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Lincoln Electric RANGER 225 GXT manual

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Table of contents for the manual

  • Page 1

    SVM201-A July , 2010 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 increased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUT[...]

  • Page 2

    RANGER® 225 GXT SAFETY i i 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® 225 GXT FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which re[...]

  • Page 4

    RANGER® 225 GXT SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. Turn 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 wi[...]

  • Page 5

    SAFETY iv iv RANGER® 225 GXT 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: [...]

  • Page 6

    RANGER® 225 GXT SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard th[...]

  • Page 7

    RANGER® 225 GXT SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected[...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I RANGER® 225 GXT Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 RANGER® 225 GXT Installation.......................................................................................................................Section A T echnical Specifications ..............................................................................................................A-2 [...]

  • Page 10

    INST ALLA TION A-2 A-2 RANGER® 225 GXT TECHNICAL SPECIFICA TIONS - RANGER ® 225 GXT ( K2733-1) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER RA TED OUTPUT @ 104°F (40°C)- GENERA TOR W el di ng Ou tp ut AC Constant Current 225A / 25V / 100% DC Constant Current 210A / 25V / 100% DC Constant V oltage 200A / 20V / 100% Auxiliary Po[...]

  • Page 11

    INST ALLA TION A-3 A-3 RANGER® 225 GXT SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or genera- tor , it creates it’s own power . It is not necessary to con- nect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). T o prevent dangerous electric shock, oth[...]

  • Page 12

    INST ALLA TION A-4 A-4 RANGER® 225 GXT FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL The RANGER® 225 GXT is shipped with the engine crankcase filled with SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, a[...]

  • Page 13

    INST ALLA TION A-5 A-5 RANGER® 225 GXT WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary . Loose connections will result in overheating of the output studs. When welding at a considerable distance from the welder , be[...]

  • Page 14

    INST ALLA TION A-6 A-6 RANGER® 225 GXT LOCA TION / VENTILA TION The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid heated air coming out of the welder recirculating back to the cooling air inlet. Also, locate the welder so that engine exhaust fumes are properly vented to an outs[...]

  • Page 15

    INST ALLA TION A-7 A-7 RANGER® 225 GXT 120/240 VOL T DUAL VOL T AGE RECEPT ACLE The 120/240 volt receptacle can supply up to 38 amps of 240 volt power to a two wire circuit, up to 38 amps of 120 volts power from each side of a three wire cir- cuit (up to 76 amps total). Do not connect the 120 volt circuits in parallel. Current sensing for the auto[...]

  • Page 16

    INST ALLA TION A-8 A-8 RANGER® 225 GXT T ABLE lll ELECTRICAL DEVICE USE WITH THE RANGER® 225 GXT . T ype Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker . Capacitive TV sets, radios, microwaves, V oltage spikes or high voltage appliances with el[...]

  • Page 17

    INST ALLA TION A-9 A-9 RANGER® 225 GXT ST ANDBY POWER CONNECTIONS The RANGER® 225 GXT is suitable for temporary , standby , or emergency power using the engine manu- facturer ’s recommended maintenance schedule. The RANGER® 225 GXT can be permanently installed as a standby power unit for 240V -3 wire, single phase 38 ampere service. (Connectio[...]

  • Page 18

    INST ALLA TION A-10 A-10 RANGER® 225 GXT Connection of RANGER® 225 GXT to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. Figure 1 CONNECTION OF RANGER® 225 GXT TO PREMISES WIRING W ARNING Return to Section TOC Return to Section TOC Return to Sect[...]

  • Page 19

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 RANGER® 225 GXT Operation ............................................................................................................................... Section B Safety Precautions ......................................................................................................................[...]

  • Page 20

    OPERA TION B-2 B-2 RANGER® 225 GXT WELDER CONTROLS - FUNCTION AND OPERA TION ENGINE SWITCH The engine switch is used to Start the Engine, Select High Idle or Auto Idle while the engine is running, and stop the Engine. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine. When held in the “ST ART” [...]

