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Lincoln Electric 305D User's Manual

Contents

1. AUTOMATIC REMOTE LOCAL SETPOINT CIRCUIT RAM MAIN WELDING CONTROL WITH MIN CURRENT ARC FORCE amp HOT START CONTROL 0 MIN CURRENT 3517 48V REF 2 EU 1 Fass RIZ 28 T
2. 5 EE RANGER 305D CE KUBOTA WIRING DIAGRAM EUROPE 5 9 5 D 5 EN 8 4 N 43 139 261 Twisted 260 515 pig Qo w10 c R4 D1 THREE PHASE BRIDGE RECTIFIER Se mE P66 T w5 STATOR VOLTS 2045 53 HEATSINK 301 WELD 1 10 WINDINGS W3 2 TWISTED PAIR 9 W6 U 206S 204S L 54 4 et 7 0 23 2 Meter SHUNT 1 838 0 25 N 50MV 400 AMPS S6 MODE SELECTOR SWITCH AM PS 2068 Wik 206A 4 w
3. 5 EE RANGER 305D CE KUBOTA WIRING DIAGRAM UK 5 9 5 D 5 gt olg 7 gt 3 261 Twisted 260 Pair 818 4 4 Qo 10 c R4 w4 D1 THREE PHASE BRIDGE RECTIFIER staton VOLTS oS _ HEATSINK 301 WELD LU w10 302 Ce 1 WINDINGS W3 B B2 1 8 wi 2065 2045 54 4 2 3 SHUNT O25 S Mato MODULE 5 50 400 AMPS 4 414 S6 MODE SELECTOR SWITCH 43 Y 206B WIH we 214 206A 79 4 w2 218 Qo 2088 cs ws eos V 5 5
4. 5 5 9 5 RANGER 305D KUBOTA WIRING DIAGRAM om u D 5 9 5 Twisted Il h 0 c 10 h R4 WA D1 THREE PHASE BRIDGE RECTIFIER E 4 P6 6 STATOR VOLT 00 5945 fo 261 m HEATSINK 301 OLTS 3 3 Shunt 10 260 WINDINGS Wa 2 wi TWISTED PAR a O W6 U 2065 2045 54 4 7 23 Meter SHUNT WRAP TWO TURNS 3 4 N q 6 LEADS IN DIRECTION 5 50MV 400 AMPS 3 SHOWN THROUGH ELA 4 ws 56 MODE SELECTOR SWITCH 2 5 1 2068 6 5 Wit 24 0 O 206 3 B 85 Lw 218 a Er 19
5. O Sonv 400 AMPS iw Lome AT SHUNT CIRCUIT ENGINE MUST 60 10 QPINMN MOBO H DE e J o 4 4 33 D 0 WELDING CURRENT SENSE CIRCUIT AND ERROR cis 512 5 pit 0 9 a AVERAGE AND ABSOLUTE CURRENT LIMIT CIRCUITS P 8 FTP2 d ERROR ras tf i xe A gt 1206 1 168 2 imer Zu vret 34 58 3m 5 R2 9 6 X16 E A QUT 475 M DIE 1 T RAMP v W MIN CUR SOFT START PWR Di CHOPPER MODULES 65 9000 2 1 ampere had T Sy E 332304 Es 2t SENSE AUX CIRCUIT HCTA0669W 4 XS A CUR SENSE Gale 1206 RT 3 gt
6. 5 E t RANGER 305D CE KUBOTA WIRING DIAGRAM UK 5 9 5 D 5 aa 7 _ Twisted N wiste 2601 Biz E E w10 R4 WA s Bene PHASE BRIDGE RECTIFIER P6J6 STATOR HEATSINK 7301 Win VOLTS Shunt 10 MC WINDINGS W3 SSS 52525 B B2 1 wt TWISTED PAIR pe 9 On WE U 206S 204S P54 J4 sooame TE M Meter MODULE BS w AMPS 50MV 400 AMPS 4 5 56 MODE SELECTOR SWITCH 43 2068 we by WIL 214 0 206A 7 B B5 wa 2 8 856 Meee 22 Q Jo wa 25222225 208B PCB 1 220 LLU 5 5 L1 CHOKE s Meter cjs Foo EJ R2 ARC CONTROL R1 OUTPUT CONT POT gt C cCW gt Ps 2068 0 206 1 cow gt T m 222 gt B 10K D 208 208C 4 D 277 1 279 77 76 75 206 NOTE STATOR LEAD 3 NOT USED 278 5 TAPE LEAD ENDAND SECURE VOLTMETER 4 4 WIRE DING o WER POLARITY o E A P7 J7 SWITCH Output amp 5 208A 9 V 42 4 Arc
