Lincoln Electric RANGER 305D SVM175-A Service Manual
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Lincoln Electric RANGER 305D SVM175-A Service Manual

Lincoln electric welder user manual
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Ranger 305D
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Summary of Contents for Lincoln Electric RANGER 305D SVM175-A

  • Page 1 RETURN TO MAIN MENU Ranger 305D...
  • Page 6 RETURN TO MAIN MENU...
  • Page 13 Note: Output stud covers not shown. Code 11275 and above...
  • Page 16 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT RECEPTACLE 120 VOLT 120 VOLT...
  • Page 20 NOTE: Layout and appearance vary between models.
  • Page 29 14-PIN AMPHENOL K867 UNIVERSAL ADAPTER PLUG TO WORK ELECTRODE CABLE TO WIRE FEED UNIT WIRE K867 FEEDER NOT USED ON RANGER POWER SOURCES SPARE CONNECT TOGETHER FOR WELDING OUTPUT 42 VAC 115 VAC POWER SOURCE FRAME CONNECTION WIRE FEEDER VOLTMETER CONNECTION CONNECTS TO (WORK TERMINAL) OF POWER SOURCE REMOTE OUTPUT CONTROL MIN.
  • Page 30 14-PIN AMPHENOL 6-PIN OPTIONAL K444-1 AMPHENOL REMOTE CONTROL LN-25 WIRE FEEDER TO WORK ELECTRODE CABLE WORK CLIP LEAD TO WORK...
  • Page 31 14-PIN AMPHENOL TO LN-25 INPUT CABLE PLUG K626-XX INPUT CABLE ASSEMBLY ELECTRODE CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WIRE FEED UNIT TO WORK...
  • Page 32 14-PIN AMPHENOL 6-PIN AMPHENOL OPTIONAL K857 REMOTE CONTROL LN-25 WIRE FEEDER TO WORK ELECTRODE CABLE WORK CLIP LEAD TO WORK...
  • Page 33 14-PIN AMPHENOL 6-PIN AMPHENOL TO LN-7 INPUT CABLE PLUG K584-XX CONTROL CABLE ELECTRODE CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WIRE FEED UNIT TO WORK OPTIONAL K857 REMOTE CONTROL...
  • Page 34 14-PIN AMPHENOL TO LN-8 INPUT CABLE PLUG K595 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK...
  • Page 35 14-PIN AMPHENOL TO LN-742 INPUT CABLE PLUG K619 CONTROL CABLE ELECTRODE CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WIRE FEED UNIT TO WORK...
  • Page 41 Service Instructions & Installation Tips Release the Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they donít hinder filter removal/installation. Most latches are spring loaded to fold back when open. The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter of the filter endcap.
  • Page 47 ENGINE PROTECTION LIGHT ENGINE ENGINE PROTECTION SENSORS CIRCUIT FUEL PUMP FUEL SOLENIOD HOLD COIL PULL COIL STARTER START BUTTON GLOW PLUG 12V. BUTTON BATTERY STOP SWITCH CHARGING SYSTEM LIGHT (CODE 10926 ONLY) GLOW ENGINE PLUGS ALTERNATOR WELD WINDING ROTOR ENGINE STATOR 42 VAC EXCIT...
  • Page 48 ENGINE PROTECTION LIGHT ENGINE ENGINE PROTECTION SENSORS CIRCUIT FUEL PUMP FUEL SOLENIOD HOLD COIL PULL COIL STARTER START BUTTON GLOW PLUG BUTTON 12V. BATTERY STOP SWITCH CHARGING SYSTEM LIGHT (CODE 10926 ONLY) GLOW ENGINE PLUGS ALTERNATOR WELD WINDING ROTOR ENGINE STATOR EXCIT 120/240 VAC...
  • Page 49 ENGINE PROTECTION LIGHT ENGINE ENGINE PROTECTION SENSORS CIRCUIT FUEL PUMP FUEL SOLENIOD HOLD COIL PULL COIL STARTER START BUTTON GLOW PLUG BUTTON 12V. BATTERY STOP SWITCH CHARGING SYSTEM LIGHT (CODE 10926 ONLY) GLOW ENGINE PLUGS ALTERNATOR WELD WINDING ROTOR ENGINE STATOR 120/240 VAC 42 VAC...