  • Page 21

    OPERA TION B-3 B-3 RANGER® 225 GXT “ RANGE” SWITCH The “Range” switch is used to select one of four amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Never change the “RANGE” Switch setting while welding. This will damage the switch. ------------------------------------------------------------[...]

  • Page 22

    OPERA TION B-4 B-4 RANGER® 225 GXT ST ARTING/SHUTDOWN INSTRUCTIONS ST ARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’s Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER ENGINE - Always pull the c[...]

  • Page 23

    OPERA TION B-5 B-5 RANGER® 225 GXT WELDING PROCESS For any electrodes the procedures should be kept with- in the rating of the machine. For electrode information see the appropriate Lincoln publication. STICK (CONST ANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "P[...]

  • Page 24

    OPERA TION B-6 B-6 RANGER® 225 GXT * When welding with MIG wire instead of self-shielded core wire, weld starts can be improved by setting the idle mode to “HIGH” . SUMMAR Y OF WELDING PROCESSES C O N TR OL EL E C T R O DE C A B LE ID LE WH EN NO T T O S T AR T P R O CE SS US ED MO DE WE LD IN G W EL DI NG STICK No AUTO Hot T ouch electrode to[...]

  • Page 25

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 RANGER® 225 GXT Accessories...........................................................................................................................Section C Optional Equipment ..................................................................... ...............................................C-2 [...]

  • Page 26

    ACCESSORIES C-2 C-2 RANGER® 225 GXT OPTIONAL EQUIPMENT (Field Installed) K2635-1 SMALL TWO-WHEEL ROAD TRAILER WITH DUO-HITCH- For heavy-duty road, of f-road, plant and yard use. Includes pivoting jack stand, safety chains, and 13" wheels. Overall width 60". Stiff .120" welded rectangu- lar steel tube frame construction is phosphate [...]

  • Page 27

    ACCESSORIES C-3 C-3 RANGER® 225 GXT RECOMMENDED EQUIPMENT STICK K704 Accessory Kit- (400 AMP Capacity) which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K875 Accessory Kit- (150 AMP Capacity) WIRE FEED K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “[...]

  • Page 28

    NOTES C-4 C-4 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 RANGER® 225 GXT -MAINTENANCE- Maintenance ......................................................................................................................... Section D Service Instructions .........................................................................................................[...]

  • Page 30

    MAINTENANCE D-2 D-2 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 31

    MAINTENANCE D-3 D-3 RANGER® 225 GXT Have qualified personnel do the maintenance work. T urn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the mainte- nance requiring their removal is complete. Alwa[...]

  • Page 32

    MAINTENANCE D-4 D-4 RANGER® 225 GXT Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-temper- ature use, -5 F to 104 F (-20 C to 40 C). See Engine Own[...]

  • Page 33

    GASES FROM BA TTER Y can explode. • Keep sparks, flame and cigarettes away from battery . T o prevent EXPLOSION when: • INST ALLING A NEW BA TTER Y - dis- connect negative cable from old bat- tery first and connect to new battery last. • CONNECTING A BA TTER Y CHARG- ER - Remove battery from welder by disconnecting negative cabl[...]

  • Page 34

    MAINTENANCE D-6 D-6 RANGER® 225 GXT 1. Case Front Assembly 2. Control Panel Assembly 3. Base/Fuel T ank/Battery Assembly 4. Engine Assembly 5. Blower Baffle Assembly 6. Stator/Rotor Assembly 7. Covers & Case Back Assembly FIGURE D.1 - MAJOR COMPONENT LOCA TION 7 7 5 5 6 6 4 4 3 3 1 1 2 2 7 7 5 5 6 6 4 4 3 3 1 1 2 2 Return to Section TOC Retu[...]

  • Page 35

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 RANGER® 225 GXT Theory of Operation ............................................................................................................. Section E Battery , Starter , Engine, Excitation, Rotor , Stator and Idler Solenoid ..............................................................[...]