7. 5 5 9 IE 5 9 RANGER 3050 KUBOTA WIRING DIAGRAM EUROPE B S 7 N sisa 261 Twisted 5 E TWISTED PAIR 20 ec AY 2065 6 6 2045 fo Shunt 10 Ra WA Meme PHASE BRIDGE RECTIFIER STATOR VOLTS HEATSINK 301 ws WELD 10 302 WINDINGS ao 5 82 1 wi S6 MODE SELECTOR SWITCH 232225 we GU 206S 204S 1 E 87 09 23 wa PIP P4 4 B7 218 5 P555 Meter SHUNT qwe BI 9 3 T 1 LOCATED BELOW 50MV 400 AMPS C Cu m T 4 TERMINAL 2 AMPS 13 Ws wa Y q 2 THTITI 206 B5 w w3 2 522 2088 eu PCB 5 5 L1 CHOKE H emm er Ll c R2 ARC CONTROL PEUT EGO o 0 206B 206C4 C gt 1 1 208 208 277 279 7 4 45 l C 206A NOTE STATOR LEAD 3 NOT USED 278 4 4 55 TAPE LEAD END ANDSECURE VOLTMETER WIPE OWER POLARITY o A P7 J7 gt SWITCH 9 STATOR AUX T Output
8. ET ce me METER PRESET CIRCUIT SC SERIALDATA 102V BUF m sur m 4557 n im 13 48428 5 0 lt 285 5 5 5 sk 8 1 tibi E an e MAX SENSE E 9 RIS2 Rr 1 lt 018 S7mo i i 2 ROZ 9 010 E ES s 3 r RISZ RIS 2 5 V 057 9 p dX TR V BATT Uu pv bcn 05 05 9 2 um 550129 8 019 BATTERY POSITIVE 5 D a 94 E 0 1 5 4 cc 1281 E wis TO BATTERY CHARGE LAMP PROGRAMMABLE 81 1 peser f RESISTOR FOR t gt SETPOINT h 1 s 101 SCALE x 545 E L 18 H 8 1 VAS ROTATION 10 4 SETPOINT SCALE 43 t SETPOINT WIPER SCALE V 1 131 10 il 28 BATTERY CHARGING SENSE CIRCUIT a Cd ap artery coin a x 12 2
9. RANGER 305D CE KUBOTA WIRING DIAGRAM UK 7 7 Twisted TWISTED PAIR JB 8 w10 h R4 we m THREE PHASE BRIDGE RECTIFIER F sit m ED VOLTS WELD 10 302 WINDINGS Eggs lO Wi S6 MODE SELECTOR SWITCH 1 ULM in we cy 206 2045 P4 4 7 0 2 2 218 12 SHUNT B8 O 25 Q LOCATED BELOW 50 400 AMPS ppm 220 TERMINAL 2 AMPS ane 2 s 4 ems 206A 7 I us we 2088 9 5 15 L1 CHOKE Meter P R2 ARC CONTROL R1 OUTPUT CONT POT 1 2068 206 1 C CCW 5 c 8 D 208 208C 277 279 77 0 76 75 206 NOTE STATOR LEAD 3 NOT USED 278 S5 TAPE LEAD END ANDSECURE WIRE FEED POWER 41 24 BEAT WINDING o F J SWITCH STATOR AUX Output amp 42 208A 34 WINDING Ar Cont lode 42 41 21 WRAP TWO TURNS Select LEADS 3 D B amp C IN N CB5 DIRECTION B SHOWN THROUGH TOROID 56 15A BOTTOM GND 7 INSIDE LEFT 5K 2244 2 12 42A SHOWN IN CASEFRONT EXCITATION 2248 METER Engine amp POSITIVE WINDING T GND R Function e 206C GND SCREW ON 42 VAC 200N INSIDE LEFT CASE FRONT
10. 5 5 9 IE 5 9 RANGER 3050 KUBOTA WIRING DIAGRAM EUROPE B S cic amp d 7 N sisa ABI 261 Twisted 5 E TWISTED PAIR il A ac ARR 2065 P66 2045 19 Shunt 10 R4 w4 Meme PHASE BRIDGE RECTIFIER STATOR VOLTS HEATSINK 302 Ws WELD w10 302 2 WINDINGS 8 82 S6 MODE SELECTOR SWITCH 1 28222 if 6 77 2065 2045 9 23 ws PIPE P4 J4 2 218 2 Meter arate 00 4184 0 25 LOCATED BELOW 50 400 AMPS 22 22 54 TEBMINAE 2 AMPS 6 m O 2068 44 BY _ LE Wil Q m Ro Y X w2 wa 2088 111 PCB 5 5 L1 CHOKE H Bt Aem Ll c R2 ARC CONTROL OUTPUT CONT POT Ula L 206B Q 206 C cow Fi gt w7 _ 208 208C 277 i 279 77 olo 206A NOTE STATOR LEAD 3 NOT USED 278 78 15 4 4 4 55 TAPE LEAD END ANDSECURE VOLTMETER c WIRE FEED POWER POLARITY G 7 17 AU SWITCH 9 STATOR AUX Output amp Bld faz vac 208 3 WINDING GND E Arc Cont Mode ojo 42 41 21 WRAP TWO TURNS Select LEADS 3 D B amp C IN N 5 DIRECTION B SHOWN THROUGH TOROID 56 15A BOTTOM GND 3 T INSIDE LEFT STATOR 2244 2 12 42A MA SHOWN IN
