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Lincoln Electric SVM150-A manual

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Table of contents for the manual

  • Page 1

    SVM150-A September , 2002 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PR[...]

  • Page 2

    SAFETY i i RANGER 250 FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _________________________[...]

  • Page 3

    SAFETY ii ii RANGER 250 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protec[...]

  • Page 4

    RANGER 250 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National[...]

  • Page 5

    SAFETY iv iv RANGER 250 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 suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Le[...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v RANGER 250 Page Safety .................................................................................................................................................i-iv Installation .....................................................................................................................[...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 RANGER 250 Installation ................................................................................................................... ..........Section A T echnical Specifications ..............................................................................................[...]

  • Page 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 INST ALLA TION A-2 A-2 RANGER 250 Onan P216 (K1725-1) Kohler CH20 (K1725-2) 2 cylinder 16 HP @ 3600 RPM (Onan) 20 HP @ 3600 RPM (Kohler) High Idle 3700 Full Load 3500 Low Idle 24[...]

  • Page 9

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer ’s manual supplied with your welder . It includes important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. ELECTR[...]

  • Page 10

    ADDITIONAL SAFETY PRECAUTIONS F ALLING EQUIPMENT can cause injury . • Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder . • Lift only with equipment of adequate lifting capacity . • Be sure machine is stable when lifting. HIGH AL TITUDE OPERA TION At higher altitudes, output de-r[...]

  • Page 11

    BA TTER Y CONNECTIONS BA TTERY ACID CAN BURN EYES AND SKIN. • Wear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. The Ranger 250 is shipped with the negative battery cable disconnected. Make [...]

  • Page 12

    T o prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must: a) Be grounded to the frame of the welder using a grounded type plug. b) Be double insulated. Do not ground the machine to a pipe that carries explo- sive or combustible material. When this welder is mounted on a truck or trailer , its fram[...]

  • Page 13

    T ABLE A.1 – T OT AL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Cable Size for Length 250 Amps 100% Duty Cycle 0-100 ft. (0-30 meters) 1 A WG 100-200 ft. (30-46 meters) 1 AWG 150-200 ft. (46-61 meters) 1/0 A WG CABLE INST ALLA TION Install the welding cables to your Ranger 250 as fol- lows. 1. The engine must be OFF to install welding cab[...]

  • Page 14

    INST ALLA TION A-8 A-8 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 FIGURE A.2 – CONNECTION OF THE RANGER 250 TO PREMISES WIRING 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOA[...]

  • Page 15

    Section B-1 Section B-1 RANGER 250 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ...................................................................................................................... .........Section B Operating Instructions ......................................................................................................[...]

  • Page 16

    OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your Ranger 250. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all the operating and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating and maintenan[...]

  • Page 17

    DESIGN FEA TURES • Single, full-range output control dial. • 4 welding modes: CC-stick, downhill stick welding on pipe, CV wire welding and T ouch-Start TIG™ (elimi- nates high frequency and tungsten contamination). • Output at welding terminals controlled by electronic contactor . Can be switched to “On”, or to “Remotely Controlled?[...]

  • Page 18

    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 OPERA TION B-4 B-4 RANGER 250 ENGINE CONTROLS 1. RUN/STOP SWITCH: RUN position energizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock [...]

  • Page 19

    OPERA TION B-5 B-5 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 WELDING CONTROLS 7. OUTPUT CONTROL: The OUTPUT dial provides continuous control of the welding current or weld- ing voltage depending on the selecte[...]

  • Page 20

    1. Remove the fuel tank cap. 2. Fill the tank approximately 4 inches (100mm) from the top of the filler neck to allow for fuel expansion. (Observe the fuel gauge while filling.) DO NOT FILL THE T ANK TO THE POINT OF OVERFLOW . 3. Replace the fuel cap and tighten securely . 4. See the Maintenance section for specific fuel rec- ommendations. ST ARTIN[...]

  • Page 21

    WELDER OPERA TION GENERAL INFORMA TION • Do not touch electrically live parts or elec- trodes with your skin or wet clothing. • Do not breathe welding fumes or gases. • Use ventilation or exhaust to remove weld- ing from the breathing area. • Keep flammable material away . • Wear eye, ear , and body protection. The Ranger 250 can deliver [...]