  • Page 36

    THEOR Y OF OPERA TION E-2 E-2 RANGER® 225 GXT BA TTER Y , ST AR TER, ENGINE, ROTOR, ST A TOR AND IDLER SOLE- NOID The 12VDC battery powers the starter motor . When the engine is started and running, the battery circuit voltage is fed, through the printed circuit board, to the rotating field coil in the rotor via a brush and slip ring configuration[...]

  • Page 37

    THEOR Y OF OPERA TION E-3 E-3 RANGER® 225 GXT FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIAR Y POWER ROTOR FIELD FEEDBACK AND AUXILIAR Y POWER The AC voltage developed in the field winding is fed to the full wave field bridge. The DC output of the bridge is filtered by the field capacitor and controlled by the printed circuit board according[...]

  • Page 38

    E-4 E-4 RANGER® 225 GXT THEOR Y OF OPERA TION FIGURE E.4 – WELD WINDING, REACTOR AND RANGE SWITCH WELD WINDING, REACTOR AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch. The inductance in the reactor of fers an impedance to current flow . The reactor coil is tapped at various points. As the range switch is ro[...]

  • Page 39

    THEOR Y OF OPERA TION E-5 E-5 RANGER® 225 GXT OUTPUT BRIDGE, CHOKE, POLARITY SWITCH AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding is delivered, through the reactor and range switch, to the output bridge and polarity switch. Depending upon the setting of the polarity switch, either AC voltage or DC voltage is delivere[...]

  • Page 40

    NOTES E-6 E-6 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 41

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 RANGER® 225 GXT T roubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide .......................................................................................F-2 PC Board T roubleshoo[...]

  • Page 42

    TROUBLESHOOTING AND REP AIR F-2 F-2 RANGER® 225 GXT This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that th[...]

  • Page 43

    TROUBLESHOOTING AND REP AIR F-3 F-3 RANGER® 225 GXT Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that t[...]

  • Page 44

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 45

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 46

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 47

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 48

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 49

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 50

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 51

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 52

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 53

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 54

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 55

    Service and repair should be performed only by 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 thr[...]

  • Page 56

    FIGURE F .1 - SLIP RINGS AND BRUSHES ROT OR VOL T AGE TEST (continued) 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 bail. 3. Remove the fuel cap. The rubber gasket for the fill tube will come off with the case top. 4. Remove the case top, th[...]

  • Page 57

    Service and repair should be performed only by 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 thr[...]

  • Page 58

    FIGURE F .2 – LEAD LOCA TIONS ROTOR RESIST ANCE TEST (continued) 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 bail. 3. Remove the fuel cap. The rubber gasket for the fill tube will come off with the case top. 4. Remove the case top, then[...]

  • Page 59

    ROTOR RESIST ANCE TEST (continued) 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. C. Check the resistance. It should read very high, at least 0.5 megohm (500,000 ohms). [...]

  • Page 60

    NOTES F-20 F-20 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 61

    Service and repair should be performed only by 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 thr[...]

  • Page 62

    FIGURE F .3 – LOCA TION OF LEADS #3 AND #5 AUXILIAR Y AND FIELD WINDING TEST (continued) TEST PROCEDURE T o test the 1 15 V AC winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver , remove the case top and left side; then reinstall the fuel cap. 2. Connect the volt/ohmmeter probes to leads #3 and #5 where the[...]

  • Page 63

    AUXILIAR Y AND FIELD WINDING TEST (continued) T o test the field winding: 1. Remove the fuel cap and lift bail rubber gasket. With the 5/16” nut driver , remove the case top and left side; then reinstall the fuel cap. 2. Connect the volt/ohmmeter probes to leads #7 and #9 where they connect to the Field Idle Control P .C. Board. 3. Start the engi[...]

  • Page 64

    NOTES F-24 F-24 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 65

    Service and repair should be performed only by 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 thr[...]

  • Page 66

    (-) (+) (+) (+) (-) (-) TO POLARITY SWITCH #8 L1 TO CHOKE W1 TO S2 (A5) TO S2 TO S1 254 D2 #10 (-) (+) (+) (+) (-) (-) TO POLARITY SWITCH #8 L1 TO CHOKE W1 TO S2 (A5) TO S2 TO S1 254 D2 #10 FIGURE F .4 – LOCA TION OF OUTPUT RECTIFIER LEADS OUTPUT RECTIFIER BRIDGE TEST (continued) TEST PROCEDURE 1. Remove the spark plug wires to prevent acci- dent[...]

