Table Of Contents - Lincoln Electric RANGER 305D SVM175-A Service Manual

Table of Contents

Safety2
Return To Main Menu6
Table Of Contents7
Installation8
Technical Specifications8
Safety Precautions10
Location And Ventilation10
Storing10
Angle Of Operation10
Lifting11
High Altitude Operation11
High Temperature Operation11
Vehicle Mounting11
Pre-Operation Engine Service12
Oil12
Fuel12
Engine Cooling System12
Remote Control13
Electrical Output Connections13
Machine Grounding13
Ranger 305D Output Connections13
Welding Output Cables14
Cable Installation14
Auxiliary Power Receptacles14
Standby Power Connections14
Connection Of Ranger 305D To Premises Wiring16
Operation Section17
Operating Instructions18
Safety Instructions18
Additional Safety18
General Description18
Operation19
Design Features19
Control And Settings19
Engine Controls20
Glow Plug Push Button20
Start Push Button20
Engine Alternator Trouble Light20
Welding Controls21
Output Control21
Arc Control21
14-Pin Amphenol21
Engine Operation22
Before Starting The Engine22
Starting The Engine22
Stopping The Engine22
Break-In Period23
Stick Welding23
Constant Current Welding23
Downhill Pipe Welding23
Tig Welding24
Wire Welding-Cv24
Arc Gouging24
Auxiliary Power24
Simultaneous Welding And Auxiliary Power Loads25
Accessories27
Field Installed Options28
Tig Welding Accessories28
Semiautomatic Fcaw And Mig Welding Accessories28
Connection Of Lincoln29
Electric Wire Feeders29
Connection Diagram29
Connection Of The Ln-25 To The Ranger 305D30
Across The Arc Connection Diagram30
Connection Of The Ln-25 To The Ranger 305D With 42 Volt31
Control Cable Connection Diagram33
Maintenance37
Routine And Periodic Maintenance38
Engine Maintenance38
Maintenance Schedule39
Engine Oil Change40
Engine Oil Refill Capacities40
Oil Filter Change40
Service Instructions & Installation Tips41
Air Cleaner42
Cooling System42
Tightening The Fan Belt42
Fuel System Service43
Bleeding The Fuel System43
Fuel Filter43
Engine Adjustment43
Cleaning The Battery44
Checking The Electrolyte Level44
Charging The Battery44
Optional Spark Arrestor44
Gfci Receptacle Testing And Resetting Procedure45
Major Component Locations46
Theory Of Operation Section47
Ranger 305D Block Logic Diagram47
Battery48
Engine Idle System49
Idle Switch Operation49
Idle Solenoid Operation49
Generating Power50
Flashing50
Building Output50
Ac Output50
Weld Power And Control51
Weld Control And Feedback51
Remote Output Control52
Electronic Output Contactor52
Digital Meters52
Chopper Technology Fundamentals53
Igbt Operation54
Pulse Width Modulation54
Minimum Output54
Maximum Output54
Troubleshooting & Repair Section55
How To Use Troubleshooting Guide56
Locate Problem56
Perform External Tests56
Perform Component Tests56
Pc Board Troubleshooting Procedures57
Case Cover Removal And Replacement Procedure75
Test Description75
Door Removal76
Removal Procedure76
Replacement Procedure76
Locking Tab76
Chopper Module Capacitor Discahrge Procedure77
Fuel Shutdown Solenoid Test79
Fuel Shutdown Solenoid Location80
Fuel Solenoid Connections81
Engine Throttle Adjustment Test83
Strobe Mark Location84
Strobe-Tach Method84
Solenoid85
Throttle Adjustment Procedure86
Vibratach Method86
Low Idle Adjustment86
High Isle Adjustment86
Idler Solenoid Test87
Plug(S) Pin Location88
Engine Alterantor Test89
Lead Locations90
Brush And Slip Ring Service Procedure91
Cleaning Slip Rings92
Seating Brushes92
Rotor Resistance And Ground Test (Static)93
Rotor Brush Leads94
Slip Rings94
Rotor Voltage Test97
Flashing Voltage Test101
Exciter Leads T1, T2, T3103
Oil Pressure Switch103
Oil Filter103
Stator Voltage Tests105
Receptacle Lead Locations106
To Test The 120 Vac Auxiliary Winding106
To Test The 240 Vac Auxiliary Winding106
Rectifier Bridge Detail107
To Test The 120 Vac Wire Feeder Supply107
To Test The 42 Vac Wire Feeder Winding108
To Test The Three-Phase Weld Winding108
Stator Short Circuit & Ground Test109
Weld Control Board110
Output Rectifier Bridge Test111
Shunt/Rectifier Leads113
Diode Test Table114
Chopper Module Function Test115
Power Module Connections116
Chopper Module Resistance Test119
Weld Control Board Pwm Gate Signal Test123
Weld Control Feedback Test125
Control Potentiometer And Mode Switch Resistance Test129
Pot/Mode Switch Resistance Test131
Remote Receptacle Resistance Test133
Amphenol 1134
Output Rectifier Bridge And Choke Removal And Replacement137
Removing The Output Rectifier138
Removing The Output Choke138
Replacing The Output Choke138
Replacing The Output Rectifier139
Chopper Module Removal And Replacement141
Stator/Rotor Removal And Replacement145
Battery Placement146
Wire Guide Hole147
Alternator Leads147
Disc Ring Location149
Removing The Rotor149
Replacing The Rotor149
Clamping Ring149
Replacing The Stator150
Normal Open Circuit Voltage Waveform151
High Idle - No Load151
Scope Settings151
Normal Open Circuit Voltage Waveform (Stick)152
Max Control Pot - High Idle - No Load152
Normal Weld Voltage Waveform (Stick Cc)153
Machine Loaded To 300 Amps At 27 Volts153
Normal Open Circuit Voltage Waveform (Wire Cv Tap)154
Normal Weld Voltage Waveform (Wire Cv)155
Retest After Repair156
Engine Output156
Welder Dc (Stick) Output156
Electrical Diagrams Section157
Ranger 305D- Kubota - Wiring Diagram158
Ranger 305D Ce Kubota Wiring Diagram - Uk161
Ranger 305D Ce Kubota - Wiring Diagram - Europe164
Ranger 305D Ce Kubota Wiring Diagram -Europe166
Electrical Diagrams167
Machine Schematic168