  • Page 22

    STICK WELDING The Ranger 250 can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows: CONST ANT CURRENT (CC-STICK) WELDING The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The OUTPUT control[...]

  • Page 23

    TIG WELDING The T OUCH ST ART TIG setting of the MODE switch is for DC TIG (T ungsten Inert Gas) welding. T o initiate a weld, the OUTPUT control is first set to the desired cur- rent and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contam[...]

  • Page 24

    The 240 V AC output can be split to provide two sepa- rate 120 V AC outputs with a maximum permissible cur- rent of 33 amps per output to two separate 20 amp branch circuits. (These circuits cannot be paralleled.) Output voltage is within ± 10% at all loads up to rated capacity . The 120 V AC auxiliary power receptacles should only be used with th[...]

  • Page 25

    T ABLE OF CONTENTS - ACCESSORIES - Accessories .................................................................................................................... ......Section C Options/Accessories ...................................................................................................................C-2 Field Installed Options .......[...]

  • Page 26

    OPTIONS/ACCESSORIES FIELD INST ALLED OPTIONS The following options/accessories are available for your Ranger 250 from your local Lincoln distributor . K957-1 HEA VY DUTY , TWO-WHEEL TRAILER FOR SMALL WELDERS - For road, of f-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements [...]

  • Page 27

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGA TIVE (-) BA TTERY LEAD before servicing. • Do not touch electrically live parts. MOVING P ARTS can injure. • Keep guards in place. • Keep away from moving parts. • Only qualified personnel should install, use or serv[...]

  • Page 28

    CONNECTION OF THE LN-25 TO THE RANGER 250 “ ACROSS THE ARC ” (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “-” terminal of the welder . Connect the work cable to the “+” terminal of the welder . NOTE: Figure C.2 shows the electrode connected for negative polarity . T o change polarity , s[...]

  • Page 29

    ACCESSORIES C-5 C-5 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 CONNECTION OF THE LN-25 TO THE RANGER 250 WITH 42 VOL T REMOTE OUTPUT CONTROL MODULE (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the elect[...]

  • Page 30

    CONNECTION OF THE LN-25 TO THE RANGER 250 “ ACROSS THE ARC ” WITH K857 REMOTE CONTROL (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “-” terminal of the welder . Connect the work cable to the “+” terminal of the welder . NOTE: Welding cable must be sized for current and duty cycle of appli[...]

  • Page 31

    CONNECTION OF THE LN-7 TO THE RANGER 250 USING K584 CONTROL CABLE (SEE FIGURE C.5.) NOTE: If your LN-7 comes equipped with a K291 or K404 input cable, refer to CONNECTION OF THE LN- 7 Using K867 UNIVERSAL ADAPTER, rather than this discussion, to connect your Ranger 250 for wire feed welding. 1. Shut the welder off. 2. Connect the electrode cable fr[...]

  • Page 32

    CONNECTION OF THE LN-8 TO THE RANGER 250 USING K595 CONTROL CABLE (SEE FIGURE C.6.) NOTE: If your LN-8 comes equipped with a K291 or K404 input cable, refer to CONNECTION OF THE LN- 7 Using K867 UNIVERSAL ADAPTER, rather than this discussion, to connect your Ranger 250 for wire feed welding. 1. Shut the welder off. 2. Connect the electrode cable fr[...]

  • Page 33

    ACCESSORIES C-9 C-9 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 CONNECTION OF THE LN-742 TO THE RANGER 250 (SEE FIGURE C.7.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-742 to the “+” [...]

  • 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 RANGER 250 T ABLE OF CONTENTS -MAINTENANCE- Maintenance .................................................................................................................... ......Section D Safety Precautions ..................................[...]

  • Page 36

    SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance and replace them when the mainte- nance requiring their removal is complete. If guards are missing from the machine, obtain replacements[...]

  • Page 37

    MAINTENANCE D-3 D-3 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 ITEM MAKE AND P ART NUMBER ONAN P216 ENGINE KOHLER CH20 ENGINE Oil Filter Onan 122-0645, Fram PH3614 Kohler 1205001, Fram PH3614 Air Filter Element[...]

