ON” position. Return to Master TOC Return to Master TOC Return to Master TOC RECOMMENDED COURSE OF ACTION 1. Check for broken or faulty connections in the sensing leads (#254 and #254A).
Return to Master TOC Return to Section TOC F-12 F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will not crank or cranks very slowly. 1. Check for loose or faulty battery cable connections. 2. The battery may be faulty. 1. If the battery is replaced or tests good, then the charging circuit may be faulty.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS The welding arc is “ cold.” The engine runs normally (3700 RPM no load). The auxiliary power is functioning normally. 1. Check for loose or faulty connections at the weld output terminals and welding cable connections. 2.
Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Output control on welder not functioning. Return to Section TOC F-14 1. Make sure the REMOTE switch (S4) is in the MACHINE CONTROL position. 1. Check the Output Control (R3). Normal resistance is 10,000 ohms.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check circuit breaker CB1. Reset is tripped. 2. The wire feeder control cable may be faulty. Check or replace. 3. The wire feeder may be faulty. Check or replace. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The contactor does not pull in when scratch starting when the engine goes to high idle. 1. Make sure the WELDING TERMINALS switch (S6) is in the “ALWAYS ON” position. 1. Check the WELDING TERMINAL switch (S6) and associated wiring. 2.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The output contactor does not pull in when using a wire feeder with a control cable connected to the RANGER 9 amphenol. 1. Make sure the WELDING TERMINALS switch (S6) is in the “REMOTELY CONTROLLED” position. 2.
Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure the WELDING TERMINALS switch (S6) is in the “REMOTELY CONTROLLED” position. 2. Remove the wire feeder control cable from the amphenol. If the contactor “drops out,” then the problem is external to the RANGER 9. Check the control cable or the wire feeder.
Return to Master TOC Return to Section TOC F-19 F-19 TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-20 F-20 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A AND 219 FOR ROTOR VOLTAGE TEST – + Lead #200A Lead #219A Return to Master TOC Return to Section TOC TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 9. Connect the negative meter probe to the other brush (lead #219). 2.
Return to Master TOC Return to Section TOC F-21 F-21 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-22 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS Lead #219A Lead #200A TEST PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2. Remove the rubber gasket (cover seal) from the lift bale. 3. Remove the fuel cap.
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR F-23 13. Measure the resistance to ground. A. Set the ohmmeter on the high scale (X100,000). B. Place one probe on either of the slip rings. Place the other probe on any good, unpainted ground. The machine ground stud works well. Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC If the test does not meet the resistance specifications, then the rotor may be faulty. Replace the rotor.
Return to Master TOC Return to Section TOC F-24 F-24 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.3 – LOCATION OF LEADS #3 AND #5 Return to Master TOC 115V Receptacle Return to Section TOC F-25 Machine Case Front Lead #3 Lead #5 Return to Master TOC Return to Section TOC TEST PROCEDURE To test the 115 VAC winding: To test the 230 VAC winding: 1. Remove the fuel cap and lift bale rubber gasket.
Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR F-26 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4 - LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER 201 201A 7 _ AC 200 200A 200B + AC 7 Return to Master TOC Return to Section TOC 9 201 201A 9 Field Bridge Rectifier 200 200A 200B Retaining Tab Cable Tie To test the field winding: Return to Master TOC Return to Section TOC Capacitor 1. Remove the fuel cap and lift bale rubber gasket.
Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR F-27 AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.4A - 14 PIN AMPHENOL PIN ASSIGNMENTS C Return to Section TOC F-27 Z D B Y L M AJ K E I G H X Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC W N F To test the feeder winding: 1. Remove the fuel cap and lift bail rubber gasket.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-28 TROUBLESHOOTING & REPAIR F-28 AUXILIARY AND FIELD WINDING TEST (continued) If the voltage readings are within specifications, then the windings are good and functioning correctly.
Return to Master TOC Return to Section TOC F-29 F-29 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-30 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-30 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.5 – LOCATION OF OUTPUT RECTIFIER LEADS Ohmmeter Probes Pigtail Return to Master TOC Return to Section TOC + - Diode Output rectifier Bridge Assembly Machine Front 1. Remove the spark plug wires to prevent accidental engine kickback or starting. Return to Master TOC Return to Section TOC TEST PROCEDURE 2.
