Lincoln Electric RANGER 305 D Service Manual
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Lincoln Electric RANGER 305 D Service Manual

Lincoln Electric RANGER 305 D Service Manual

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RANGER
305 D
For use with machines having Code Numbers:
10926, 11121, 11188, 11275, 11457 (Domestic)
11027, 11122, 11189, 11314 (UK)
11039, 11123, 11190, 11315 (EUROPE)
11458, 11459, 11527, 11587, 12484, 12486 (CE)
11692, 12193, 11909
SERVICE MANUAL
SVM175-A
| Issue D ate 17-Oct
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. ® RANGER 305 D For use with machines having Code Numbers: 10926, 11121, 11188, 11275, 11457 (Domestic) 11027, 11122, 11189, 11314 (UK) 11039, 11123, 11190, 11315 (EUROPE) 11458, 11459, 11527, 11587, 12484, 12486 (CE)

  • Page 2: Safety

    Service and repair should be performed by only USE ENOUGH VENTILATION or Lincoln Electric Factory Trained Personnel. Unauthorized exhaust at the arc, or both, to keep repairs performed on this equipment may result in danger to the fumes and gases from your breathing zone and the general area.

  • Page 3: Operation

    ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE TH T LL INST LL TION, OPER TION, 2.a.
  • Page 4 RANGER 305D OPERATION ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do not eyes from sparks and the rays of the arc when welding or touch these “hot”...
  • Page 5 RANGER 305D OPERATION WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.
  • Page 6 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding shielding the supply cable of permanently installed welding Equipment. It is for use with other Lincoln Electric equipment. It is equipment, in metallic conduit or equivalent. Shielding should be designed for industrial and professional use.

  • Page 7: Table Of Contents

    RANGER 305D OPERATION M STER T BLE OF CONTENTS FOR LL SECTIONS Page Safety....................................i-iv Installation................................Section A Operation .................................Section B Accessories ................................Section C Maintenance................................Section D Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G Parts Manuals............................(Code 10926) P-417 ........................(Code 11027, 11039) P-479 ...................(Code 11121, 11188, 11275, 11457) P-492 ........(Code 11122, 11123, 11189, 11190, 11314, 11315, 11458, 11459, 11587) P-494...
  • Page 8 RANGER 305D INSTALLATION T BLE OF CONTENTS - INST LL TION SECTION - Installation ..........................Section Technical Specifications....................A-2, A-3, A-4 Safety Precautions........................A-5 Location and Ventilation ......................A-5 Storing ..........................A-5 Stacking..........................A-5 Angle of Operation .......................A-5 Lifting............................A-6 High Altitude Operation......................A-6 High Temperature Operation ....................A-6 Cold Weather Starting and Operation..................A-6 Towing ..........................A-6 Pre-Operation Engine Service ....................A-7...

  • Page 9: Installation

    RANGER 305D INSTALLATION GENERAL DESCRIPTION TECHNICAL SPECIFICATIONS The Ranger 305D is a diesel-engine-powered DC multi-process welding power source and 120 / 240 VAC power generator. The engine drives a generator that supplies three-phase power for the DC NOTE: Technical specifications are subject to change without prior notice. Specifications and guarantees are valid only when specified welding circuit and single-phase power for the AC auxiliary outlets.
  • Page 10 RANGER 305D INSTALLATION TECHNIC L SPECIFIC TIONS - Ranger 305D (K1727-2) Code 10926, 11121, 11188, 11275, 11475 PHYSICAL DIMENSIONS HEIGHT 30.00* IN. 762.0 MM WIDTH 21.50 IN. 546.0 MM DEPTH 52.25 IN. 1327.0 MM WEIGHT 698 LBS. (317KG.) RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES (2) 120VAC DUPLEX (5-20R) (1) 120/240VAC DUAL VOLTAGE...
  • Page 11 RANGER 305D INSTALLATION TECHNIC L SPECIFIC TIONS - R NGER 305D (CE) K2279-1 (UK) Code 11027, 11122, 11189, 11314 & K2279-2 (EUROPE) Code 11039, 11123, 11190, 11315 PHYSICAL DIMENSIONS INPUT - DIESEL ENGINE MAKE/MODEL KUBOTA HEIGHT 762.0 MM (30.00 IN.) D722 WIDTH 546.0 MM (21.50 IN.)
  • Page 12 RANGER 305D INSTALLATION TECHNIC L SPECIFIC TIONS - Ranger 305D ( U) (K2922-1) Code 11458, 11459, 11587 PHYSICAL DIMENSIONS INPUT - DIESEL ENGINE MAKE/MODEL KUBOTA** HEIGHT 30.00* IN. 762.0 MM D722 WIDTH 21.50 IN. DESCRIPTION 3 CYLINDER 4 STROKE 546.0 MM 18.8 HP DEPTH 52.25 IN.

  • Page 13: Storing

    RANGER 305D INSTALLATION S FETY PREC UTIONS drains completely. Attach a note that says “NO WATER” on the radiator. 3. While the engine is still warm, drain the oil and refill with fresh W RNING 10W30 oil. Change the oil filter. Run the engine for about five minutes to circulate oil to all the parts.

  • Page 14: Lifting

    5°C) it is recommended that No. 1D diesel fuel is used in place of No. 2D. Allow engine to warm up before applying a load or switching to high idle. Lincoln Electric supplies a Cold Weather Kit if the unit is to be used in Cold Weather Extremes for long periods. See Field Installed options in the Accessories section of this manual.