  • Page 38

    ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drain the oil into a suitab[...]

  • Page 39

    Air Filter Paper Element Service 1. Loosen the cover retaining knob and remove the cover . 2. Remove the pre-cleaner from the paper element. 3. Remove the element cover nut, element cover , and paper element. 4. Do not wash the paper element or use pressurized air , as this will damage the element. Replace a dirty , bent, or damaged element with a [...]

  • Page 40

    BA TTER Y MAINTENANCE T o access the battery , remove the screws from the rear battery tray using a screwdriver or a 3/8" socket. Slide the battery tray out only far enough to access the bat- tery terminals. GASES FROM BA TTERY can explode. • Keep sparks, flame, and cigarettes away from battery . T o prevent EXPLOSION when: • INST ALLING A[...]

  • Page 41

    WELDER/GENERA TOR MAINTENANCE STORAGE Store the Ranger 250 in clean, dry , protected areas. CLEANING Blow out the generator and controls periodically with low pressure air . Do this at least once a week in par- ticularly dirty areas. RECEPT ACLES Keep the electrical receptacles in good condition. Remove any dirt, oil, or other debris from their sur[...]

  • Page 42

    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 MAINTENANCE D-8 D-8 RANGER 250 FIGURE D.1 – MAJOR COMPONENT LOCA TIONS 1 2 3 4 5 6 7 8 9 14 13 12 11 10 1. CASE COVER AND DOOR ASSEMBL Y/CASE BACK 2. ENGINE 3. IDLER SOLENOID 4[...]

  • Page 43

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 RANGER 250 Theory of Operation ............................................................................................................ .Section E General Description .......................................................................[...]

  • Page 44

    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 GENERAL DESCRIPTION The Ranger 250 is a gasoline engine-driven welding power source capable of producing 250 amps at 25VDC at a 100% duty cycle. The engine is coupled to a brush-[...]

  • Page 45

    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 WELD WINDINGS, RECTIFIER, POWER MODULE AND FEEDBACK The three-phase stator weld windings are connected to a three-phase rectifier bridge. The resultant DC volt- age is applied to[...]

  • Page 46

    THEOR Y OF OPERA TION E-4 E-4 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 ANALOG POWER BOARD AND CONTROL BOARD The analog power board, which is powered by the two filter capacitors on the power module, supplies [...]

  • Page 47

    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 THEOR Y OF OPERA TION E-5 E-5 RANGER 250 FIGURE E.5 – IGBT OPERA TION DRAIN SOURCE GATE INJECTING LAYER BUFFER LAYER DRAIN DRIFT REGION BODY REGION p + n + n - p n + n + DRAIN [...]

  • Page 48

    RANGER 250 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine. MINIMUM OUTPUT By contr[...]

  • Page 49

    CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the Ranger 250 employ a technology whereby a DC source is turned on and off (chopped up) at high speed, thensmoothed through an inductor to control an arc. Hence the name “Chopper .” The biggest advantage of chopper technology is the high-speed control of the arc, similar [...]

  • 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 RANGER 250 T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide ....................................................................[...]

  • Page 52

    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 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may [...]

  • Page 53

    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 ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes[...]

  • Page 54

    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 TROUBLESHOOTING & REP AIR F-4 F-4 RANGER 250 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincol[...]

  • Page 55

    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 TROUBLESHOOTING & REP AIR F-5 F-5 RANGER 250 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand[...]

  • Page 56

    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 TROUBLESHOOTING & REP AIR F-6 F-6 RANGER 250 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincol[...]

  • Page 57

    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 TROUBLESHOOTING & REP AIR F-7 F-7 RANGER 250 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understand[...]

  • Page 58

    F-8 F-8 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 TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincol[...]

  • Page 59

    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 TROUBLESHOOTING & REP AIR F-9 F-9 RANGER 250 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincol[...]

  • Page 60

    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 TROUBLESHOOTING & REP AIR F-10 F-10 RANGER 250 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Linc[...]

  • Page 61

    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 F-11 F-11 RANGER 250 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not understa[...]

  • Page 62

    TROUBLESHOOTING & REP AIR F-12 F-12 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 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Linc[...]

  • Page 63

    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 TROUBLESHOOTING & REP AIR F-13 F-13 RANGER 250 CASE COVER REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory [...]