  • Page 50 ENGINE PROTECTION LIGHT ENGINE ENGINE PROTECTION SENSORS CIRCUIT FUEL PUMP FUEL SOLENIOD HOLD COIL PULL COIL STARTER START BUTTON GLOW PLUG 12V. BUTTON BATTERY STOP SWITCH CHARGING SYSTEM LIGHT (CODE 10926 ONLY) GLOW ENGINE PLUGS ALTERNATOR WELD WINDING ROTOR ENGINE STATOR 42 VAC EXCIT...
  • Page 51 ENGINE PROTECTION LIGHT ENGINE ENGINE PROTECTION SENSORS CIRCUIT FUEL PUMP FUEL SOLENIOD HOLD COIL PULL COIL STARTER START BUTTON GLOW PLUG BUTTON 12V. BATTERY STOP SWITCH CHARGING SYSTEM LIGHT (CODE 10926 ONLY) GLOW ENGINE PLUGS ALTERNATOR WELD WINDING ROTOR ENGINE STATOR 120/240 VAC 42 VAC...
  • Page 76 ( ontinued) ENGINE SERVICE ACCESS DOOR LOCKING TAB HINGES...
  • Page 78 ( ontinued) INSULATED PLIERS INSULATED GLOVES...
  • Page 80 ( ontinued) SHUTDOWN SHUTDOWN SOLENOID SOLENOID IDLE IDLE SOLENOID SOLENOID...
  • Page 81 ( ontinued) GND-L BLACK 225B TO FRAME TO "D-4" WHITE TO STARTER SOLENOID FUEL SOLENOID FUEL SOLENOID WIRING HARNESS CONNECTOR CONNECTOR (LEAD ENTRY VIEW) (LEAD ENTRY VIEW)
  • Page 84 ( ontinued) ENGINE SPEED CONTROL LEVER FAN HUB STROBE TACH MARK...
  • Page 85 Solenoid & Fuel Pump Bracket Electric Fuel Pump (codes 10926 &11121 only) High Idle Screw & Jam Nut Rubber Boot • Solenoid viewed from above and shown in High Idle position • Engine Engine Speed Control Lever Swivel Low Idle Fitting Jam Nuts Solenoid...
  • Page 86 ( ontinued)
  • Page 88 P-72 BLACK WHITE IDLE SOLENOID CONNECTOR (LEAD ENTRY VIEW) ( ontinued) J-72 210A START BUTTON TO CONTROL PULL COIL P.C. BOARD P.C. BOARD IDLE SOLENOID WIRING HARNESS CONNECTOR (LEAD ENTRY VIEW)
  • Page 89 F 35...
  • Page 90 BATTERY IGNITION OIL PRESSURE SWITCH...
  • Page 91 F 37...
  • Page 94 SLIP RINGS BRUSHES LEADS 200A LEADS ( ontinued)
  • Page 95 F 41...
  • Page 98 ( ontinued) SLIP RINGS BRUSHES LEADS 200A LEADS...
  • Page 99 ( ontinued)
  • Page 101 F 47...
  • Page 103 ENGINE ALTERNATOR #229 OIL PRESSURE SWITCH OIL FILTER...
  • Page 106 CONTACTOR AMPHENOL 1 CONTROL REMOTE CONTROL 2 TIMES THRU FERRITE LEADS 75A, 76A, & 77A ( ontinued) GROUND 120 VAC FOR WIRE FEEDER 40 VAC FOR WIRE FEEDER 21 WORK SENSE...
  • Page 107 ( ontinued) NEG. POS. W4,W5 W6,W11 FROM SHUNT...
  • Page 108 ( ontinued)
  • Page 110 CONTACTOR AMPHENOL 1 CONTROL REMOTE CONTROL 2 TIMES THRU FERRITE LEADS 75A, 76A, & 77A ( ontinued) GROUND 120 VAC FOR WIRE FEEDER 40 VAC FOR WIRE FEEDER 21 WORK SENSE...
  • Page 112 ( ontinued)
  • Page 113 POS. W4,W5 W6,W11 FROM SHUNT ( ontinued) NEG. CENTER BOTTOM OUTPUT RECTIFIER BRIDGE CHOKE...