  • Page 15: Pre-Operation Engine Service

    RANGER 305D INSTALLATION PRE-OPER TION ENGINE SERVICE B TTERY CONNECTION READ the engine operating and maintenance instructions supplied W RNING with this machine. W RNING BATTERY ACID CAN BURN EYES AND SKIN. • Wear gloves and eye protection and be •...

  • Page 16: Remote Control

    RANGER 305D INSTALLATION REMOTE CONTROL M CHINE GROUNDING The RANGER 305D is equipped with both a 6-pin and a 14-pin Because this portable engine driven welder creates its own power, it Amphenol connector. The 6-pin connector is primarily used to is not necessary to connect its frame to an earth ground, unless the connect a remote control device, such as a K857, or a TIG Amptrol, machine is connected to premises wiring (home, shop, etc.)

  • Page 17: Machine Grounding

    RANGER 305D INSTALLATION In general, if the machine is to be grounded, it should be connected C UTION with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having •...
  • Page 18 RANGER 305D INSTALLATION Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customer’s premises disconnect and service over-current protection. Take necessary steps to assure load is limited to the capacity of the Ranger 305D by installing a 50 amp, 240 VAC double-pole circuit breaker.
  • Page 19 RANGER 305D INSTALLATION FIGURE .2 CONNECTION OF R NGER 305D TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
  • Page 20 RANGER 305D OPERATION T BLE OF CONTENTS - OPER TION SECTION - Operation..........................Section B Operating Instructions ........................B-2 Safety Instructions ........................B-2 General Description ........................B-2 Design Features ..........................B-3 Controls and Settings .........................B-3 Engine Controls ........................B-4 Welding Controls ........................B-5 Engine Operation ........................B-6 Before Starting the Engine ....................B-6 Starting the Engine.......................B-6 Stopping the Engine......................B-6 Stick Welding ..........................B-7...

  • Page 21: Operation

    RANGER 305D OPERATION OPERATING W RNING INSTRUCTIONS MOVING PARTS can injure. Read and understand this entire section before operating your • Do not operate this equipment with any Ranger 305D. of its doors open or guards off. • Stop the engine before servicing it. S FETY INSTRUCTIONS •...

  • Page 22: Design Features

    RANGER 305D OPERATION CONTROL ND SETTINGS DESIGN FE TURES • Single, full-range output control dial. The diesel engine stop/start and idler controls are located on the case front panel. The welder controls are also located here. See • 4 welding modes: CC-stick, downhill stick welding on pipe, CV Figure B.1.

  • Page 23: Engine Controls

    RANGER 305D OPERATION FIGURE B.1 NOTE: Layout and appearance vary between models. ENGINE CONTROLS (FIGURE B.1) ENGINE ALTERNATOR TROUBLE LIGHT: The yellow engine RUN.STOP SWITCH: RUN position energizes the engine prior to alternator light is off when the battery charging system is starting.

  • Page 24: Welding Controls

    RANGER 305D OPERATION IDLER SWITCH: Has two positions as follows: arc is preferred for fill and cap passes where weld puddle control and deposition ("stacking" of iron) are key to fast travel speeds. It In the HIGH position, the engine runs at the high idle is recommended that the ARC CONTROL be set initially at 0.

  • Page 25: Engine Operation

    RANGER 305D OPERATION ENGINE OPERATION ST RTING THE ENGINE 1. Remove all plugs connected to the AC power receptacles. W RNING 2. Set IDLER switch to AUTO. 3. Set the RUN/STOP switch to RUN. DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the Ranger 305D is 4.

  • Page 26: Stick Welding

    RANGER 305D OPERATION BRE K-IN PERIOD STICK WELDING Any engine will use a small amount of oil during its “break-in” period. The Ranger 305D can be used with a broad range of DC stick For the diesel engine on the Ranger 305D, break-in is about 50 electrodes.

  • Page 27: Tig Welding

    VAC (5-20R) duplex receptacles and one 50 amps 120/240 VAC (14- 50R) receptacle. The 240 VAC receptacle can be split for single-phase Connect a wire feeder to the RANGER 305 D according to the 120 VAC operation. instructions in INSTALLATION INSTRUCTIONS Section.

  • Page 28: Simultaneous Welding And Auxiliary Power Loads

    RANGER 305D OPERATION The 240 VAC receptacle can be split to provide two separate120 VAC SIMULTANEOUS WELDING AND outputs with a maximum permissible current of 42 amps pea, 40 AUXILIARY POWER LOADS amps continuous per outlet to two separate 20 amp branch circuits. (These circuits cannot be paralleled.) Output voltage is within +/- The above auxiliary power ratings are with no welding load.
  • Page 29 RANGER 305D OPERATION B 10...
  • Page 30 Field Installed Options ......................C-2 TIG Welding Accessories .....................C-2 Semiautomatic FCAW and MIG Welding Accessories ............C-2 Connection of Lincoln Electric Wire Feeders...............C-3 Connection of the K867 Universal Adapter ..............C-3 Connection of the LN-25 “Across the Arc” ..............C-4 Connection of the LN-25 with 42V Remote Output Control Module ......C-5 Connection of the LN-25 with K857 Remote Control ...........C-6...