  • Page 64

    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 TROUBLESHOOTING & REP AIR F-14 F-14 RANGER 250 ENGINE ACCESS DOOR HINGES FIGURE F .1 – DOOR REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (continued) REMOV AL PROC[...]

  • Page 65

    TROUBLESHOOTING & REP AIR F-15 F-15 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 W ARNING POWER MODULE CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory tr[...]

  • Page 66

    TROUBLESHOOTING & REP AIR F-16 F-16 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 POWER MODULE CAP ACITOR DISCHARGE PROCEDURE (continued) FIGURE F .2 – POWER MODULE CAP ACITOR TERMINAL DISCHARGE SHORT ACROSS[...]

  • Page 67

    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 TROUBLESHOOTING & REP AIR F-17 F-17 RANGER 250 W ARNING IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unautho[...]

  • Page 68

    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 TROUBLESHOOTING & REP AIR F-18 F-18 RANGER 250 IDLER SOLENOID TEST (continued) FIGURE F .3 – IDLER SOLENOID LEADS SOLENOID HOUSING STATOR LEADS #210C AND #215 TO CONNECTORS[...]

  • Page 69

    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 TROUBLESHOOTING & REP AIR F-19 F-19 RANGER 250 W ARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained person[...]

  • Page 70

    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 TROUBLESHOOTING & REP AIR F-20 F-20 RANGER 250 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .4 – STROBE MARK LOCA TION MARK BLOWER P ADDLE TEST PROCEDURE 1. T urn t[...]

  • Page 71

    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 TROUBLESHOOTING & REP AIR F-21 F-21 RANGER 250 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .5 – HIGH IDLE ADJUSTMENT THROTTLE LINKAGE 3/8" HIGH IDLE ADJUSTMEN[...]

  • Page 72

    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 TROUBLESHOOTING & REP AIR F-22 F-22 RANGER 250 ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method 1. Connect the oscilloscope to the 120 V AC receptacle, accordi[...]

  • Page 73

    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 TROUBLESHOOTING & REP AIR F-23 F-23 RANGER 250 W ARNING ROTOR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unau[...]

  • Page 74

    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 TROUBLESHOOTING & REP AIR F-24 F-24 RANGER 250 ROTOR RESIST ANCE TEST (continued) FIGURE F .7 – ROTOR BRUSH LEADS SLIP RINGS BRUSHES LEADS 201 5H + - LEADS 200A 200 TEST PR[...]

  • Page 75

    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 TROUBLESHOOTING & REP AIR F-25 F-25 RANGER 250 W ARNING FLASHING AND ROTOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained pers[...]

  • Page 76

    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 TROUBLESHOOTING & REP AIR F-26 F-26 RANGER 250 FLASHING AND ROTOR VOL T AGE TEST (continued) FIGURE F .8 – ROTOR BRUSH LEADS SLIP RINGS BRUSHES LEADS 201 5H + - LEADS 200A [...]

  • Page 77

    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 TROUBLESHOOTING & REP AIR F-27 F-27 RANGER 250 FIGURE F .9 – FIELD DIODE RECTIFIER BRIDGE AND FIL TER CAP ACITOR FIELD RECTIFIER BRIDGE RETAINING TA B 7 9 CAPACITOR 201 201[...]

  • Page 78

    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 TROUBLESHOOTING & REP AIR F-28 F-28 RANGER 250 W ARNING ST A TOR VOL T AGE TESTS Service and repair should be performed by only Lincoln Electric factory trained personnel. Un[...]

  • Page 79

    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 TROUBLESHOOTING & REP AIR F-29 F-29 RANGER 250 ST A TOR VOL T AGE TESTS (continued) FIGURE F .10 – RECEPT ACLE LEAD LOCA TIONS CASE FRONT - REAR VIEW AMPHENOL 2 AMPHENOL 1 [...]

  • Page 80

    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 TROUBLESHOOTING & REP AIR F-30 F-30 RANGER 250 ST A TOR VOL T AGE TESTS (continued) FIGURE F .1 1 – LOCA TION OF LEADS #7 AND #9 A T FIELD DIODE RECTIFIER BRIDGE FIELD RECT[...]