11. 5 511 RANGER 3050 KUBOTA WIRING DIAGRAM 5 D 0 818 cle 5 gt Il 0 9 c 7 N Twisted Pair L3 TWISTED PAIR A 2065 P6J6 coc 2063 H 2045 t Sh nt w10 e ws D1 THREE PHASE BRIDGE RECTIFIER STATOR uu x HEATSINK 730 Ws WELD w10 302 ca WINDINGS Es gees 0 Wi 56 MODE SELECTOR SWITCH w we 2065 2045 1 B3 24 01 4 WRAP TWO TURNS 300 3 2 21gP PE SHUNT MODULE dan cool QA LOCATED BELOW Meter 0 400 AMPS DIRECTION SHOWN we 1 2 4 TERMINAL2 E 3 THROUGH 10800 5 Ws Fe 2068 6 ws 5 wi y C 206A 1 3 Bb Lw 0 CB 5 15 o o L1 CHOKE TT FIELD WINDING R2 ARC CONTROL R OUTPUT CONT POT 1 2068 0 206 1 m CCW 8 208C a clc S5 206A 278 5 VOLTMETER STATOR AUX WIN DING 6 81 WINDING 7 7 0 A 208A 4 BOTTOM GND INSIDE LEFICASEFRONT Output amp cc 42 VAC d Arc Cont 2 4 21 GND N GND E Select SHOWN IN 50 POSITIVE 4 GND R 25 9 POSITION GND K q D 224 215 pa P2 J2 QA GND R p2248 OUR METER Engine amp 5 UU t 1 9 Ty 8 1 206 GND SCREWON B ante Function INSIDE LEFTCASE FRONT 83 BYPASS 210 T
12. TOOT HERPARTIESO R USE DF ORANY PU RPOSEWIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN COLN GLOBAL INC SUMUS E TURI DESIGN INFORMATION REFERENCE EQ IPM ENT TYPE RANGER 305D CE UK DRAWN BY DEO L12039 SUBJECT MACHINE SCHEMATIC ENGINEER SCALE WITH PUB LISHED STANDARDS MATERIAL PROJECT CRM35573 DO NOT SCALE THIS DRAWING NONE pisposirion NUMBER PAGE lor 2 DOCUMENT DOCUMENT NUMBER REVISION EN 168 APPROVAL DATE 12 11 2003 L12213 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 RANGER 305D G 20 G 20 SCHEMATIC ENTIRE MACHINE CODE 11122 L12213 PAGE 2 OF 2 ELECTRICAL DIAGRAMS ENGINEERING CONTROLLED CHANCE DETAIL RELEASED A02 FROM X MANUFACTURER No AUXLLARY CURRENT SENSE Return to Section TOC Return to Master TOC WELDING TERMINAL CONTROL ISOLATEDCIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT 12 Battery Supply to qo ide Hold Solencid 9 22 gt 125 5 Other side of the Hold Solenoid OV when energized LOWIDLE 12V when not energized HGH IDLE 15VCOM 5700 IDLE SWITCH SENSE
13. STARTER BUTTON 12V when starting the machine RUN switch ON and Stat Button Pressed and held OV when the machine is not ON 40V or more when the machine is running Return to Section TOC Return to Master TOC ANN AAN 9 ANN ANNA ANN 9 ANN 579 1 5 FOLD S 53 I5 155 gt 156 gt 159 1540 58 NOJ 40RJ SONRANGER 250 METER 4 INPUT 0 24 1V 100 0 METER INPUT CURRENTFEEDBACK 5700 64107 ONLY 5700 FCRWELDCONTROL 5 REG ULATING CURRENT LIMITS AVERAGE ABSOLUTE amp FOLDBACK PWM CHOPPER PIC PASON 210 12V when the RUN switch is CNand the START Button is held IN If externally shorted the PTC will change to high impedance VBATTERY 127 BATTERY POSTIVE BATERY NEGWE 123 lt Pia me d 7 ROTOR PAMSIGNAL 12V ON MULTIMETER PAMSIGNAL 412V CONTROL E CIRCUIT 2 P AMPLIFIER 5700