  • Page 31: Accessories

    RANGER 305D ACCESSORIES OPTIONS / ACCESSORIES SEMI UTOM TIC FC W ND MIG FIELD INST LLED OPTIONS WELDING CCESSORIES The following options/accessories are available for your Ranger 305D LN-25 WIRE FEEDER K449 - This portable unit provides CC/CV for from your Lincoln distributor. flux-cored arc welding (FCAW) and metal inert gas welding (MIG).

  • Page 32: Connection Of Lincoln Electric Wire Feeders

    (SEE FIGURE C.1) preset at the factory - do not adjust above RPM specifications listed in NOTE: When you use the Ranger 305D with non-Lincoln Electric wire feeders this manual. or with certain earlier models of Lincoln wire feeders, you will require the K867 Universal Adapter.
  • Page 33 RANGER 305D ACCESSORIES CONNECTION OF THE LN-25 TO C UTION THE RANGER 305D “ACROSS THE ARC” If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the Ranger 305D is started. (SEE FIGURE C.2.) 7.
  • Page 34 RANGER 305D ACCESSORIES CONNECTION OF THE LN-25 TO C UTION THE RANGER 305D WITH 42 VOLT REMOTE OUTPUT CONTROL Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause MODULE an increase in the AC auxiliary voltage.

  • Page 35: Connection Of The Ln-25 With K857 Remote Control

    RANGER 305D ACCESSORIES CONNECTION OF THE LN-25 TO C UTION THE RANGER 305D “ACROSS THE ARC” WITH K857 REMOTE If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the Ranger 305D is started. CONTROL (SEE FIGURE C.4.) 6.
  • Page 36 RANGER 305D ACCESSORIES CONNECTION OF THE LN-7 TO C UTION THE RANGER 305D USING K584 CONTROL CABLE Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage. If this voltage goes (SEE FIGURE C.5.) over 140 volts, wire feeder control circuit may be damaged.
  • Page 37 RANGER 305D ACCESSORIES CONNECTION OF THE LN-8 TO C UTION THE RANGER 305D USING K595 CONTROL CABLE Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage. If this (SEE FIGURE C.6.) voltage goes over 140 volts, wire feeder control circuit may NOTE: If your LN-8 comes equipped with a K291 or K404 input cable, refer...
  • Page 38 RANGER 305D ACCESSORIES CONNECTION OF THE LN-742 TO C UTION THE RANGER 305D. An increase of the high idle engine RPM by changing the (SEE FIGURE C.7.) governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage. If this 1.
  • Page 39 RANGER 305D ACCESSORIES C 10...
  • Page 40 RANGER 305D MAINTENANCE T BLE OF CONTENTS -M INTEN NCE- Maintenance .........................Section D Safety Precautions........................D-2 Routine and Periodic Maintenance ....................D-2 Engine Maintenance......................D-3 Engine Oil Change ......................D-4 Oil Filter Change........................D-4 Service Instruction & Installation Tips..................D-5 Cooling System ........................D-6 Tighten the Fan Belt......................D-6 Fuel System Service......................D-7 Battery Maintenance ......................D-7 Welder/Generator Maintenance....................D-8...

  • Page 41: Maintenance

    RANGER 305D MAINTENANCE SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE W RNING ENGINE M INTEN NCE • Have qualified personnel do all maintenance and C UTION troubleshooting work. • Turn the engine off before working inside the machine. To prevent the engine from accidentally starting, disconnect •...
  • Page 42 RANGER 305D MAINTENANCE TABLE D.2 - KUBOTA D722 ENGINE MAINTENANCE SCHEDULE INTERVAL REQUIRED MAINTENANCE DAILY FILL FUEL TANK CHECK OIL LEVEL CHECK COOLANT LEVEL CHECK AIR CLEANER FOR DIRT OR DAMAGE CHECK AIR INTAKE FOR CRACKS/LOOSENESS (200 HRS PER KUBOTA) CHECK FAN BELT TENSION (KUBOTA MANUAL EVERY 100 HRS) FIRST 50 HOURS...
  • Page 43 RANGER 305D OPERATION ENGINE OIL CH NGE OIL FILTER CH NGE Drain the engine oil while the engine is warm to assure rapid and • Drain the oil. complete draining. It is recommended that each time the oil is • Remove the oil filter with an oil filter wrench and drain the oil into a changed the oil filter be changed as well.

  • Page 44: Service Instruction & Installation Tips

    RANGER 305D OPERATION Service Instructions & Installation Tips For Engine Air Filter Check the Old Release the Donaldson filters with RadialSeal™ Sealing Technology are self-aligning, self-centering, Seal Carefully Filter for Leak Clues and self-sealing. A new filter has a dry Visually inspect the old filter for any signs Unlatch and remove the service lubricant to aid installation.

  • Page 45: Cooling System

    RANGER 305D MAINTENANCE Periodically remove the dirt from the radiator fins. W RNING Periodically check the fan belt and radiator hoses. Replace if signs of deterioration are found. Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result. TIGHTENING THE F N BELT C UTION If the fan belt is loose, the engine can overheat and the battery lose...

  • Page 46: Fuel System Service

    RANGER 305D MAINTENANCE FUEL SYSTEM SERVICE OVERSPEED IS H Z RDOUS The maximum allowable high idle speed for this machine is At the end of each day, refill the fuel tank to minimize moisture 3650 RPM, no load. Do NOT tamper with governor condensation and dirt contamination in the fuel line.

