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CHANGE DETAIL:
NEW
E N G IN E E R IN G C O N T R O L L E D
No
L12213-1
M A N U FA C T U R E R :
R4 is located on front of
POSITIVE
Shunt on back of positive
SH UNT
fan baffle near top of
output terminal
OUTPUT
50MV= 400 AMPS
machine
TERMINAL
206B
206S 204S
WELD CURRENT
FEED BACK SIGNAL
206A
206C
BY-PASS
WIREFEEDER
PC BOARD
VOLTMETER
21
Located on back of
208C
POLARITY
output panel
SWITCH
between terminals
208
208A
NEGATIVE
OUTPUT
L1 CH O KE
2 TURNS
TERMINAL
THRU
Power Supply
Choke is beneath bearing end
FERRITE
to Control
of generator on support.
Open Circuit Volts:
L6
Board
Max
Min
L3
2 TURNS
L5
CC
58
58
THRU
TWISTED
58
CV
58
FERRITE
2 TURNS
PAIR
TWISTED
Pipe
26
58
THRU FERRITE
PAIR
Tig
12
12
Control Board senses Weld Output
13 (J3-8)
from Current Feedback Shunt
204S (J6-1)
to activate idler.
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
208B (J3-15)
10 V
77 (J7-1)
OUTPUT
0-10 V
R1
76 (J7-4)
CONTROL 10K
0 V
75 (J7-5)
10 V
77A (J1-11)
REMOTE
-15 V (W/O POT.)
(TO AMPHENOL)
76A (J1-14)
CONTROL 10K
0 V
75A (J1-10)
279 (J7-6)
ARC
R2
278 (J7-7)
CONTROL 10K
277 (J7-8)
TOROID-
SENSES AC
260A (J3-4)
POWER TO
261A (J3-3)
ACTIVATE
IDLER
Located on wiring behind
receptacles.
5K (J2-3)
Control board circuits associated with J2 a re part
(J4-1 to 10)
of engine electrical system and are common to
frame ground (negative battery terminal.
L8
WELD AMMETER
Meters display setpoint volts o r amps when not welding.
Meters display actual volts and am ps when welding.
Hold function displays actual volts and a m ps for
approximately 5 sec onds after welding stops.
During this hold display the right most decimal point w ill
blink.
42VAC
WORK
A
77B
REMOTE
B
REMOTE
76B
CONTROL
CONTROL
C
75B
D
2B
CONTACTOR
E
4B
F
GND-B
GROUND
GROUND
AMPHENOL
AMPHENOL
This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CHOPPER PC BOARD
IGBT'S, FLYBACK DIODES AND
p/n
Recti f ier mounted to generator support
FILTER CAPACITORS ARE INTEGRAL
above output choke.
L11845-1
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
D1 - THREE PHASE BRIDGE RECTIFIER
+COM
B2
B5
10,000uF x4
Chopper is mounted on the back side of fan
baffle near top of machine. Requi r es added
+
FLYBACK
baffle for cooling ai r flow.
R4
DIODES (6)
50 OHM
DC BUS VOLTAGE
FILTER
100 W
90+/-10VDC @ HI IDLE
CAPACITORS (4)
IGBT (8)
B3
B1
E
C
-OUTPUT
-INPUT
B6
B4
PWM Signal to Chopper
15 volt @ 20 kHz
B7
B8
GATE SIGNAL
Rotor Flashing: +12 volts
TWISTED
@ 0.5 amps
PAIR
R3 located on front of fan baffle
until generator builds up
on left side nea r bottom of
then +50 volts @ 0 amps.
machine
23 (J3-10)
14 (J3-16)
25 (J3-9)
R3 25 OHM
ROTOR FLASHING
(J2-1) 200N
LOW IDLE SOLENOID HOLD COIL (0V @ LO W IDLE)
(J2-5) 215
Control board common is
at welder positive output
+15V @ LOW IDLE TO PULL COIL BOARD
(J2-4) 404
and shunt
0 V
WELD CONTROL
Swich closed for high
(J3-14) 252
IDLER SWITCH
idle.
2 TURNS THRU
PC BOARD
(J3-7) 251
FERRITE
15 V
2A
(TO AMPHENOL)
15 V
L2
(J1-4) 2
P/N G4107-1
WELD TERM. SW.
(J1-3) 4
0 V
(TO AMPHENOL)
CV
4A
Located on front of fan
(J7-9) 214
PIPE
baffle near top of
(J7-14) 218
MODE
machine.
CC
SWITCH
TIG
(J7-15) 220
(J7-16) 222
+12 to 14V @ NORMAL OIL PRES. (INPUT)
(J2-9) 224B
+12 to 14V @ RUN (INPUT)
(J2-7) 210B
GLOWPLUG
SWITCH S7
(J1-7) 305
(J1-12) 305
(J5-1 to 10)
All leads
All leads
305 I.D. JUMPER (Part
1 time thru
1 time thru
15A BATTERY
of amphenol plug and
ferrite
L7
ferrite
CIRCUIT BREAKER
lead assembly.)