14. THIS SCHEMATIC USED BOARD ARTWORK IN 64107 AND G4109 EARTH GROUND CONNECTION 5 zm 5 MEME Me m uam ED ON ME SY EM NE MEER EE us m SS ru cnm m J4 tumper in Plug Bla da TR 7 DECIMAL COMMON in CUR SCALE 104 AMMETER N olo 3 1 AMMETER GND K x10 19 R135 fi Bi 21 iw 2 1 Rita FOR AUK USE PULL COM 7 cic 1V 100A ts laok RETI 8 455 S m E 5 RIERA HI SUPLLY ON TO AMMETER 1 doc C26 D D TH HCT4066PW c E o A METER HOLD A LEFT MOST DECIMAL FAN Aw o Vew T A 8j pg Ras D i ofi L2 R8 2456 A HOLD HBI ON m A0 100 2 1 1 168 V_METER_HOLO Lee Es SCALE 104 a cac A FAN DR LOW ILE 10 i H LOW
15. 5700 JHIS D OCUME NTC ONTAINS RIETARY INF ORMATION LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU D PROPRIETARY amp CONFIDENTIAL HERPARTIESO USE DF OR ANY PU RP OSEWIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN COLN GLOBAL INC 7 MANUFAC TURN G TOLERANCE PER 205 6 DESIGN INFORMATION REFERENCE EQUIPMENT TYPE RANGER 305D CE EURCPE axi Bord ON 3 PLACE DECIMALS IS 002 DRAWN BY DOCUME 10 ONALLANG LESIS SOFADEGREE SUBJECT MATERIA LTOL ERANCE t TOAGREE f ENGINEER MACHINE TIC WITH PUB LISHEDS TANDARDS MATERIAL APPROVAL PROJECT 2 70 NOTSCALE THIS DRAWING DATE _ 07 5 204 CRM3587 L12214 1 EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D 29 ELECTRICAL DIAGRAMS 0 29 SCHEMATIC WELD CONTROL BD ALL CODES G4108 1 PG 1 OF 5 1B TIG SWITCH 10 468 PIPE SWITCH TEST SWITGE X 109 P3 NOT USED SWITCH 1019 PA4 NOT USED SWITCH 1 MC141380 TOUCH STICK SWITCH X8 6 WIRE SWITCH vos 12 TWO FOUR m voie TIG TOUCH DeTECT gt THERMAL SENSE
16. LOW IDLE SOLENOID HOLD COIL 0V 9 LOW IDLE 150vdc ARC VOLTAGE FEEDBACK SIGNAL 2 5 215 12088 315 Control board common is AMPHENOLS 42 VOLT AC 10V at welder positive output 15V LOW IDLE TO PULL COILBOARD VIA CIRCUIT WIRE FEEDER 71 1 1 and shunt 2 4 404 POWER 5H 0 10 V 76 74 Suich dosed for high BREAKERS f ov WELD CONTROL 3 14 252 R SWITCH 755075 pC BOARD 3 7 251 __ 2 TURNS THRU FERRI OL 42 VOLT AC REVOLVING FIELD I FIELD RESISTANCE E 14 2 APPROX 5 OHMS Q 75F TO AMPHENOL REMO 1 15 144 2314 LD TERM SW ROTOR FELD CIRCUIT Located on front of fan TO AMPHENOL 15 1 10 baffle near top of 7 9 214 2 Relay CR1 and 04 locatal on fron 279 zo 896 714 218 baffle on right side of machire OK R2 35 28 7 1 17 15 220 7 16 222 Return to Master TOC Return to Section TOC 1277 7 8 TOROID SENSES AC 260A 34 POWER 12 to 14V NORMAL OIL PRES INPUT ENERGIZED FOR ACTIVATE 261A J 33 2 9 224B IDLER 2 7 2108 12 to 14V RUN INPUT 4 21 rug i TUE GLOWELUGSWITCHENERGIZES TF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH Located wiring behind J 1 7 305 GLOWPLUGS CLOSE CR1ENERGIZES OPENING CONTACTS AND S