  • Page 47: Welder/Generator Maintenance

    RANGER 305D MAINTENANCE CLEANING THE BATTERY WELDER / GENERATOR MAINTENANCE Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables and STORAGE: Store the RANGER 305D in clean, dry protected areas. wash the terminals with an ammonia solution or a solution of 1/4 CLEANING: Blow out the generator and controls periodically with low pound (0.1113 kg) of baking soda and 1 quart (0.9461) of water.
  • Page 48 RANGER 305D MAINTENANCE GFCI RECEPT CLE TESTING ND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
  • Page 49 RANGER 305D MAINTENANCE FIGURE D.1 – M JOR COMPONENT LOC TIONS 1. C SE FRONT SSEMBLY 2. CONTROL P NEL SSEMBLY 3. ST TOR & ROTOR SSEMBLY 4. BLOWER B FFLE SSEMBLY 5. B SE, FUEL T NK SSEMBLY 6. ENGINE SSEMBLY 7.
  • Page 50 RANGER 305D THEORY OF OPERATION T BLE OF CONTENTS -THEORY OF OPER TION SECTION- Theory of Operation ......................Section E General Description ......................E-2 Battery, Engine, Rotor, Stator and Engine Protection ............E-2 Engine Idle System........................E-3 Generating Power........................E-4 Weld Power and Control .......................E-5 Remote Output Control, Output Contactor, Digital Meters...........E-6 Chopper Technology Fundamentals..................E-7 Pulse Width Modulation ......................E-8...
  • Page 51 RANGER 305D THEORY OF OPERATION FIGURE E.2 – B TTERY, ENGINE, ENGINE PROTECTION, CH RGING, IDLE CONTROL SHUNT IGBTs POWER CHOKE MODULE ENGINE CHARGING PROTECTION SYSTEM LIGHT LIGHT (CODE 10926 ONLY) ENGINE ENGINE GLOW PROTECTION ENGINE SENSORS PLUGS CIRCUIT ALTERNATOR WELD WINDING FUEL...

