Lincoln Electric RANGER 305G EFI Service Manual
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Lincoln Electric RANGER 305G EFI Service Manual

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RANGER ® 305G EFI
For use with machines having Code Numbers:
Ranger 305G EFI: 12157, 12206, 12653
SERVICE MANUAL
SVM280
| Issue D ate 17-Nov
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric RANGER 305G EFI

  • Page 1 RANGER ® 305G EFI For use with machines having Code Numbers: Ranger 305G EFI: 12157, 12206, 12653 SERVICE MANUAL SVM280 | Issue D ate 17-Nov © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY 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 eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY 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 welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Ranger® 305G EFI Service Manual Last update: 2017/11/01 RANGER® 305G EFI ............................1 Service Manual ..............................1 Troubleshooting & Repair ..........................3 HOW TO USE TROUBLESHOOTING GUIDE ..................... 3 PC BOARD TROUBLESHOOTING PROCEDURES ....................4 Troubleshooting guide ............................
  • Page 7 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual IDLE SOLENOID TEST PROCEDURE....................... 62 Removal And Replacement Procedures ...................... 64 OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT PROCEDURE ......64 FIELD BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE ............68 WELD CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE ............70 CHOPPER MODULE BOARD REMOVAL AND REPLACEMENT PROCEDURE ..........

  • Page 8: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE 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 9: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.

  • Page 10: Troubleshooting Guide

    RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical 1. Contact your local 1. Contact the Lincoln Electric damage is evident. authorized Lincoln Electric Service Department at 1-888- Service Facility. 935-3877. No welding output or auxiliary 1. Check for loose or faulty 1.
  • Page 11 4. Perform the Stator Voltage Test Procedure. 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 12 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELD OUTPUT PROBLEMS The machine will weld, but the 1. Make sure the machine is 1.
  • Page 13 Test Procedure. Replace the weld control board. 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 14 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELD OUTPUT PROBLEMS The machine welds, but it will 1. This condition may be 1.
  • Page 15 8. Replace the weld control board. 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 16 3. The weld control board may be defective. 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 17 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELD OUTPUT PROBLEMS The machine seems to be 1. Check the position of the 1.
  • Page 18 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 19 3. Perform the Stator Voltage Test Procedure. 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 20 5. The wire feeder may be defective. 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 21 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 22 5. Check the oil level. 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 23 3. The air filter may be clogged; replace if necessary. 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 24 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ENGINE AND IDLE PROBLEMS The engine will not idle down 1. Make sure the idle switch is 1.
  • Page 25 Ranger® 305G EFI Service Manual defective. Replace it. 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 26 7. The weld control board may be defective. 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 27 4. The weld control board may be defective. 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 28: Test Procedures

    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 29 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual REPLACEMENT PROCEDURE 1. Using a 3/8” nutdriver, attach the three screws securing the right case side to the machine. 2. Using a 3/8” nutdriver, attach the three screws securing the left case side to the machine.

  • Page 30: Chopper Module Capacitor Discharge Procedure

    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 31 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.2 – Chopper module capacitor discharge...

  • Page 32: Brush And Slip Ring Service Procedure

    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 33 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual slip rings and the brushes, with the abrasive side against the brushes. Pull the sandpaper strip around the circumference of the slip rings in the direction of rotor rotation only. Repeat this procedure until the surface of each brush is in full contact with its matching slip ring.

  • Page 34: Rotor Resistance And Ground Test Procedure (Static)

    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 35 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.3 – Lead, slip ring and brush locations...

  • Page 36: Rotor Resistance And Ground Test Procedure (Dynamic) (Also Refered To As Flying Resistance Test)

    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 37: Rotor Voltage Test Procedure

    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 38 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 13. If the voltage measures about 3 to 5 VDC, the generator is not building up to normal output even though the flashing circuit appears to be functioning normally. This condition could be caused by one of several failed components or connections.
  • Page 39 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.4 – Brush terminals location...

  • Page 40: Flashing Voltage Test Procedure (Engine Not Running)

    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 41 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 17. Using a volt/ohmmeter, check for the presence of about 12 VDC battery voltage, at the following locations on the weld control board. See Figures F.6 and F.7. See Wiring Diagram. (-) Lead 5P (J2-3) to (+) Lead 210B (J2-7) (-) Lead 5P (J2-3) to (+) Lead 224A (J2-9) (-) Lead 5P (J2-3) to (+) Lead 211 (J2-8) –...
  • Page 42 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.6 – Weld control board plug locations Figure F.7 – Plug J2 lead locations...

  • Page 43: Stator Voltage Test Procedure

    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 44 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual To test the 240 VAC auxiliary winding: 9. Connect the meter probes to leads 6F and 3E where they connect to the 120/240 VAC receptacle or insert the probes into the 240 VAC connection slots in the front of the receptacle. See Figure F.8.
  • Page 45 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 24. If the voltage readings are not within the specified limits, check for loose connections or broken wires between the test points and the stator windings. If there are no wiring problems, the stator is defective and should be replaced.

  • Page 46: Stator Short Circuit & Ground Test Procedure

    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 47 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual E. Lead 5 and lead W1, W2 or W3. This checks for a connection between the auxiliary winding and the weld winding. See Wiring Diagram. F. Lead 7 or 9 and lead W1, W2 or W3. This checks for a connection between the exciter winding and the weld winding.
  • Page 48 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.10 – Field bridge rectifier lead locations Figure F.11 – 14 pin Amphenol pin locations...