Return to Master TOC Return to Section TOC F-31 F-31 TROUBLESHOOTING & REPAIR CHARGING CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC TROUBLESHOOTING & REPAIR F-32 CHARGING CIRCUIT TEST (continued) FIGURE F.6 – LOCATION OF VOLTAGE REGULATOR Voltage Regulator AC Lead DC Lead AC Lead Return to Master TOC Return to Section TOC Return to Section TOC F-32 Engine Cooling Shroud TEST PROCEDURE 2. Set the voltmeter for AC volts and place one meter probe on each of the two outside leads that attach to the engine voltage regulator. See FIgure F.6 for location. Check for 52 VAC at the voltage regulator.
Return to Master TOC Return to Section TOC F-33 F-33 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-34 TROUBLESHOOTING & REPAIR F-34 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Blower Paddle Return to Master TOC Return to Section TOC TEST PROCEDURE This test can be conducted by any one of four methods. 8. Connect the strobe-tach according the manufacturer’s instructions. Strobe-tach Method: 9. Reconnect the spark plug wires and start the engine.
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 HIGH IDLE ADJUSTMENT NUT Throttle Linkage Choke Cable Return to Master TOC Return to Section TOC 3/8" High Idle Adjustment Nut Adjust HIGH IDLE: Use the 3/8” wrench to turn the spring-loaded adjustment nut. See Figure F.8 for location of the adjustment nut. Turn the nut clockwise to increase HIGH IDLE speed. Adjust the speed until the tach reads between 3700 and 3750 RPM.
Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR F-36 ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 115 VAC receptacle, according to the manufacturer’s instructions. At 3700 RPM, the waveform should exhibit a period of 15.8 milliseconds. At 2200 RPM, the waveform should exhibit a period of 27.02 milliseconds.
Return to Master TOC Return to Section TOC F-37 F-37 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 15.8 ms Return to Master TOC Return to Section TOC CH1 0 volts 5 ms This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
Return to Master TOC Return to Section TOC F-38 F-38 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP) MACHINE LOADED Return to Master TOC Return to Section TOC CH1 0 volts 20 volts 5 ms This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank.
Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING & REPAIR F-39 TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED Return to Master TOC Return to Section TOC CH1 0 volts 20 volts 5 ms This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-40 TROUBLESHOOTING & REPAIR F-40 TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CH1 0 volts 20 volts 5 ms This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank.
Return to Master TOC Return to Section TOC F-41 F-41 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING Return to Master TOC Return to Section TOC CH1 0 volts 5 ms This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was disconnected to simulate an open or non-functioning output diode.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-42 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM OUTPUT CAPACITOR BANK NOT FUNCTIONING CH1 0 volts 50 volts 5 ms This is NOT the typical CV output voltage waveform. The capacitor bank is not functioning. Note the “ripple” in the waveform.
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR F-43 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts 5 ms This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
Return to Master TOC Return to Section TOC F-44 F-44 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts 5 ms This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
Return to Master TOC Return to Section TOC F-45 F-45 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts 5 ms This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR F-46 BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wires. 2. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 3. Remove the rubber gasket (cover seal) from the lift bale. Return to Master TOC 5. Remove the case top, then reinstall the fuel cap. 6. WIth the 5/16” nut driver, remove the 5 screws holding the right case side. Return to Master TOC Return to Section TOC 4.
Return to Master TOC TROUBLESHOOTING & REPAIR F-48 BRUSH REMOVAL AND REPLACEMENT (continued) SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a general overhaul is necessary. If brushes are to be replaced, clean slip rings with a fine emery paper. Return to Master TOC Return to Section TOC Return to Section TOC F-48 CAUTION Do not attempt to polish slip rings while engine is running. FIGURE F.
Return to Master TOC Return to Section TOC F-49 F-49 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR F-50 FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.11 RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR 201 201A 7 _ AC 200 200A 200B Return to Master TOC Return to Section TOC 9 + AC 7 201 201A 9 Field Bridge Rectifier 200 200A 200B Jumper Retaining Tab Cable Tie PROCEDURE Return to Master TOC Return to Section TOC Capacitor 1. Remove the engine spark plug wires.
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE - RECTIFIER BRIDGE REMOVAL AND REPLACEMENT 1. To remove the rectifier bridge, first you will have to remove the field capacitor. Follow Steps 1 - 10 above. 2. Depress the retainer clip on the molded plastic holder and slide the rectifier bridge out. 3. With the needle nose pliers, gently remove the 6 wires from the rectifier bridge.
Return to Master TOC Return to Section TOC F-52 F-52 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.12 - PRINTED CIRCUIT BOARD LOCATION Current Sensor Current Sensing Leads Return to Master TOC In Line Connectors Return to Section TOC F-53 6 Pin Molex Plug 12 Pin Molex Plug 5/16" Screw (2) Before starting the following procedure, refer to the topic “PC Board Troubleshooting Procedures” at the beginning of this section.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-54 TROUBLESHOOTING & REPAIR F-54 PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. 12. With the 1/4” nut driver, remove five screws holding the printed circuit board. 13. Replace the old printed circuit board with a new one. 14.