  • Page 52: Theory Of Operation

    RANGER 305D THEORY OF OPERATION FIGURE E.3 –ENGINE IDLE SYSTEM, IDLE SWITCH & IDLE SOLENOID SHUNT IGBTs POWER CHOKE MODULE ENGINE CHARGING PROTECTION SYSTEM LIGHT LIGHT (CODE 10926 ONLY) ENGINE ENGINE GLOW PROTECTION ENGINE SENSORS PLUGS CIRCUIT ALTERNATOR WELD WINDING FUEL ENGINE ROTOR...
  • Page 53 RANGER 305D THEORY OF OPERATION FIGURE E.4 – GENER TING POWER & OUTPUT SHUNT IGBTs POWER CHOKE MODULE ENGINE CHARGING PROTECTION SYSTEM LIGHT LIGHT (CODE 10926 ONLY) ENGINE ENGINE GLOW PROTECTION ENGINE SENSORS PLUGS CIRCUIT ALTERNATOR WELD WINDING FUEL ENGINE ROTOR PUMP FUEL...
  • Page 54 RANGER 305D THEORY OF OPERATION FIGURE E.5 – WELD POWER & CONTROL SHUNT IGBTs POWER CHOKE MODULE ENGINE CHARGING PROTECTION SYSTEM LIGHT LIGHT (CODE 10926 ONLY) ENGINE ENGINE GLOW PROTECTION ENGINE SENSORS PLUGS CIRCUIT ALTERNATOR WELD WINDING FUEL ENGINE ROTOR PUMP FUEL SOLENIOD...
  • Page 55 RANGER 305D THEORY OF OPERATION Remote output control: The Weld control PC board automatically detects when a remote control potentiometer is connected to either of the Amphenols. In “CC-STICK”, “DOWNHILL PIPE” or “CV-WIRE” modes, the front panel output control is disabled when a remote control device is connected. In “TOUCH START TIG”...
  • Page 56 RANGER 305D THEORY OF OPERATION CHOPPER TECHNOLOGY FUND MENT LS The new era of welding machines such as the Ranger 305D employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “Chopper.”...
  • Page 57 RANGER 305D THEORY OF OPERATION FIGURE E.6 – IGBT OPER TION MINIMUM OUTPUT (Dwell or Off Time) MAXIMUM OUTPUT (Dwell or Off Time) PULSE WIDTH MODUL TION: MAXIMUM OUTPUT: The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle.
  • Page 58 RANGER 305D TROUBLESHOOTING & REPAIR T BLE OF CONTENTS TROUBLESHOOTING & REP IR SECTION Troubleshooting & Repair Section .................Section F How to Use Troubleshooting Guide ..................F-2 PC Board Troubleshooting Procedures .................F-3 Troubleshooting Guide....................F-4 - F-20 Test Procedures ........................F-21 Case Cover Removal and Replacement Procedure ............F-21 Chopper Module Capacitor Discharge Procedure............F-23 Fuel Shutdown Solenoid Test ..................F-25 Engine Throttle Adjustment Test ...................F-29...
  • Page 59 HOW TO USE TROUBLESHOOTING GUIDE W RNING 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 60 Do not touch electrically hot parts. them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further Sometimes machine failures appear to be due to damage and allow proper failure analysis.
  • Page 61 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 62 4. Perform the Stator Voltage Test. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 63 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 64 PC board. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 65 PC board. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 66 14 pin amphenol receptacle. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 67 3. The Weld control PC board may be defective. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 10...
  • Page 68 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 11...
  • Page 69 VOLTAGE TEST. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 12...
  • Page 70 5. The wire feeder may be defective. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 13...
  • Page 71 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 14...
  • Page 72 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 15...
  • Page 73 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 16...
  • Page 74 C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 17...
  • Page 75 DEFECTIVE. REPLACE IT. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 18...
  • Page 76 “HIGH IDLE” position. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 19...
  • Page 77 4. THE WELD CONTROL PC BOARD MAY BE DEFECTIVE. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F 20...
  • Page 78 C SE COVER REMOV L ND REPL CEMENT PROCEDURE W RNING 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.
  • Page 79 RANGER 305D TROUBLESHOOTING & REPAIR C SE COVER REMOV L ND REPL CEMENT PROCEDURE (continued) FIGURE F.1 – DOOR REMOV L ENGINE SERVICE ACCESS DOOR LOCKING TAB HINGES REMOV L PROCEDURE on when working on the Ranger 305D. REPL CEMENT PROCEDURE Turn the engine off.
  • Page 80 CHOPPER MODULE C P CITOR DISCH RGE PROCEDURE W RNING 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.
  • Page 81 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE C P CITOR DISCH RGE PROCEDURE (continued) FIGURE F.2 – CHOPPER MODULE C P CITOR TERMIN L DISCH RGE INSULATED PLIERS INSULATED GLOVES TEST PROCEDURE discharged by holding the resistor with insulated pliers and using the resistor terminals to bridge Chopper Module Turn the engine off.
  • Page 82 FUEL SHUTDOWN SOLENOID TEST W RNING 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.
  • Page 83 RANGER 305D TROUBLESHOOTING & REPAIR FUEL SHUTDOWN SOLENOID TEST (continued) FIGURE F.3 – FUEL SHUTDOWN SOLENOID LOC TION SHUTDOWN SHUTDOWN SOLENOID SOLENOID IDLE IDLE SOLENOID SOLENOID TEST PROCEDURE Apply 12VDC to the hold coil, leads, (black-) to (red+) While the voltage is applied, manually move Turn the engine off.
  • Page 84 RANGER 305D TROUBLESHOOTING & REPAIR FUEL SHUTDOWN SOLENOID TEST (continued) FIGURE F.4 – FUEL SOLENOID CONNECTIONS GND-L BLACK 225B TO FRAME TO "D-4" WHITE TO STARTER SOLENOID FUEL SOLENOID FUEL SOLENOID WIRING HARNESS CONNECTOR CONNECTOR (LEAD ENTRY VIEW) (LEAD ENTRY VIEW) F 27...