  • Page 67

    Service and repair should be performed only by 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 thr[...]

  • Page 68

    Voltage Regulator AC Lead DC Lead AC Lead V oltage Regulator AC Lead DC Lead AC Lead FIGURE F .5 – LOCA TION OF VOL T AGE REGULA TOR LEADS CHARGING CIRCUIT TEST (continued) TEST PROCEDURE 1. Start the engine and run it at high idle (3650 RPM). 2. Set the voltmeter for AC volts and place one meter probe on each of the two outside leads that atta[...]

  • Page 69

    Service and repair should be performed only by 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 thr[...]

  • Page 70

    FIGURE F .6 – BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD ENGINE THROTTLE ADJUSTMENT TEST (continued) TEST PROCEDURE This test can be conducted by any one of four methods. Strobe-tach Method: 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 bail. 3. Remove[...]

  • Page 71

    ENGINE THROTTLE ADJUSTMENT TEST (continued) 1 1. If either of the readings is incorrect, adjust the throttle as follows: Adjust HIGH IDLE: Use the 3/8” wrench to turn the spring-loaded adjustment nut. See Figure F .8 for location of the adjustment nut. T urn the nut clockwise to increase HIGH IDLE speed. Adjust the speed until the tach read[...]

  • Page 72

    ENGINE THROTTLE ADJUSTMENT TEST (continued) Oscilloscope Method: 1. Connect the oscilloscope to the 1 15 V AC receptacle, according to the manufacturer ’s instructions. At 3700 RPM, the waveform should exhibit a period of 16.2 milliseconds. At 2400 RPM, the waveform should exhibit a period of 25.0 milliseconds. Refer to NOR- MAL OPEN CIRCUIT VOL [...]

  • Page 73

    TROUBLESHOOTING AND REP AIR F-33 F-33 RANGER® 225 GXT CH1 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep .....5 ms/Div . Coupling .............................DC T rigger .........................Internal This is the typical AC output voltage generated from a properly operating machine. Note that ea[...]

  • Page 74

    This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div ..[...]

  • Page 75

    This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div ..[...]

  • Page 76

    This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div ..[...]

  • Page 77

    This is NOT the typical CV output volt- age waveform. One output diode is not functioning. Note the “gap” in the waveform. One output diode was dis- connected to simulate an open or non- functioning output diode. Each vertical division represents 20 volts and each horizontal division represents 5 mil- liseconds in time. Note: Scope probes c[...]

  • Page 78

    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 nonfunctioning output diode. Each vertical division represents 50 volts and each horizontal division repre- sents 5 milliseconds in time. Note: Scope probes con[...]

  • Page 79

    This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 mil- liseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep ....[...]

  • Page 80

    This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 mil- liseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep ....[...]

  • Page 81

    This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep[...]

  • Page 82

    NOTES F-42 F-42 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 83

    Service and repair should be performed only by 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 thr[...]

  • Page 84

    BRUSH REMOV AL AND REPLACEMENT PROCEDURE (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 bail. 4. Remove the fuel cap. The rubber gasket for the fill tube with come off with the case top. 5. Remove the cas[...]

  • Page 85

    7/16" Brush Assembly Bracket Bolts 7/16" Brush Assembly Bracket Bolts FIGURE F .9 – MOUNTING BOL TS BRUSH REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-45 F-45 RANGER® 225 GXT SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal. Brushes should be inspected when a gener[...]

  • Page 86

    NOTES F-46 F-46 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 87

    Service and repair should be performed only by 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 thr[...]

  • Page 88

    12 Pin Plug 4 Pin Plug 4 Self Tapping Screws (at corners) 1/4" Q.C. Tabs 12 Pin Plug 4 Pin Plug 4 Self T apping Screws (at corners) 1/4" Q.C. T abs FIGURE F .10 – PLUG LOCA TIONS PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE Before starting the following procedure, refer to the topic “PC Board T rouble[...]

