Lincoln Electric Ranger 305G Troubleshooting Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. Ranger 305 G
  6. Troubleshooting manual
Lincoln Electric Ranger 305G Troubleshooting Manual

Lincoln Electric Ranger 305G Troubleshooting Manual

Hide thumbs Also See for Ranger 305G:

Advertisement

Table of Contents

Ranger 305G
Troubleshooting Guide
Prior to attempting any troubleshooting procedures, please see important safety
Refer to this unit's operators manual for proper Installation and Input power
requirements.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely please contact Lincoln electric call center at 1-888-935-3877
SYSTEM CONFIGURATION
Place the machine into the following configuration prior to performing any
troubleshooting procedures
1. Check all circuit breakers are
not tripped before proceeding
to tests.
2. Refer to Operator's Manual for
guidances on machine
operation.
3. Set Run/ Stop to Run then, Idle
switch to High Idle, pull out
choke.
4. Then press the start button.
5. Set mode to CC Stick, and Weld
Terminals ON.
Publication | Issue D ate 04/23
Lincoln Global, Inc. All Rights Reserved.
information starting on page 19.
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Avenue • Cleveland, OH 44117-1199 • U.S.A.
PH: +1.888-935-3877 • www.lincolnelectric.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Ranger 305G and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Lincoln Electric Ranger 305G

Summary of Contents for Lincoln Electric Ranger 305G

  • Page 1 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely please contact Lincoln electric call center at 1-888-935-3877 SYSTEM CONFIGURATION Place the machine into the following configuration prior to performing any troubleshooting procedures 1.
  • Page 2 If NO AUX. but   OCV  normal  goto Page 4. Measure the  Are both  If NO OCV but  Is the engine  AUX.115 VAC  AUX. and OCV  AUX normal  running? and OCV  normal? goto Page 5. 60VDC. If NO OCV and  NO AUX  Load Battery  Is engine  Continuation  present goto  Test Page 7. cranking? on Page 3. Page 6. Measure across  CB7 terminals  Replace Battery Is Battery Good? should measure < 1  Ohm. Replace CB7. Is CB7 Good? Run/Stop switch  measure across leads 210 and 212A.
  • Page 3 Measure across Oil  Pressure switch  Continuation  from Engine  while cranking  should measure  Cranking Page 1 < 1 Ohm. Replace Oil Pressure  Is Oil Pressure  Switch. switch Good? Fuel Pump Test.Page 9. Replace Is fuel Pump Fuel Pump Good? Fuel Shutoff Diodes Test  Page 10. Replace Fuel Shutoff   the Fuel Shutoff Diodes. Diodes good? Fuel Shutoff Solenoid Test  Page 11.   Replace Shutdown Is Shutoff  Solenoid. Solenoid good? Weld Control  board Test Page 12. Weld Control May  Is Weld Control  Engine Should Start Be Faulty. PCB Good? 03/11/2024 Page 3...
  • Page 4 Continuation  from NO AUX.  Circuit  but  OCV   breakers test  normal Page 13.  Page 2. Check  Replace  Receptacles  Are the Breakers Breakers are not  Good? broken. Are the Stator  Replace the  Receptacles  Winding Reptacles.  Test Page 14. Good?   Are  the stator  Replace the  Stator is normal windings voltage  Stator.  correct?  03/11/2024 Page 4...
  • Page 5 Continuation  from  NO OCV  but AUX normal  Page 2. Chopper  Board Test Page 15. Does  D1 Bridge Replace  chopper test  Test  Chopper. good? Page 16. Perform the Weld  Replace D1  Is D1 Bridge  Control BD. Test  Bridge. Good? Page 12. Is  Replace Weld  the Weld Control  Control BD. BD. good? Stator Test Page 14. Stator may  Is Stator Should be able  be Faulty. Good? to Weld 03/11/2024 Page 5...
  • Page 6 Measure across slip  Continuation  rings should  from NO OCV  measure ~5 VDC  and NO AUX  while Run/Stop set  Page 2. to Run. Measure J2 pin 1 to  Is  J2 pin3 at Weld  flashing  Perform Rotor  Control BD. should  voltage on  Test  Page 17. measure ~12 VDC  slip rings? while Run/Stop set to  Run. Is  Do  Replace rotor. the Rotor   we have Flashing  Good? Replace Weld  voltage at Weld  Control BD. Control BD? Measure across R3  resistor terminals  should measure  ~10 Ohms. D3 rectifier  test Page 18. Is  the R3 flashing Replace R3 resistor Resistor good? ...
  • Page 7 Ranger 305 G Use a load tester similar to the above testers to determine if battery is good.  03/11/2024 Page 7...