  • Page 115 F 61...
  • Page 116 HL W6 HL W4 HL W9 SL302 SL13 SL301 SL14 ( ontinued) HL W11 HL W5 HL W8...
  • Page 117 ( ontinued)
  • Page 119 F 65...
  • Page 120 ( ontinued)
  • Page 121 ( ontinued)
  • Page 123 F 69...
  • Page 125 F 71...
  • Page 129 F 75...
  • Page 130 Case cover Removal Procedure...
  • Page 133 F 79...
  • Page 134 AMPHENOL 1...
  • Page 137 F 83...
  • Page 141 F 87...
  • Page 142 HL W6 HL W4 HL W9 SL302 SL13 SL301 SL14 HL W11 HL W5 HL W8...
  • Page 145 F 91...
  • Page 146 Battery Terminals Remove Through Here...
  • Page 147 HOLE BATTERY IGNITION OIL PRESSURE SWITCH...
  • Page 149 COUPLING DISC CLAMPING RING...
  • Page 157 TABLE OF CONTENTS Section G-1 Section G-1 - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams Section G...
  • Page 158 HEATSINK TWISTED PAIR 206S 204S 300 AMP SHUNT WRAP TWO TURNS #3 & MODULE #6 LEADS IN DIRECTION 50MV=400 AMPS SHOWN THROUGH TOROID 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A STATOR AUX. WINDING VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH...
  • Page 159 Twisted TWISTED PAIR Pair HEATSINK 206S 204S WRAP TWO TURNS #3 & #6 LEADS IN 300 AMP SHUNT MODULE DIRECTION SHOWN THROUGH TOROID 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A STATOR AUX. WINDING VOLTMETER WIRE FEED POWER POLARITY WINDING...
  • Page 160 RANGER 305D- KUBOTA - WIRING DIAGRAM Twisted Pair TWISTED PAIR HEATSINK 206S 204S 6 WRAP TWO TURNS 300 AMP SHUNT #3 & #6 LEADS IN MODULE DIRECTION SHOWN 50MV=400 AMPS THROUGH TOROID 206B 206A 208B PCB 1 L1 CHOKE 206B 206C 208C 206A...
  • Page 161 HEATSINK TWISTED PAIR 206S 204S 300 AMP SHUNT MODULE 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH STATOR AUX. 208A WINDING 42 VAC WRAP TWO TURNS OF LEADS A, 3, D, B, & C IN DIRECTION SHOWN THROUGH TOROID GND-E...
  • Page 162 HEATSINK TWISTED PAIR 206S 204S 300 AMP SHUNT MODULE 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH STATOR AUX. 208A WINDING 42 VAC WRAP TWO TURNS OF LEADS A, 3, D, B, & C IN DIRECTION SHOWN THROUGH TOROID GND-E...
  • Page 163 TWISTED PAIR HEATSINK 206S 204S 300 AMP SHUNT MODULE 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH STATOR AUX. GND-E 208A WINDING 42 VAC WRAP TWO TURNS OF LEADS A, 3, D, B, &...
  • Page 164 HEATSINK TWISTED PAIR 206S 204S 300 AMP SHUNT MODULE 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH STATOR AUX. 208A WINDING 42 VAC WRAP TWO TURNS OF LEADS A, 3, D, B, & C IN DIRECTION SHOWN THROUGH TOROID GND-E...
  • Page 165 TWISTED PAIR HEATSINK 206S 204S 300 AMP SHUNT MODULE 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH STATOR AUX. GND-E 208A WINDING 42 VAC WRAP TWO TURNS OF LEADS A, 3, D, B, &...
  • Page 166 TWISTED PAIR HEATSINK 206S 204S 300 AMP SHUNT MODULE 50MV=400 AMPS 206B 206A PCB 1 208B L1 CHOKE 206B 206C 208C 206A VOLTMETER WIRE FEED POWER POLARITY WINDING SWITCH STATOR AUX. GND-E 208A WINDING 42 VAC WRAP TWO TURNS OF LEADS A, 3, D, B, &...
  • Page 167 14 (J3-16) 25 (J3-9) 204S (J6-1) (J2-1) 200N 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) WELD CONTROL...