  • Page 89

    PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-49 F-49 RANGER® 225 GXT 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” phillips head screw driver , remove four self ta[...]

  • Page 90

    NOTES F-50 F-50 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 91

    Service and repair should be performed only by 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 thr[...]

  • Page 92

    FIGURE F .1 1 – LEAD LOCA TIONS OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove the engine 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 bail. 4. Remove the fuel cap. The rubber gasket for the f[...]

  • Page 93

    OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT PROCEDURE (continued) 12 . Using a 13mm wrench, remove the two mounting nuts. Note the placement of the nylon insulators. 13. Remove the rectifier assembly by pulling it away from the blower baffle. 14. Reassembly: Refer to the Wiring Diagram for proper connections to the positive and nega- tive si[...]

  • Page 94

    NOTES F-54 F-54 RANGER® 225 GXT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 95

    Service and repair should be performed only by 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 thr[...]

  • Page 96

    3 3 4 4 8 8 10A 10A 9 9 7 7 5B 5B 1B 1B 1C 1C 1A 1A 10B 10B 10C 10C 2 2 6 6 5A 5A 3 3 4 4 8 8 10A 10A 9 9 7 7 5B 5B 1B 1B 1C 1C 1A 1A 10B 10B 10C 10C 2 2 6 6 5A 5A ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-56 F-56 RANGER® 225 GXT 1A. T olerance Ring 1B. Rotor Thru-Bolt 1C. Blower Fan 2. Kohler Engine[...]

  • Page 97

    ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-57 F-57 RANGER® 225 GXT PROCEDURE 1. Refer to Figure F .12 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. 4. Remove the rubber gasket (cover seal) from the li[...]

  • Page 98

    ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) ROTOR REMOV AL PROCEDURE 1. T o remove the rotor , double check that the engine spark plug wires are disconnected. Y ou will be turning the rotor during this procedure, and this could accidentally cause engine kick- back. 2. With an impact wrench, remove the rotor thru- bolt. See Figure F [...]

  • Page 99

    ENGINE/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) REASSEMBL Y 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. 2. Insert the rotor thru-bolt, and with the torque wrenc[...]

  • Page 100

    TROUBLESHOOTING AND REP AIR F-60 F-60 RANGER® 225 GXT 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 af fect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE OUTPUT Mode No Load RPM Load R[...]

  • Page 101

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 RANGER® 225 GXT Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram Complete Machine (M21812) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 102

    ElEcTrical DiaGramS G-2 raNGEr® 225 GXT WiriNG DiaGram - cOmplETE machiNE - (m21812) ST ART ER CR1 ST ART ER SOLENOI D 1 2 VO LT IDLER SOLENOID BA TT ERY AC AC B+ SWI TCH REG ULA T OR FL Y WHEEL A LT ER NATOR B- HO U RME T ER 5E 5D 224 ENGINE CO MPO NE NTS 22 4A 1 2 3 CO N NE CTOR PIN N UMBE RS: 7 6 12 1 2 3 4 PC B1 /J1 N. A. PC B1 /J2 SOLENOID FU[...]

  • Page 103

    ElEcTrical DiaGramS G-3 raNGEr® 225 GXT SchEma Tic - cOmplETE machiNE - (l13820) L13820 RANGER 225 GXT MACHIN E SCHEM ATI C NO NE L12330 DO N OT S CA LE TH IS D RAW ING EQU IP ME NT TYPE : SU BJ EC T: UF CRM39 820 1 PA GE ___ OF ___ 1 ENGINE ERING CONTROL L ED MANUFACTURER: No T HIS DOC UME N T C ON TAINS P R OP RIETA RY IN FO RMATIO N OW NE D BY [...]

  • Page 104

    ElEcTrical DiaGramS G-4 raNGEr® 225 GXT SchEma Tic - cONTrOl pc BOarD - (l12197-1) G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Re[...]