  • Page 85 RANGER 305D TROUBLESHOOTING & REPAIR F 28...
  • Page 86 ENGINE THROTTLE DJUSTMENT TEST W RNING 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.
  • Page 87 RANGER 305D TROUBLESHOOTING & REPAIR ENGINE THROTTLE DJUSTMENT TEST (continued) FIGURE F.5 – STROBE M RK LOC TION ENGINE SPEED CONTROL LEVER FAN HUB STROBE TACH MARK TEST PROCEDURE the rotating mark. See the strobe-tach manufacturer instructions. The tach should read between 3625 and 3675 Strobe-Tach Method RPM.
  • Page 88 120VAC auxiliary receptacles. NOTE: For the Ranger 305D, and any other Lincoln Electric Start the engine and place the idle switch in the 3600 RPM (2 Pole) machine, engine RPM can be “HIGH IDLE”...
  • Page 89 RANGER 305D TROUBLESHOOTING & REPAIR ENGINE THROTTLE DJUSTMENT TEST (continued) Vibratach Method If the low idle RPM requires adjustment, loosen the low idle adjustment jam nuts. Turn both nuts A Vibratach is used to measure the vibrations caused by so they are clear of the swivel fitting. Rotate the the running engine.
  • Page 90 IDLER SOLENOID TEST W RNING 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.
  • Page 91 RANGER 305D TROUBLESHOOTING & REPAIR IDLER SOLENOID TEST (continued) FIGURE F.7 – PLUG(S) PIN LOC TION P-72 J-72 210A START BUTTON BLACK WHITE TO CONTROL PULL COIL P.C. BOARD P.C. BOARD IDLE SOLENOID IDLE SOLENOID WIRING HARNESS CONNECTOR CONNECTOR (LEAD ENTRY VIEW) (LEAD ENTRY VIEW) TEST PROCEDURE Apply 12VDC to the hold-in coil at pin #3...
  • Page 92 TROUBLESHOOTING & REPAIR ENGINE LTERN TOR TEST 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.
  • Page 93 RANGER 305D TROUBLESHOOTING & REPAIR ENGINE LTERN TOR TEST (continued) FIGURE F.8 – LE D LOC TIONS BATTERY IGNITION OIL PRESSURE SWITCH TEST PROCEDURE back of the alternator. (Lead #209) See Figure F.8. See Wiring Diagram. Turn the engine off. The meter should read about 13.7 to 14.2 VDC.
  • Page 94 TROUBLESHOOTING & REPAIR BRUSH ND SLIP RING SERVICE PROCEDURE 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.
  • Page 95 RANGER 305D TROUBLESHOOTING & REPAIR BRUSH ND SLIP RING SERVICE PROCEDURE (continued) TEST PROCEDURE 7. If there is any evidence that the brushes may have been sticking in the brush hold- ers, a new brush holder and brush assem- 1. Perform the Case Cover Removal bly should be installed..
  • Page 96 ROTOR RESIST NCE ND GROUND TEST (ST TIC) W RNING 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.
  • Page 97 RANGER 305D TROUBLESHOOTING & REPAIR ROTOR RESIST NCE ND GROUND TEST (ST TIC) (continued) FIGURE F.9 – ROTOR BRUSH LE DS SLIP RINGS BRUSHES LEADS 200A LEADS TEST PROCEDURE Turn the engine off. Measure the resistance to ground. Place one meter probe on either of the slip rings.
  • Page 98 ( lso referred to as flying resistance test) 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.
  • Page 99 RANGER 305D TROUBLESHOOTING & REPAIR ROTOR RESIST NCE ND GROUND TEST (DYN MIC) (continued) TEST PROCEDURE 4. Shut off engine, and move one of the ohm- This test requires that the brushes and slip rings meter leads to a good clean chassis are clean, in good condition, and are properly ground.
  • Page 100 ROTOR VOLT GE TEST W RNING 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.
  • Page 101 RANGER 305D TROUBLESHOOTING & REPAIR ROTOR VOLT GE TEST (continued) FIGURE F.10 – LE D LOC TIONS SLIP RINGS BRUSHES LEADS 200A LEADS TEST PROCEDURE intrusion from one of the higher voltage stator windings to the stator exciter winding. Perform the Engine Throttle Adjustment Test, and the Perform the Case Cover Removal procedure.
  • Page 102 RANGER 305D TROUBLESHOOTING & REPAIR ROTOR VOLT GE TEST (continued) If the meter reading indicates battery voltage, necessary, disconnect and isolate the stator about 12 to 14 VDC, the rotor may be open, or output leads as close to the starter as possible. See wiring diagram.
  • Page 103 RANGER 305D TROUBLESHOOTING & REPAIR F 46...
  • Page 104 FL SHING VOLT GE TEST (Engine Not Running) 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.
  • Page 105 RANGER 305D TROUBLESHOOTING & REPAIR FL SHING VOLT GE TEST (continued) TEST PROCEDURE 11. If the voltage measures zero or very near zero; this condition could be caused by a poor connection or a defective component 1. Perform the Case Cover Removal in the flashing circuit, or a shorted rotor Procedure.
  • Page 106 RANGER 305D TROUBLESHOOTING & REPAIR FL SHING VOLT GE TEST (continued) FIGURE F.11 – EXCITER LE DS T1, T2, T3 ENGINE ALTERNATOR #229 OIL PRESSURE SWITCH OIL FILTER 16. If battery voltage is present at leads #210H the chassis. and #224B, but not present at leads #200N The Control PC board is probably defective.
  • Page 107 RANGER 305D TROUBLESHOOTING & REPAIR F 50...
  • Page 108 ST TOR VOLT GE TESTS W RNING 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.
  • Page 109 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR VOLT GE TESTS (continued) FIGURE F.12 – RECEPT CLE LE D LOC TIONS (TYPIC L) GROUND AMPHENOL 1 CONTACTOR CONTROL 120 VAC FOR WIRE FEEDER REMOTE 40 VAC FOR WIRE FEEDER CONTROL 21 WORK SENSE 2 TIMES THRU FERRITE LEADS 75A, 76A, &...
  • Page 110 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR VOLT GE TESTS (continued) FIGURE F.13 – RECTIFIER BRIDGE DET IL NEG. POS. W4,W5 W6,W11 FROM SHUNT To test the 120 V C wire feeder supply: Start the engine and run it at high idle (3625 to 3675 RPM).
