Lincoln Electric RANGER 305G EFI Service Manual page 84

LINCOLN ELECTRIC
REPLACEMENT PROCEDURE
1. If necessary attach the screws, rotor clamping ring and coupling disc to the rotor hub.
2. Attach the screws and disc clamping bars to the rotor coupling disc and secure the rotor to the
engine.
3. Carefully slide the stator frame onto the rotor.
4. Using a 9/16" open-end wrench, attach the four bolts and lock washers securing the stator frame to
the engine.
5. Remove the wood blocking from beneath the engine.
6. Carefully slide the fuel tank assembly into the machine.
7. Connect leads 230, 5L and 5M to the fuel sender. See Wiring Diagram.
8. Using a 5/8" socket, attach the large bolt and centering washer securing the plastic blower to the
rotor shaft. It may be necessary to prevent the rotor shaft from turning; a small pipe wrench can be
used for this purpose. DO NOT HOLD THE ROTOR BY THE SLIP RINGS.
9. Carefully slide the stator support into the machine.
10. Using a 7/16" nutdriver, attach the ten screws securing the stator support to the machine base.
11. Adjust the hoist to lift the engine and stator frame assembly to place the stator frame onto the
stator frame mounting studs.
12. Using a 9/16" deep well socket and a 9/16" open-end wrench, attach the two nuts, lock washers,
bolts and four washers securing the generator to the support bracket.
13. Carefully position the firewall into the machine.
14. Connect any previously disconnected leads as necessary and rout leads thru the firewall.
15. Attach the fuel return line to the fitting in the top of the fuel tank.
16. Compress the spring clamp and attach the fuel line to the fuel filter/shut-off valve.
17. Pull all of the stator leads through the hole in the blower baffle assembly. Wrap leads 3 and 6
around the toroidal current transformer. See Wiring Diagram for the number and direction of turns
around the toroidal current transformer.
18. Connect all previously disconnected stator winding leads. See Wiring Diagram.
19. Carefully position the brush holder assembly back into the machine.
20. Using a 7/16" socket and a 7/16" open-end wrench, attach the two nuts, bolts, lock washers and
four flat washers securing the brush holder to the stator frame.
21. Connect leads 201, 5H, 200A and 200 to the brush terminals. See Wiring Diagram.
22. Carefully position the blower baffle into the machine.
23. Using a 3/8" nutdriver, attach the four screws securing the blower baffle to the machine.
24. Connect any previously disconnected leads to the components mounted on the blower baffle. See
Wiring Diagram.
25. Perform the Weld Control Board Replacement Procedure.
26. Perform the Chopper Module Board Replacement Procedure.
27. Perform the Idle Solenoid Replacement Procedure.
28. Perform the Output Rectifier Bridge And Choke Replacement Procedure.
29. Perform the Case Cover Replacement Procedure.
30. Perform the Retest After Repair Procedure.
Ranger® 305G EFI Service Manual
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