  • Page 168 CHANGE DETAIL: RELEASED FROM "X" L11946 ENGINEERING CONTROLLED MANUFACTURER: AUXILLARY AUXILIARY CURRENT J3-3 SENSE SENSE TOROID WELDING + STUD TERMINAL J3-4 +15V CONTROL SWITCH J1-4 2-4 SENSE SHOWN IN "ALWAYS ON" POSITION J1-3 +15V +15V IDLER CONTROL + STUD J3-7 IDLE SWITCH SENSE SHOWN IN "HIGH"...
  • Page 169 204S (J6-1) (J2-1) 200N to activate idler. 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V (J2-4) 404 77 (J7-1) and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 170 E N G IN E E R IN G C O N T R O L L E D L12212 M A N U FA C T U R E R : CHANGE DETAIL: RELEASED "A.02" FROM "X" J3-3 AUXI LL ARY AUXILIARY CURRENT SENSE...
  • Page 171 204S (J6-1) (J2-1) 200N to activate idler. 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 172 E N G IN E E R IN G C O N T R O L L E D L12212-1 CHANGE DETAIL: M A N U FA C T U R E R : J3-3 AUXI LL ARY AUXILIARY CURRENT SENSE SENSE TOROID...
  • Page 173 14 (J3-16) 25 (J3-9) 204S (J6-1) (J2-1) 200N 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 174 CHANGE DETAIL: RELEASED FROM "X" L12039 ENGINEERING CONTROLLED MANUFACTURER: AUXILLARY AUXILIARY CURRENT J3-3 SENSE SENSE TOROID WELDING + STUD TERMINAL J3-4 +15V CONTROL SWITCH J1-4 2-4 SENSE SHOWN IN "ALWAYS ON" POSITION J1-3 +15V +15V IDLER CONTROL J3-7 IDLE SWITCH SENSE + STUD SHOWN IN "HIGH"...
  • Page 175 204S (J6-1) (J2-1) 200N to activate idler. 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 176 E N G IN E E R IN G C O N T R O L L E D L12213 CHANGE DETAIL: RELEASED "A.02" FROM "X" M A N U FA C T U R E R : J3-3 AUXI LL ARY AUXILIARY CURRENT SENSE...
  • Page 177 204S (J6-1) (J2-1) 200N to activate idler. 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 178 E N G IN E E R IN G C O N T R O L L E D L12213-1 CHANGE DETAIL: M A N U FA C T U R E R : J3-3 AUXI LL ARY AUXILIARY CURRENT SENSE SENSE TOROID...
  • Page 179 14 (J3-16) 25 (J3-9) 204S (J6-1) (J2-1) 200N 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 180 CHANGE DETAIL: RELEASED FROM "X" L12039 ENGINEERING CONTROLLED MANUFACTURER: AUXILLARY AUXILIARY CURRENT J3-3 SENSE SENSE TOROID WELDING + STUD TERMINAL J3-4 +15V CONTROL SWITCH J1-4 2-4 SENSE SHOWN IN "ALWAYS ON" POSITION J1-3 +15V +15V IDLER CONTROL J3-7 IDLE SWITCH SENSE + STUD SHOWN IN "HIGH"...
  • Page 181 204S (J6-1) (J2-1) 200N to activate idler. 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 182 E N G IN E E R IN G C O N T R O L L E D L12214 CHANGE DETAIL: RELEASED "A.02" FROM "X" M A N U FA C T U R E R : J3-3 AUXI LL ARY AUXILIARY CURRENT SENSE...
  • Page 183 204S (J6-1) (J2-1) 200N to activate idler. 206S (J6-2) (J2-5) 215 ARC VOLTAGE FEEDBACK SIGNAL 208B (J3-15) Control board common is at welder positive output 10 V 77 (J7-1) (J2-4) 404 and shunt OUTPUT 0-10 V 76 (J7-4) CONTROL 10K...
  • Page 184 E N G IN E E R IN G C O N T R O L L E D L12214-1 CHANGE DETAIL: M A N U FA C T U R E R : J3-3 AUXI LL ARY AUXILIARY CURRENT SENSE SENSE TOROID...
  • Page 185 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 186 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 187 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 188 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 189 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 190 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 191 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 192 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 193 This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 194 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

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Ranger 305d

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