209
WELD VOLTMETER
START BUTTON
SWITCH S2
2 TURNS THRU
FERRITE
J
31
209
NO CONNECTION
A
32
I
41A
K
42A
H
21
E
BAT
77A
L4
77B
F
IGN
76A
76B
INPUT TO
G
75A
L
75B
AMPHENOL
D
4A
ALTERNATOR
4B
C
2A
2B
Battery voltage:
B
GND-A
12.6 volts at rest
14 volts engine
4
1
running
FUEL SENDER
FUEL
GAUGE
PROPRIETARY & CONFIDENTIAL:
240-265 OHMS EMPTY
UNLESS OTHERW
ISE SPEC IF IE D TOLERAN CE
20-35 OHMS FULL
MANUFAC TURIN G TOLERANCE PER E205
ON 2 PLAC E DECIMA LS IS ± .02
O N 3 P LACE D ECIM ALS IS ± .002
ON ALL ANG LES IS ± .5 OF A DEGREE
MA TERIA L TOL ERANCE ("
t
WITH PUB LISHED S TANDARDS.
DO N O T SCALE TH IS D RAW IN G
W1
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W2
TWO POLE 3600 RPM ALTERNATOR
W3
C
D
TO AUX.
A-B-C 400 VAC, 3 PH.
SLIP RINGS
A-5
A
OUTLETS
B-5
230 VAC, 1 PH.
200
5
C-5
200A
D-E 115 VAC, 1 PH.
E
CENTER-TAP
AND
B
EARTH
41
AMPHENOLS
(VIA CIRCUIT
42 VOLT AC
201
WIRE FEEDER
BREAKERS)
5H
POWER
42
REVOLVING FIELD
42 VOLT AC
FIELD RESISTANCE
POWER FOR
APPROX. 5 OHMS @ 75F
ROTOR FI E LD CIRCUIT
7
9
210
GLOWPLUG SWITCH ENERGIZES
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
ELECTRIC FUEL PUMP AND FUEL
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
GLOWPLUGS
SOLENOID HOLD COIL THRU D4. IT
SHUTTING OFF FUEL S OLENOID TO STOP ENGINE.
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
ENGINE
PRESSURE BUILDS UP.
PROTECTION
223
RELAY
B
7
9
S1
212
RUN-STOP SWITCH
CR1
(SHOWN IN RUN)
1
3
A
210
210
211
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
D4
STARTER SOLENOID.
231
225
J73-4
209
J73-2
P73-4
P73-2
STARTER
FUEL
+
SOLENOID
WHITE
RED
SOLENOID
12 VOLT
PULL
BATTERY
0.2 OHM
STARTER
HOLD
MOTOR
11 OHMS
FRAME
OIL PRESSURE
BLACK
GROUND
P73-3
SWITCH
FUEL
(CLOSES ON
SOLENOID
J73-3
LOW OIL
AND FUEL
PRESSURE)
PUMP
ENERGIZED
FOR RUN
THIS D O C UME NT C O NTAINS PR OP RIETARY INF
O RMATION
O W NE D BY LINC OLN GLOBAL, INC. A
TO OT HE R PARTIES O
R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION
RANGER 305D CE (UK)
EQUIPMENT TYPE:
REFERENCE:
DESIG N INFO RM ATIO N
6
L12213
MACHINE SCHEMATIC
DRAW N BY:
MAP
SUBJECT:
SCALE:
") TO AGREE
E NG IN EER:
BAM
MATERIAL
APPROVAL
PROJECT
NA
CRM35578
07/15/2004
NONE
-
APPRO VED:
DISPOSITION:
DATE:
NUMBER:
C3 and D3 locate d on rear of fan baffle
on left side of machine.
50 V DC
+
C3
D
800uf
3
150vdc
Relay CR1 and D4 locate d on fron
baffle on right side of machin e.
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
P72-3
IDLE
BLACK
SOLENOID
YELLOW
PULL
ENGINE
0.2 OHM
PROTECTION
HOLD
LIGHT
11 OHMS
WHITE
RED
P72-4
P72-2
215
PL
J72-4 J72-2
1
232
+
224
HOUR METER
+15V @ LOW
IDLE
229
B2
404 (J43-8)
TIMER
CIRCUIT
B1
PULL COIL
PC BOARD
COOLANT
B4
TEMPERATURE
P/N
L11768-1
SWITCH
Located next to
(CLOSES ON HIGH
control board.
TEMPERATURE
ABOVE 230F)
N D MAY N OT BE D UPLICATE D, COMMU NICATE D
OF LIN C OLN GLOBAL, INC.
2
1
PA GE ___ O F ___
DOCUMENT
DOCUMENT
NUMBER:
REVISION:
L12213-1
A
RANGER 305D
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Troubleshooting