17. A na THE i 5 GENERAL INFORMATION Ris 8E REMOTE uj idm Bux OTHERMISE 15 pi 10 A 1 E 0 SINE RESISTORS One OBS UNLESS OTMERVISE SPECTIED 2 Sue Jig TO 77 i CS 8 503 2 DIODES 2 200V UNLESS OTHERWISE SPECIFIED SH Y VOLTAGE NET CAT Le SUL 9 EA RESPONSE POWER SUPPLY SOURCE POINT R351 Hys 11840 57 COMMON CONNECTION REMOTE RR STR rate Srila a ee FRAME CONE 3 0217 100 EARTH GROUND CONNE iy THIS SCHEMATIC USED FOR BOARD ARTWORK IN 66107 AND 64109 EIN 02258 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMM PROPRIETARY amp CONFIDENTIAL Ranks UR USE EUR ART PURPOSE MUI THE EXPRESS PERMISSION DF DINGEN GLOBAL NC no au ANY oxo WITHOUT THE ABILITY OF COMPLETE BOARD THIS PAGE 02 OF 5 DOCUMENT DOCUMEN DIAGRAM MAY NOT SHOW THE EXACT ENGINEER MS NUMBER REVISION COMPONENTS OR CIRCUITRY OF CONTROLS NA Are 1172 2006 weiss 64108 1 7 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D
18. 2225 PCB T 2 N 5 15 O18 Lt CHOKE Meter S m R2 CONTROL R1 OUTPUT CONT 1 2068 206 1 gt 07 un 7 K 208 208C 217 i 279 7 g 2 206A 278 16 49 c S5 FIELD WINDING VOLTMETER STATOR AUX WINDING 6 515 WIRE POLARITY o 3 142 VAG cape Bg SWITCH 7 9 Output amp 0 Taovacl 208A 34 BOTTOM GND INSIDE CASEFRONT 5 Arc Cont 21 6 0 Mode T GND N M x Select cnh ENDR gt 3 56 A r D 215 P2 J2 GND R 5K 215 b o SHOWN IN 2248 OUR METER Engine amp 5 OB POSITIVE 4 3 bt 9 15A POSITION ee 49A TOP GND SCREW ON 200N 200859 5 INSIDE OF CASE 83 ziok G 206c 6 2008 BYPASS 5H 1 1 FILTER aN gt 2 5 IDLER CONTROL s Job Amphenol 4 5 2 90 305 208c FRAME GND 251 b ode IO 58 56 1 Y Select 1 252 3 HotStart SHOWN IN 5 D CR1 AUTO POSITION 515 J 9 3 200 115 GND 75 i 016 0 32 SN SCORE 210 210 Sesa INSIDE CASEFRONT 6 1 MONS gt 42VAC 4 1 Engine Protection Battery Charge 2088 80 42 GN Light PL1 Light PL2 216 9 low 3 WORK FRAME GND i 228 37 vhs 85 cic 5279 77
19. na der A 7 iac dk a ttd rra are A 7 E Welding Output 8 9 Installation 8 Auxiliary Power 8 c Standby Power Connections 8 9 Connection of Ranger 3050 to Premises Wiring A 10 Q 2 12 5 3050 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 G 5 Return to Section Return to Master TOC o p 0 5 2 2 INSTALLATION TECHNICAL SPECIFICATIONS Ranger 3050 K1727 2 Code 10926 11121 11188 11275 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities in cu System 3 cylinder 43 88 789 12VDC Battery amp Fuel 12 gal 45L 4 stroke starter 18 8 HP High Idle 3650 Bore x Stroke inch mm Oil 3 4Qts 3 2L Kubota 14 KW D722 Net intermittent Full Load 3500 2 64 x 2 68 Group 58 550 Radiator Coolant 3600 RPM 67 x 68 mm cold crank amps 3 85Qts