  • Page 111 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR VOLT GE TESTS (continued) To test the 42 V C wire feeder winding: they connect to the three-phase output bridge rectifier. See Figure F.13. See wiring diagram. Connect the voltmeter probes to pins “I” (lead 41A) Start the engine and run it at high idle (3625 to and “K”...
  • Page 112 ST TOR SHORT CIRCUIT & GROUND TEST W RNING 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.
  • Page 113 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR SHORT CIRCUIT & GROUND TEST (continued) FIGURE F.14 – WELD CONTROL BO RD GROUND AMPHENOL 1 CONTACTOR CONTROL 120 VAC FOR WIRE FEEDER REMOTE 40 VAC FOR WIRE FEEDER CONTROL 21 WORK SENSE 2 TIMES THRU FERRITE LEADS 75A, 76A, &...
  • Page 114 OUTPUT RECTIFIER BRIDGE TEST W RNING 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.
  • Page 115 RANGER 305D TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.15 TEST PROCEDURE Remove leads W4, W5, and W10 from the positive terminal of the Rectifier, and remove leads W6 and Turn the engine off. W11 from the negative terminal. Position these leads so they do not come to contact with any part Perform the Case Cover Removal procedure.
  • Page 116 RANGER 305D TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) Test all of the diode groups per the Table F.1. Check for grounds by placing one of the ohm meter probes on a clean, unpainted metal surface of the machine. Touch the other probe to each of the five rectifier terminals.
  • Page 117 RANGER 305D TROUBLESHOOTING & REPAIR TABLE F.1 – DIODE TEST TABLE TEST INSTRUMENT READING DIODE BIAS (-) LEAD (+) LEAD AND EXPECTED TEST RESULT FORWARD BIAS DC(+) (LOW RESISTANCE) FORWARD BIAS DC(+) (LOW RESISTANCE) FORWARD BIAS DC(+) (LOW RESISTANCE) FORWARD BIAS DC(-) (LOW RESISTANCE) FORWARD BIAS...
  • Page 118 CHOPPER MODULE FUNCTION TEST W RNING 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.
  • Page 119 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE FUNCTION TEST (continued) FIGURE F.17 – POWER MODULE CONNECTIONS HL W11 HL W6 HL W5 HL W4 HL W9 HL W8 SL302 SL13 SL301 SL14 TEST PROCEDURE present, disconnect leads #23 and #25 from the chopper module PC board.
  • Page 120 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE FUNCTION TEST (continued) TEST PROCEDURE (CONTINUED) If the weld control board is producing a PWM gate signal, check th e#23 and #25 leads for damaged conductors and faulty connections between the control PC board and the chopper module. If about 58 VDC is present at chopper module If testing is complete, Perform the Case Cover terminals B2+ to B3-, and B5+ to B6-, but not at...
  • Page 121 RANGER 305D TROUBLESHOOTING & REPAIR F 64...
  • Page 122 CHOPPER MODULE RESIST NCE TEST W RNING 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.
  • Page 123 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE RESIST NCE TEST TEST PROCEDURE Perform the Case Cover Removal Procedure. Perform the Capacitor Discharge Procedure. Check that all of the leads connected to the chopper module terminals are clearly marked to facilitate reassembly. Remove all of the leads from the chopper module and position them so they do not make electrical contact with any part of the module.
  • Page 124 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE RESIST NCE TEST (continued) TABLE F.2 – DIODE TEST TABLE OHMMETER OHMMETER READING DIODE BIAS (-) LEAD (+) LEAD AND EXPECTED TEST RESULT 6K TO 9K 6K TO 9K 200K OR HIGHER 400K OR HIGHER 200K OR HIGHER 400K OR HIGHER 6K TO 9K...
  • Page 125 RANGER 305D TROUBLESHOOTING & REPAIR F 68...
  • Page 126 WELD CONTROL BO RD PWM G TE SIGN L TEST 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.
  • Page 127 RANGER 305D TROUBLESHOOTING & REPAIR WELD CONTROL BO RD PWM G TE SIGN L TEST (continued) TEST PROCEDURE 13. Test for 80 to 100 VDC at the terminals where the #13 and #14 leads connect to the chopper module. See the wiring diagram. 1.
  • Page 128 TROUBLESHOOTING & REPAIR WELD CONTROL FEEDB CK TEST 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.
  • Page 129 RANGER 305D TROUBLESHOOTING & REPAIR WELD CONTROL FEEDB CK TEST (continued) TEST PROCEDURE 9. If the readings differ significantly, continue 1. Place the idle switch in the “HIGH IDLE” with this procedure position. 10. Turn off the engine and release the load 2.
  • Page 130 RANGER 305D TROUBLESHOOTING & REPAIR WELD CONTROL FEEDB CK TEST (continued) 16. If the voltage readings are different, check 20. To calculate the correct millivolt signal for a the wiring and connections between the given load, you divide the number of amps welding terminals and the control PC board.
  • Page 131 RANGER 305D TROUBLESHOOTING & REPAIR F 74...
  • Page 132 CONTROL POTENTIOMETER ND MODE SWITCH RESIS- T NCE TEST 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.
  • Page 133 RANGER 305D TROUBLESHOOTING & REPAIR CONTROL POTENTIOMETER ND MODE SWITCH RESIST NCE TEST (continued) TEST PROCEDURE If the resistance is lower than 500k Ohms, replace the potentiometer and mode switch plug and lead assembly, or replace the defective component within the assembly. See wiring diagram. Turn the engine off Perform the resistance tests per Table F.3.
  • Page 134 RANGER 305D TROUBLESHOOTING & REPAIR CONTROL POTENTIOMETER ND MODE SWITCH RESIST NCE TEST (continued) T BLE F.3 POT/MODE SWITCH RESISTANCE TEST MODE SWITCH OHMMETER OHMMETER SETTING READING CONNECTION CC-STICK P7-9 (#214) TO P7-14 (#218) 500K OR HIGHER CC-STICK P7-9 (#214) TO P7-15 (#220) 500K OR HIGHER CC-STICK P7-9 (#214) TO P7-16 (#222)