  • Page 49: Output Rectifier Bridge Test Procedure

    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 50 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 11. Perform the Case Cover Replacement Procedure. Table F. 1 – Diode test table DIODE BIAS AND EXPECTED TEST POINT (+) TEST POINT (–) RESULT DC(+) 0.3 - .7V DC(+) 0.3 - .7V DC(+) 0.3 - .7V...

  • Page 51: Chopper Module Function Test Procedure

    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 52 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 13. Connect leads 23 (B7) and 25 (B8) and place the welding terminal switch in the “WELD TERMINALS ON” position. 14. Check for about 58 VDC between chopper module terminals B2+ to B3- and B5+ to B6 and between the welder output terminals.

  • Page 53: Chopper Module Resistance Test Procedure

    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 54 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Table F. 2 – Diode test table TEST POINT (+) TEST POINT (–) EXPECTED RESULT 1.7V 1.6V Figure F.14 – Chopper module terminal locations...

  • Page 55: Weld Control Board Pwm Gate Signal Test Procedure

    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 56 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 16. If the 80 to 100 VDC supply voltage is present at the weld control board, but there is no PWM gate signal, check the voltage between leads 2+ (J1-4) and 4 (J1-3). See Wiring Diagram. The voltage should be about zero VDC.
  • Page 57 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.15 – Weld control board plug locations Figure F.16 – Weld control board plug J3 and J1 lead locations...

  • Page 58: Weld Control Feedback Test Procedure

    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 59 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 15. Locate plugs J3 and J6 on the weld control board. See Figure F.17. See Wiring Diagram. Reconnect the plugs and check for dirt, corrosion, damaged, expanded or incorrectly positioned terminals. Repair or replace wiring components as needed and reconnect the plugs to the weld control board.
  • Page 60 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.17 – Weld control board plug locations Figure F.18 – Weld control board plugs J3 and J6 lead locations...

  • Page 61: Control Potentiometer And Mode Switch Resistance Test Procedure

    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 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Table F. 3 – Control potentiometer and mode switch test points POT/MODE SWITCH RESISTANCE TEST MODE SWITCH SETTING OHMMETER CONNECTION OHMMETER READING CC-STICK J7-9 (214) TO J7-14 (218) 500K OR HIGHER CC-STICK J7-9 (214) TO J7-15 (220)
  • Page 63 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.19 – Weld control board plug J7 location Figure F.20 – Weld control board plug J7 lead locations...

  • Page 64: Remote Receptacle Resistance Test Procedure

    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 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Table F. 4 – Remote receptacle resistance tests WELDING TERMINAL SWITCH OHMMETER CONNECTION EXPECTED READING SETTING PIN G (75B) TO PIN A (32) 500,000 (500K) OHMS OR HIGHER PIN G (75B) TO PIN B (GND-A)
  • Page 66 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.21 – Weld control board plug J1 location Figure F.22 – Remote receptacle pin locations...

  • Page 67: Idle Solenoid Test Procedure

    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 68 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.23 – Idle solenoid lead locations...

  • Page 69: Removal And Replacement Procedures

    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 70 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 9. Using a 1/2” socket and a 1/2” open-end wrench, remove the bolt, nut, lock washer and two flat washers securing lead W7 to the choke terminal. See Figure F.26. See Wiring Diagram.
  • Page 71 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 12. Using a 1/2” socket and a 1/2” open-end wrench, attach the bolt, nut, lock washer and two flat washers securing leads W4, W5 and W10 to the output rectifier. See Wiring Diagram.
  • Page 72 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.25 – Case front panel mounting screw locations Figure F.26 – Output rectifier bridge and choke lead locations...

  • Page 73: Field Bridge Rectifier Removal And Replacement Procedure

    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 74 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.27 – Field bridge rectifier lead locations Figure F.28 – Field bridge rectifier mounting hardware locations...

  • Page 75: Weld Control Board Removal And Replacement Procedure

    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 76 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.29 – Weld control board plug locations Figure F.30 – Weld control board mounting screw locations...

  • Page 77: Chopper Module Board Removal And Replacement Procedure

    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 78 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 4. Connect leads 23 and 25 to terminals B7 and B8 of the chopper module board. See Wiring Diagram. 5. Using a 7/16” nutdriver, attach the screw, lock washer and flat washer securing leads W6, W4, 301, W9, 302, 14, W11, 13, W5 and W8 to terminals B1, B2, B3, B4, B5 and B6 of the chopper module board.
  • Page 79 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.32 – Chopper module board mounting hardware locations...

  • Page 80: Idle Solenoid Removal And Replacement Procedure

    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 81 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.33 – Idle solenoid lead locations Figure F.34 – Idle solenoid mounting screw locations...

  • Page 82: Stator And Rotor Removal And Replacement Procedure

    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 83 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 13. Clearly mark all stator leads to insure proper reconnection. See Wiring Diagram. 14. Disconnect all of the stator winding leads. Note how the leads are routed and connected as well as the order and placement of leads. See Wiring Diagram.
  • Page 84 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual 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.
  • Page 85 LINCOLN ELECTRIC Ranger® 305G EFI Service Manual Figure F.35 – Brush lead locations Figure F.36 – Blower bolt, plastic blower, stator frame, lift bail, firewall and rotor locations...

  • Page 86: Retest After Repair

    LINCOLN ELECTRIC Ranger® 305G EFI Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components.

This manual is also suitable for:

121571220612653

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