20. VOLTAGE FEEDBACK SIGNAL Return to Section TOC Return to Master TOC 1217 7 8 TOROID SENSES AC POWER TO 260A 034 412 to 14V NORMAL OIL PRES INPUT 2 0 2248 ACTIVATE 261A 33 LOW IDLE IDLER 2 7 2108 12t014V RUN INPUT o 210 ELECTRIC FUEL PUMP AND FUEL GLOWPLUGS SOLENOID HOLD COIL THRU D4 IT CLOSE CR1ENERGIZES OPENING CONTACTS SHUTTING OFF FUEL DLENOID TO STOP ENGINE receptacles 1 12 308 i ALSO FUNCTIONS AS AN ENGINE Control board circuits associated with J 2 ae part 023 411910 015 1 010 olL ENGINE d of engine electrical system and are common to 305 1 D J UMPER Part 223 PROTECTION frame ground negative battery terminal WELDAMMETER WELD VOLTMETER of amphenol plug and EUN RELAY 9 lead assembly Meters display setpoint volts amps when mot welding CIRCUIT BREAKER 20 Meters display actual volts and when welding 209 Hold function displays actual volts and mps for approximately 5 seonds after welding stops 210 During this hold display theright most decimal point wil blink START BUTTON SWITCH S2 ot e s 3l FUELSOLENOID PULL 2 bo CONNECTION COILIS ENERGIZED BY HOUR METER 209 STARTER SOLENOID 15V LOW IDLE 77 231 YELLOW 229 404 43 8 82 CONTROL CHARGING STARTER LIGHT SOLENOID 1 INPUT
21. G MODE CONNECTOR PIN NUVBERS 12 NNECTOR OTHER MODES 12 6 000000 COMMON T 17 77 FRAVEGROUND LATCH gt EARIHGFROUND VEW OF CRCBOARD REMOTE 10K CONTROL 5700 JHIS D OCUME NTC ONTAINS RIETARY INF ORMATION LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU D PROPRIETARY 8 CONFIDENTIAL HERPARTIESO USE DF OR ANY PU RP OSEWIT HOUTT HEEX PRESS W_RITTE NPE RMISSION OF LIN COLN GLOBAL INC MANUFAC TURN G TOLERANCE PER EOS 6 DESIGN INFORMATION REFERENCE EQUIPMENT PAGE 20 2 ON 3 PLACE DECIMALS IS 007 DRAWN BY DOCUMT SUBJECT ON ALLANG 1 5 SOFADEGREE NUMER MATERIAL APPROVAL PROJECT DATE 07 5 204 587 112213 1 MATERIA LTOL t AGREE ENGINEER BAM WITH PUB LISHED STANDARDS 50 NOT SCALE THIS DRAWING EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 305D LINCOLN 8 aAa ELECTRICAL DIAGRAMS unes SCHEMATIC ENTIRE MACHINE CODE 11039 L12038 PAGE 1 OF 2 6 0211 CHANGE DETAIL RELEASED FROM X CHOPPER PC BOARD Rectifier mounted to generator support L11845 1 IGBT S FLYBACK DIODES AND Shunt on back of positive
22. 5 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine welds normally in all modes and the range of weld out put seems normal but one or both of the front panel displays is blank displaying an obviously incorrect value or only parts of numbers are illuminated Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S MISC WELD ISSUES It is normal for one of the dis plays to be off when there is no load across the weld output ter minals In CV WIRE mode only the VOLTS display will be illu minated in all other modes only the AMPS display will be illu minated RECOMMENDED COURSE OF ACTION 