  • Page 135 RANGER 305D TROUBLESHOOTING & REPAIR F 78...
  • Page 136 TROUBLESHOOTING & REPAIR REMOTE RECEPT CLE RESIST NCE TEST 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.
  • Page 137 RANGER 305D TROUBLESHOOTING & REPAIR F 80...
  • Page 138 RANGER 305D TROUBLESHOOTING & REPAIR REMOTE RECEPT CLE RESIST NCE TEST (continued) FIGURE F.18 AMPHENOL 1 TEST PROCEDURE contamination and drying the components completely. If the resistance values are still too low, replace the Amphenol harness assembly. Turn the machine off. Perform the Case Cover Removal Procedure.
  • Page 139 RANGER 305D TROUBLESHOOTING & REPAIR REMOTE RECEPT CLE RESIST NCE TEST (continued) T BLE - F.4 AMPHENOL RESISTANCE TEST OHMMETER WELDING TERMINAL OHMMETER READING CONNECTION SWITCH SETTING PIN “G” (#75B) TO PIN “Å” (#32) 500K OR HIGHER PIN “G” (#75B) TO PIN “B” (GND-A) 500K OR HIGHER PIN “G”...
  • Page 140 RANGER 305D TROUBLESHOOTING & REPAIR F 83...
  • Page 141 OUTPUT RECTIFIER BRIDGE ND CHOKE REMOV L ND REPL CEMENT 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.
  • Page 142 RANGER 305D TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE ND CHOKE REMOV L ND REPL CE- MENT (continued) REMOV L PROCEDURE 3. Carefully remove the choke. REPLACEMENT PROCEDURE 1. Turn the engine off. Replacing the Output Choke 2. Remove negative battery cable. 1.
  • Page 143 RANGER 305D TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE ND CHOKE REMOV L ND REPL CE- MENT(continued) Replacing the Output Rectifier 6. Reconnect all of the leads and plugs that were disconnected during the removal 1. Place the Output Rectifier into the machine so procedure, and replace any cable ties that its mounting studs fit into the holes in the that were removed.
  • Page 144 RANGER 305D TROUBLESHOOTING & REPAIR F 87...
  • Page 145 CHOPPER MODULE REMOV L ND REPL CEMENT 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.
  • Page 146 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE REMOV L ND REPL CEMENT (continued) FIGURE F.19 – EXCITER LE DS T1, T2, T3 HL W11 HL W6 HL W5 HL W4 HL W9 HL W8 SL302 SL13 SL301 SL14 PROCEDURE Removal 7.
  • Page 147 RANGER 305D TROUBLESHOOTING & REPAIR CHOPPER MODULE REMOV L ND REPL CEMENT(continued) Replacement 4. Replace any cable ties cut at disassembly. 1. Mount the heat sink to the brackets on the vertical baffle with the three 3/8” screws. 5. When procedures are complete, perform the Mount the plastic strip with the top two Case Cover Replacement procedure.
  • Page 148 RANGER 305D OPERATION F 91...
  • Page 149 ST TOR/ROTOR REMOV L ND REPL CEMENT 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.
  • Page 150 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR/ROTOR REMOV L ND REPL CEMENT (continued) FIGURE F.20 – B TTERY PL CEMENT Battery Terminals Remove Through Here TEST PROCEDURE and bolts holding it to the engine mounting bracket. Turn engine off. Clearly mark all stator leads to insure proper reconnection.
  • Page 151 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR/ROTOR REMOV L ND REPL CEMENT (continued) FIGURE F.21 – WIRE GUIDE HOLE HOLE FIGURE F.22 – LTERN TOR LE DS BATTERY IGNITION OIL PRESSURE SWITCH F 94...
  • Page 152 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR/ROTOR REMOV L ND REPL CEMENT (continued) The wires connected to the solenoid side of the Rotate the engine and generator assembly 180 engine can remain attached, in most cases. degrees and line up the engine mounting bracket to the rubber engine mounts.
  • Page 153 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR/ROTOR REMOV L ND REPL CEMENT (continued) FIGURE F.23 – DISC/RING LOC TION COUPLING DISC CLAMPING RING F 96...
  • Page 154 RANGER 305D TROUBLESHOOTING & REPAIR ST TOR/ROTOR REMOV L ND REPL CEMENT (continued) Replacing the Stator Attach the hoist to the lift bale to support the engine and stator assembly. Remove the support blocks, remove the screws from the engine support Examine the stator frame assembly.
  • Page 155 RANGER 305D TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (120VAC SUPPLY) HIGH IDLE – NO LOAD 16.4 ms 0 volts 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 rep- resents 5 milliseconds in time.
  • Page 156 RANGER 305D TROUBLESHOOTING & REPAIR NORM L OPEN CIRCUIT VOLT GE W VEFORM (STICK) M X CONTROL POT - HIGH IDLE - NO LO D 0 volts This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal divi- sion represents 5 milliseconds in...
  • Page 157 RANGER 305D TROUBLESHOOTING & REPAIR NORM L WELD VOLT GE W VEFORM (STICK CC) M CHINE LO DED TO 300 MPS T 27 VOLTS Trig +15V 0 volts This is the typical DC output voltage generated from a properly operating machine.
  • Page 158 RANGER 305D TROUBLESHOOTING & REPAIR NORM L OPEN CIRCUIT VOLT GE W VEFORM (WIRE CV T P) M X CONTROL POT - HIGH IDLE - NO LO D 0 volts This is the typical DC open circuit output voltage generated from a properly operating machine.
  • Page 159 RANGER 305D TROUBLESHOOTING & REPAIR NORM L WELD VOLT GE W VEFORM (WIRE CV) M CHINE LO DED TO 300 MPS T 28 VOLTS 0 volts This is the typical DC voltage gener- ated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 1 millisecond in time.
  • Page 160 RANGER 305D TROUBLESHOOTING & REPAIR RETEST FTER REP IR 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 charac- teristics. • If you repair or replace any electrical components. ENGINE OUTPUT MODE NO LOAD RPM...

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