  • Page 81

    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 TROUBLESHOOTING & REP AIR F-31 F-31 RANGER 250 ST A TOR VOL T AGE TESTS (continued) FIGURE F .12 – 14-PIN AMPHENOL PIN ASSIGNMENTS Z W Y X K B I H N L C D M G E F A J T o t[...]

  • Page 82

    TROUBLESHOOTING & REP AIR F-32 F-32 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 ST A TOR VOL T AGE TESTS (continued) FIGURE F .13 – OUTPUT RECTIFIER BRIDGE CONNECTIONS W1 W2 W3 W4 W5 W10 W8 W9 W6 W7 W11 OU[...]

  • Page 83

    TROUBLESHOOTING & REP AIR F-33 F-33 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 W ARNING ANALOG POWER PC BOARD VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained p[...]

  • Page 84

    TROUBLESHOOTING & REP AIR F-34 F-34 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 ANALOG POWER PC BOARD VOL T AGE TEST (continued) FIGURE F .14 – ANALOG POWER PC BOARD 1 1 1 1 1 PCB2 ANALO G POWER PC BOA RD [...]

  • Page 85

    T ABLE F .1. – ANALOG PC BOARD OUTPUT VOL T AGE T ABLE TEST POINTS COMPONENT TESTED VOL T AGE READING 1J42 to 6J42 Chopper Power Supply +20 VDC 2J42 to 7J42 W eld Control PC Board Power Supply +5 VDC 5J42 to 7J42 W eld Control PC Board Power Supply +15 VDC 9J42 to 7J42 W eld Control PC Board Power Supply -15 VDC 10J42 to 4J42 W eld Control PC Boa[...]

  • Page 86

    TROUBLESHOOTING & REP AIR F-36 F-36 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 W ARNING OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel[...]

  • Page 87

    TROUBLESHOOTING & REP AIR F-37 F-37 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 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .15 – PLUG J41 AND RESISTOR R3 LOCA TIONS 1 1 1 1 1 PCB2 ANALO G POWER PC B[...]

  • Page 88

    TROUBLESHOOTING & REP AIR F-38 F-38 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 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .16 – OUTPUT RECTIFIER BRIDGE LEAD REMOV AL AND TEST POINTS W1 W2 W3 OUTPUT[...]

  • Page 89

    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 TROUBLESHOOTING & REP AIR F-39 F-39 RANGER 250 W ARNING POWER MODULE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthori[...]

  • Page 90

    TROUBLESHOOTING & REP AIR F-40 F-40 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 POWER MODULE TEST (continued) FIGURE F .17 – POWER MODULE CONNECTIONS POSITIVE (+) STRAP W6 W9 POWER MODULE PC BOARD TEMPERA [...]

  • Page 91

    TROUBLESHOOTING & REP AIR F-41 F-41 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 POWER MODULE TEST (continued) FIGURE F .18 – IGBT TEST HEA T SINK POSITIVE (+) CAP ACITOR TERMINAL CONNECTIONS Check IGBT for[...]

  • Page 92

    TROUBLESHOOTING & REP AIR F-42 F-42 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 POWER MODULE TEST (continued) FIGURE F .19 – DIODE MODULE TEST HEA T SINK DIODE MODULE TERMINALS Check Diode Module 10. Using[...]

  • Page 93

    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 TROUBLESHOOTING & REP AIR F-43 F-43 RANGER 250 W ARNING FL YWHEEL AL TERNA TOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.[...]

  • Page 94

    TROUBLESHOOTING & REP AIR F-44 F-44 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 FL YWHEEL AL TERNA TOR TEST (continued) FIGURE F .20 – PLUG J51 PIN LOCA TION ENGINE CONNECTOR BLOCK J51 ONAN P216 ENGINE 210[...]

  • Page 95

    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 TROUBLESHOOTING & REP AIR F-45 F-45 RANGER 250 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division repr[...]

  • Page 96

    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 TROUBLESHOOTING & REP AIR F-46 F-46 RANGER 250 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical divis[...]

  • Page 97

    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 TROUBLESHOOTING & REP AIR F-47 F-47 RANGER 250 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical divis[...]