1 NOTE Both the AMPS and the VOLTS front panel dis plays use the same part num bered display unit If one of the digital displays appears to be functioning normally it can be used to test the weld control PC board output to the malfunction ing display the known good display func tions normally when plugged in in place of the malfunctioning display the weld control PC board is good and only the mal functioning display unit should be replaced If the known good display exhibits the same type of prob lem as the malfunctioning dis play the weld control PC board is defective and should be replaced A control cable type wire feeder does not functi
23. C 8 2 Connectoniot the 9 2 o 9 i c 5 Return to Master TOC RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 5 2 5 Return to Section Return to Master TOC o 2 0 5 2 ACCESSORIES OPTIONS ACCESSORIES FIELD INSTALLED OPTIONS The following options accessories are available for your Ranger 305D from your Lincoln distributor K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc K1737 1 FOUR WHEEL ALL TERRAIN UNDERCAR RIAGE For moving by hand K1770 1 UNDERCARRIAGE FACTORY For moving by hand on a smooth surface One or two gas cylinders can be mounted on the rear of the undercarriage with the installation of K1745 1 Cylinder Holder s K1739 1 CABLE CARRIER KIT For use on K1737 1 and K1770 1 Undercarriages K1745 1 SINGLE GAS CYLINDER HOLDER For use on K1770 1 Undercarriage One or tow may be installed on an undercarriage K1789 1 ROLL CAGE Gives added damage protection K886 2 CANVAS COVER Protects machine when not in use K1898 1 SPARK ARRES
24. 2 G 5 Return to Section TOC Return to Master TOC o 2 0 5 ACCESSORIES CONNECTION OF THE LN 8 TO THE RANGER 305D USING K595 CONTROL CABLE SEE FIGURE C 6 NOTE If your LN 8 comes equipped with a K291 or K404 input cable refer to CONNECTIONS OF THE LN 7 Using K867 UNIVERSAL ADAPTER rather than this discussion to connect your Ranger 305D for wire feed welding 1 Shut the welder off 2 Connect the electrode cable from the LN 8 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 5 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the output terminals 3 Connect the K595 XX Control Cable to the LN 8 4 Connect the K595 XX to the 14 pin amphenol on the Ranger 305D 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control cir cuit may be damaged The engine governor setting is preset at the factory do not adjust above RPM speci fications listed in this manual 6 Set the VO