Return to Master TOC Return to Section TOC F-55 F-55 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-56 F-56 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.13 - OUTPUT RECTIFIER CONNECTIONS W1 Return to Master TOC Return to Section TOC #235 #242 To polarity switch To S2 Range Sw. Choke Lead Mounting Screws with Insulators S2 To Range Switch To capacitor bank To Polarity Switch #236 #236A Return to Master TOC Return to Section TOC Machine Front PROCEDURE 1. Remove the engine spark plug wires. 2.
Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR F-57 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 12. With the 3/8” wrench and slot head screw driver, remove the four mounting screws (two on each side). Note the placement of the nylon insulators. These must be in place when you reinstall the rectifier bridge assembly in order to electrically insulate the bridge from the choke lamination assembly. 13.
Return to Master TOC Return to Section TOC F-58 F-58 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.14 - OUTPUT CAPACITOR BANK/PRINTED CIRCUIT BOARD LOCATION 7 6 5 1. PC BOARD COVER 2. PC BOARD COVER MOUNTING SCREW (2) 3. PC BOARD MOUNTING SCREW (5) 4. CAPACITOR BANK MOUNTING SCREW (4) 5. VERTICAL BAFFLE 6. CAPACITOR (4) 7. BUSS BAR (2) 8.
Return to Master TOC Return to Section TOC F-60 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR REMOVAL AND REPLACEMENT (continued) CAUTION Be sure to follow the recommended static-free methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. Return to Master TOC Return to Section TOC 9. With the 1/4” nut driver, remove the five screws holding the printed circuit board. 10.
Return to Master TOC Return to Section TOC F-61 F-61 TROUBLESHOOTING & REPAIR OUTPUT CONTACTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-62 TROUBLESHOOTING & REPAIR F-62 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – OUTPUT CONTACTOR LOCATION 1. 2. 3. 4. 5. CONTACTOR COIL LEAD CONNECTIONS HEAVY LEAD CONNECTIONS MOUNTING HARDWARE (3 SETS) VERTICAL BAFFLE 5 1 4 3 2 Return to Master TOC Return to Section TOC 4 PROCEDURE 1. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-63 TROUBLESHOOTING & REPAIRs F-63 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-64 F-64 TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-65 F-65 TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL 5 Return to Master TOC Return to Section TOC 3 1 6 7 8 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 9 1. 2. 3. 4. 5. 6. 7. 8. 9.
Return to Master TOC Return to Section TOC F-66 TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) ENGINE AND ROTOR REMOVAL PROCEDURE 1. Refer to Figure F.17 for component locations. 2. Remove the engine spark plug wires. 3. With the 5/16” nut driver, remove the 6 sheet metal screws from the case top. Return to Master TOC Return to Section TOC 4. Remove the rubber gasket (cover seal) from the lift bale. 5. Remove the fuel cap.
Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR F-67 ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.18 - ENGINE AND ROTOR REMOVED FROM STATOR 1 2 1. THRU-BOLT 2. ROTOR ROTOR REMOVAL PROCEDURE Return to Master TOC Return to Section TOC 1. To remove the rotor, double check that the engine spark plug wires are disconnected. You will be turning the rotor during this procedure, and this could accidentally cause engine kickback. 2.
Return to Master TOC Return to Section TOC F-68 TROUBLESHOOTING & REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT (KIT S20788) (continued) REASSEMBLY PROCEDURE NOTE: Lincoln Electric recommends that a new bearing (Lincoln part #M9300-85) be installed when you replace the rotor and blower assembly. 1. Clean the tapered engine crankshaft. Slide the rotor onto the shaft. Return to Master TOC 3. Support the engine/rotor assembly with the chain hoist.
Return to Master TOC Return to Section TOC F-69 F-69 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components.
Return to Master TOC Section G-1 Section G-1 TABLE OF CONTENTS DIAGRAMS SECTION Diagrams Section............................................................................................................Section G Wiring Diagram RANGER 9 Onan (Code 9975) ....................................................................G-2 Wiring Diagram RANGER 9 Onan CSA (Code 9976)............................................................G-3 Control PC Board (L9062) Schematic........................................