  • Page 98

    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 TROUBLESHOOTING & REP AIR F-48 F-48 RANGER 250 This is the typical DC open circuit out- put voltage generated from a properly operating machine. Note that each vertical divis[...]

  • Page 99

    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 TROUBLESHOOTING & REP AIR F-49 F-49 RANGER 250 This is the typical DC voltage gener- ated from a properly operating machine. Note that each vertical divi- sion represents 20 [...]

  • Page 100

    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 TROUBLESHOOTING & REP AIR F-50 F-50 RANGER 250 W ARNING POWER MODULE ASSEMBL Y/POWER MODULE PC BOARD/ DIODE MODULE REMOV AL AND REPLACEMENT Service and repair should be perfo[...]

  • Page 101

    TROUBLESHOOTING & REP AIR F-51 F-51 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 POWER MODULE ASSEMBL Y REMOV AL AND REPLACEMENT FIGURE F . 21 – POWER MODULE CONNECTIONS POSITIVE (+) STRAP W6 W9 POWER MODUL[...]

  • Page 102

    TROUBLESHOOTING & REP AIR F-52 F-52 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 POWER MODULE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) 7. Label and remove leads #232 and #233 from the temperature switch[...]

  • Page 103

    TROUBLESHOOTING & REP AIR F-53 F-53 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 POWER MODULE PC BOARD REMOV AL AND REPLACEMENT FIGURE F .22 – DIODE MODULE/POWER MODULE ASSEMBL Y DET AILS PLUG J50 ALLEN HEA[...]

  • Page 104

    TROUBLESHOOTING & REP AIR F-54 F-54 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 DIODE MODULE REMOV AL AND REPLACEMENT Removal Refer to Figure F .23. 1. Remove the Power Module PC Board as described above. 2.[...]

  • Page 105

    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 TROUBLESHOOTING & REP AIR F-55 F-55 RANGER 250 W ARNING POWER CAP ACITOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trai[...]

  • Page 106

    TROUBLESHOOTING & REP AIR F-56 F-56 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 POWER CAP ACITOR REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Perform the Case Cover Removal proce- dure. 2. Perform the P[...]

  • Page 107

    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 TROUBLESHOOTING & REP AIR F-57 F-57 RANGER 250 W ARNING OUTPUT RECTIFIER BRIDGE AND CHOKE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Elec[...]

  • Page 108

    TROUBLESHOOTING & REP AIR F-58 F-58 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 OUTPUT RECTIFIER BRIDGE AND CHOKE REMOV AL AND REPLACEMENT (continued) REMOV AL PROCEDURE Refer to Figure F .25. Output Rectifi[...]

  • Page 109

    TROUBLESHOOTING & REP AIR F-59 F-59 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 OUTPUT RECTIFIER BRIDGE AND CHOKE REMOV AL AND REPLACEMENT (continued) 5. Using the 1/2" and 9/16" wrenches, hold and[...]

  • Page 110

    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 TROUBLESHOOTING & REP AIR F-60 F-60 RANGER 250 W ARNING ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factor[...]

  • Page 111

    TROUBLESHOOTING & REP AIR F-61 F-61 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .26 – BA TTER Y AND CASE BACK REMOV AL ACCESS P ANEL SCR[...]

  • Page 112

    TROUBLESHOOTING & REP AIR F-62 F-62 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F . 27 – ENGINE ST ARTER SOLENOID LEADS (ONAN ENGINE SHOWN[...]

  • Page 113

    TROUBLESHOOTING & REP AIR F-63 F-63 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .28 – ST A TOR LEADS (FRONT P ANEL) Stator Lead Disconne[...]

  • Page 114

    TROUBLESHOOTING & REP AIR F-64 F-64 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .29 – ENGINE/ST A TOR/ROTOR ASSEMBL Y REMOV AL LIFTING E[...]

  • Page 115

    TROUBLESHOOTING & REP AIR F-65 F-65 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .30 – ST A TOR AND ROTOR REMOV AL 8 6 1 2 5 3 4 7 9 Stat[...]

  • Page 116

    TROUBLESHOOTING & REP AIR F-66 F-66 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 6. Double check that the spark plug wires are disconnected. Y ou wi[...]