  • Page 8: Starter Test

    Ranger 305 G Terminal B+ Lead 211 Terminal S Ground Starter Test Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Expected Value Engine not running. Run/Stop set to Run. Coil Voltage Lead 211 Case Ground ~12.6 VDC Lead 211 Removed. Pressing Start Button. Engine not running.

  • Page 9: Fuel Pump Test

    Ranger 305 G Red Lead Black Lead Fuel Pump Test Expected Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Value One Lead Other Lead Fuel Pump Resistance Engine not running. ~28K Ohms (Red) (Black) Engine cranking or running. Red Lead Fuel Pump Case Ground ~12.6 VDC Run/Stop set to Run.
  • Page 10 Ranger 305 G J51 & P51 Fuel Shut-OFF Diodes Test Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Expected Value Engine Not Running J51 Pin 3 0.3 VDC – 0.7 VDC Fuel Shut-Off Diodes TP1 & J51 J51 Pin 4 0.3 VDC – 0.7 VDC Disconnected Disconnect TP1 and J51 to perform the test in the table to determine if the Fuel Shut-Off diodes are bad.
  • Page 11 Ranger 305 G Fuel Shut-OFF Solenoid Static Test Expected Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Value Engine Not Running Fuel Shut-Off Solenoid ~35 Ohms Coil Resistance (RED) Case Ground TP1 Disconnected Engine Running Fuel Shut-Off Solenoid ~10.6 VDC Supply Voltage (RED) Case Ground TP1 Reconnected...
  • Page 12 Weld Control Board Test Expected Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Value J3 Pin 8 J3 pin 16 ~ 90 VDC Input Power Engine running. J2 Pin 7 J2 Pin 3 12 VDC Run/Stop set to Run. Oil Pressure Input J2 Pin 9 J2 Pin 3 12 VDC...
  • Page 13 Ranger 305 G CB1 CB2 CB5 Breakers Test Expected Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Value Engine not running CB1 Not Tripped Lead 3A Lead 3D < 1 Ohms Leads 3A, 32, and 3D Terminal Terminal Disconnected Engine not running Lead 6B Lead 6E CB2 Not Tripped...

  • Page 14: Auxiliary Winding

    Ranger 305 G Lead 9 Lead 6 Lead 7 Lead 3 Lead 5C 14 pin Pins I & K Stator Winding Test Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Expected Value Lead 3 Lead 6 < 1 Ohm Auxiliary Winding Lead 3 Lead 5C <...
  • Page 15 Ranger 305 G Chopper Board Test Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Expected Value Engine not running. ~0.334 VDC ~0.338 VDC Run/Stop set to STOP. Chopper Board ~0.334 VDC Terminals B1, B2, B3, B4, B5, and B6 disconnected. Remove panels to access Chopper Board. Label and disconnect leads. Perform test in table to determine if Chopper Board is bad.
  • Page 16 Ranger 305 G D1 Output Rectifier Test Expected Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Value Terminal W1 Positive Terminal 0.3 – 0.7 VDC Terminal W2 Positive Terminal 0.3 – 0.7 VDC Engine not running. Terminal W3 Positive Terminal 0.3 – 0.7 VDC Leads W1, W2, W3, D1 Output Rectifier Positive and...

  • Page 17: Rotor Test

    Lead 200N Lead 200 Rotor Test Expected Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Value Engine not running One Slip Ring Other Slip Ring ~5 OHM Rotor Run/Stop set to Stop One Slip Ring Case Ground > 500 Ohms Isolate Brushes From Slip Rings. Isolate the brushes from the slip rings.
  • Page 18 Lead 200A Lead 9 Lead Lead 7 D3 Excitation Rectifier Test Component/Circuit Tested Condition(s) +Meter Lead -Meter Lead Expected Value Engine not running. Positive 0.3 VDC - 0.7 VDC Terminal (7) Terminal (200A) Run/Stop switch set Positive 0.3 VDC - 0.7 VDC to STOP Terminal (9) Terminal (200A)

  • Page 19: Safety Depends On You

    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 20: Section A: Warnings

    P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current ˜owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 21: Electric Shock Can Kill

    SAFETY 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 22 SAFETY 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 23 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish AVISO DE No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 24 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish AVISO DE Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 25 Lincoln Electric is a responsive manufacturer, but the deÿnition of speciÿcations, and the selection and use of speciÿc products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Table of Contents

Save PDF