G-2 Return to Master TOC Return to Section TOC G-2 DIAGRAMS WIRING DIAGRAM RANGER 9 ONAN (CODE 9975) RANGER 9 (ONAN) 254 S1 ELECTRODE POLARITY SWITCH 3 232 224E 242 242 240 CV+ DC+ 242 235 Return to Master TOC 254 25W D1 C5 232 240 R2 224E CR1 R2 R1 50W 224C E S2 S1 25 OHM R3 241 224 R4 R5 R6 200B 3 3 C2 C1 C3 CW C1 IN LINE CONNECTORS (3 PLACES) 6 3 32 42 31 5 75A (H) PCB2 BYPASS PC 2A 4 21 (E) 77C (F) 76C (G) 75C (I) 31B (K) 42 42VAC GROUND
Return to Master TOC Return to Section TOC G-3 G-3 DIAGRAMS WIRING DIAGRAM RANGER 9 ONAN CSA (CODE 9976) RANGER 9 ONAN (CSA VERSION) 254 S1 ELECTRODE POLARITY SWITCH 3 232 224E 242 242 240 236 DC+ 242 235 245 OUTPUT RECTIFIER (+) Return to Master TOC 254 100 25W D1 C3 C2 C4 C5 236A 232 240 R2 224E CR1 E S2 S1 25 OHM R2 R1 50W 224C R3 241 224 R4 R5 R6 CW S4 50A 6 GND-G 76B 76B C 75B 1 4B 2B 2 GND-B 4 76A 2C 4C 77A 3E 3A J3 75A AMPHENOL 2 11
G-4 DIAGRAMS CONTROL PC BOARD (L9062) SCHEMATIC +10V D17 D 12 8 BY-PASS C 11 7 CLOCK INH B 10 8 V SS 11 4 26.7K 3.32K 4536B COM 15V .05 5W 600V .5 COM D42 1N5406 5 X4 -B 4 J2 242 C39 18 9 A R22 C23 3A COM +10V COM 600V D19 6 J1 5 +10V +10V 15V R15 COM COM 2K COM Q11 200V R12 8A 20 D41 TP-D 6 R56 1.00K +10V R38 475 9 R5 D7 R46 4.75K 4.75K R50 4.75K 475 50V D8 20V X2 -C R61 12 .0047 1400V R47 4.75K R45 R51 47.5 47.
3 J3 2 J4 3 2 1 2 1 1 6 C4 J4 .0047 J5 1400V J3 C3 J5 .0047 J4 1400V J3 C2 J5 .0047 8 J5 7 J5 6 J5 5 J5 5 J4 4 J4 S20272-1A THE LINCOLN ELECTRIC CO. FRAME CONNECTION EARTH GROUND CONNECTION S20272 RF BYPASS SCHEMATIC SHT. NO.
CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 21.21 20.51 30.00 Return to Master TOC Return to Master TOC OF SHAFT 30.28 10.32 8.80 Return to Master TOC C L 9.29 26.59 Return to Section TOC 9.31 9.09 Return to Section TOC 2.75 FOR OIL FILTER REMOVAL DIMENSION PRINT Return to Section TOC Return to Master TOC 17.00 9.09 42.
Return to Master TOC DIAGRAMS G-7 CONTROL PC BOARD (L9062) LAYOUT Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-7 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-8 G-8 DIAGRAMS CONTROL PC BOARD (L9062) COMPONENTS X7 IC-VOLT REF,ADJ,PRECISION,431I X4 IC-VOLT REG,ADJ,3-T,(+),A X3 IC-CMOS,TIMER,PROGRAMMABLE,4536 X1 IC-OP-AMP,QUAD,GEN-PURPOSE,224N TP2 MOV-130VRMS,38J,14MM TP1 MOV-50VRMS,15J,14MM R93,R94 RESISTOR-MF,1/4W,75.0,1% R83 RESISTOR-CC,1/2W,5.
RF-BYPASS PC BOARD (M16675) LAYOUT BYPASS RF C3 J3 C4 M16675 Return to Master TOC Return to Master TOC C2 J3 Return to Section TOC C1 J4 Return to Section TOC J5 Return to Master TOC Return to Master TOC DIAGRAMS J4 Return to Section TOC G-9 J5 Return to Section TOC G-9 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
Return to Master TOC DIAGRAMS G-10 RF-BYPASS PC BOARD (M16675) COMPONENTS Item Description J3 J4 J5 C1,C2,C3,C4 CONNECTOR,MOLEX,MINI,PCB,4-PIN CONNECTOR,MOLEX,MINI,PCB,6-PIN CONNECTOR,MOLEX,MINI,PCB,8-PIN CAPACITOR-CD,.0047/.