  • Page 117

    TROUBLESHOOTING & REP AIR F-67 F-67 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 ENGINE/ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 6. Insert the rotor thru-bolt and centering wash- er . With the tor[...]

  • Page 118

    RETEST AFTER REP AIR 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. ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 2350 - 2450 N/A High Idle 3700 - 3750 3350 -[...]

  • Page 119

    G-1 G-1 RANGER 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM RANGER 250 KOHLER . . .[...]

  • Page 120

    ELECTRICAL DIAGRAMS G-2 RANGER 250 WIRING DIAGRAM - RANGER 250 KOHLER CONTAC TOR CONTR OL SHOWN IN "WELDIN G ON" POSIT ION WIRE FEED POWE R W INDING 42 VAC + + C2 C1 25 watts 250 oh ms J50 42 VAC FIELD WINDIN G CENTER GND. SCREW ON INSIDE OF CASE FRONT WHIT E 211A D3 ARC CONTROL 10K ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR. 42 W3 [...]

  • Page 121

    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 ELECTRICAL DIAGRAMS G-3 RANGER 250 WIRING DIAGRAM - RANGER 250 ONAN CON TACTOR CON TROL SHOWN IN "WELDIN G ON" POSIT ION WIRE FEED POWE R W INDING 42 VAC + + C2 C1 25 w[...]

  • Page 122

    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 ELECTRICAL DIAGRAMS G-4 RANGER 250 CONTROL INTER-CONNECTION DIAGRAM PCB3 WELD CONTROL PC BOARD J1 J3 J6 J4 J11 J2 J5 J10 J7 J13 J12 J9 J8 115A 1J13 to 5J42 -15 VOL T POWER 101A 2[...]

  • Page 123

    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 ELECTRICAL DIAGRAMS G-5 RANGER 250 SCHEMA TIC - COMPLETE MACHINE W3 W2 D1 - THREE PHASE BRIDGE RECTIFIER D3 C3 800uf 150 vdc ROTOR FIELD 7 201 5H 200 200 A W1 C E IGBT MODULE - E[...]

  • Page 124

    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 ELECTRICAL DIAGRAMS G-6 RANGER 250 SCHEMA TIC - ANALOG CONTROL POWER SUPPL Y G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by thi[...]

  • Page 125

    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 ELECTRICAL DIAGRAMS G-7 RANGER 250 SCHEMA TIC - BA TTER Y PRINTED CIRCUIT BOARD G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by [...]

  • Page 126

    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 ELECTRICAL DIAGRAMS G-8 RANGER 250 SCHEMA TIC - BYP ASS PRINTED CIRCUIT BOARD G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by th[...]

  • Page 127

    ELECTRICAL DIAGRAMS G-9 RANGER 250 SCHEMA TIC - CHOPPER PRINTED CIRCUIT BOARD FILENAME: M19462_1BA 10.0 R5 10.0 R9 (UNLESS OTHER WISE SPECIFIED) UNLESS OTHER WISE SPECIFIED) .022/50V 10.0 R7 10.0 R6 to heatsink to + cap UNLESS OTHER WISE SPECIFIED) 10.0 R8 DR. 3/26/99 15 to 32 V ac B1 B[...]

  • Page 128

    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 ELECTRICAL DIAGRAMS G-10 RANGER 250 SCHEMA TIC - DISPLA Y PRINTED CIRCUIT BOARD G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by[...]

  • Page 129

    ELECTRICAL DIAGRAMS G-11 RANGER 250 SCHEMA TIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 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 Mast[...]

  • Page 130

    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 ELECTRICAL DIAGRAMS G-12 RANGER 250 SCHEMA TIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 2 G-12 NOTE: This diagram is for reference only . It may not be accurate for all machi[...]

  • Page 131

    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 ELECTRICAL DIAGRAMS G-13 RANGER 250 SCHEMA TIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 3 G-13 NOTE: This diagram is for reference only . It may not be accurate for all machi[...]

  • Page 132

    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 ELECTRICAL DIAGRAMS G-14 RANGER 250 SCHEMA TIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 4 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machi[...]

  • Page 133

    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 ELECTRICAL DIAGRAMS G-15 RANGER 250 SCHEMA TIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 5 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machi[...]

  • Page 134

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w[...]