25. CURRENT LIMITS AVERAGE ABSOLUTE amp FOLDBACK BATTERY POSITIVE p ROCV ENABLE VFORALSTRAUANVANTAGE 575 KR KR KR KR N CURRENTFEEDBACK BATERY 123 64107 ONLY NNGDLPHSIVIWHZHL PAMSIGNAL 12V ON MULTIMETER FEEDBACK PWM arans REG ULATING CHOPPER CONTROL 4 2 VOITAGE FEEDBACK AMPLIFIER Sp CIR CUIT CHOPPER 5700 BOARD VANTAGE ONLY J 5700 FOR WELDCONTROL PAMSIGNAL 412 CONTROL CIRC UITRY FE is HIE ols gle ES ply 9 ojo 5700 TOUCH START VARIAB LE PINCH PIPE ARCF ORCE oa SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON 1 WHAT PARTS OF THE G4107 G4109ARE USED IN EACH CONNECTORS APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIVE FIXED HOT START J1 AMPHENOL amp MACHINE ID JUVPER 42 ENGINE 12V CONTROL FUNCTIONS 43 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK NO CONNECTOR ON RANGER 250 45 VOLTVETER NO CONNECTOR ON RANGER 250 46 SHUNT CURRENT FEEDBACK J7 OUTPUT CONTROL ARC FORCE MODE SELECT COWPONENT VALUE UNTS CAPACITOR MFD VOLTS RESISTOR OHVSWATTS G MODE CONNECTOR PIN NUVBERS 12
26. XCS20XL Return to Master TOC Return to Section TOC 28 gt AO SETPOINT CTRL 8 id 28 gt AL SETPOINT CTRL MACH SEL 1 qa MACLSEL 2 1 020 5 05 28 gt A2 SETPOINT CTRI 50V von MACHLSEL A AUX CUR SENSE REMOTE SENSE 675 Sada 520 1 64109 X18 75 Return to Section TOC Return to Master TOC MODE SELECTOR SWITCH MACHINE SPECIFIC EEPROM ig 1E 00254 5 SOFTWARE 00700 4 SOFTWARE X9 ve PIPE SWITCH DATA igi gu XC17S20XL 64109 Xi7S10XL TH s e en 51 B 50 7 orga BK 027 VK 118 48 fpga mc USED FOR TEST PURPOSES ONLY E AT25128 27 TS MEM 4 fpga 332 USEN DEVELOPMENT 04w PURPOSES 9 SHOWN LOOKING FROM THE 1x FRONT OF THE
27. LL E i 1B i100V 64109 17A 200V E 8007 Veo T 019 ee 0 qm UU Y TK 04 6 90 ag H 16v 8 xd 16 159 Colt PCB 8 VOLTMETER ON HCTLOSEPW 1169 5 V LEFT MOST DECIMAL PT E 732 M ux Bye LES 5A x 3 01 ay VOLTMETER 5 Laa 1 168 717 SUPPLY ON TO VOLTMETER Lo OIO AMETER PSET ACT votas sense e ES AMMETER DISPLAYS PRESET Y 515 Vaw BANGER OIL PRESS olov 3 he TO AMMETER INPUT 90 44 X i R27 9 T t 1 HCT40S3PW 044 AMMETER IN 9 LEN ed Stu Bs pz STARTER BUTTON PRESET lt olo PRESET LEVEL INPUT 4 ano xe 5 4 05 4 jd 1 10 VOLTMETER INPUT x E 105 VOLTMETER 1N ee 876 9 amp v RIGHT MOST DECIMAL 5 5 2 c 61W VOLTMETER N CIs gt DECIMAL PT COMMON eios D t _ i 50 zi in Plug cc VOLTMETER DISPLAYS PRESET 84107 ac METER INTERFACE CIRCUIT w BLINKING LEFT DECIMAL DURING HOLD 9 Nisl nu e
28. GND E EXCITATION 2248 HOUR METER Engine amp POSITIVE WINDING Battery POSITION m CUR MU 206 GND SCREW ON 2001 INSIDE LEFT FRONT BYPASS 2 7 9 R3 5M 224A 5N gt 5N 5K FUEL GAUGE ASSEMBL GND K 5M e 208C 5H 4008 P1 J1 56 IDLER CONTROL Amphenol 210F 251 Model 3 tm a 1 Q NOTE LEADS 31 AND32 NOT USED c 150 201A HOWNIN TAPE LEAD ENDS AND SECURE FUEL SENDER 7210F AUTO POSITION 200A 200 115 12 5 GND N Engine Protection 2 e410 RYDE CASEERORIOHT 58 121814 2 28 2 au Light ate de itu 42VAC aan 0000 1 2088 0 K 77 GND A 2106 572251 0 RCDI 2298 15 p WORK H e43 21 GND B 5 E 50 360 lo Sense REMOTE 2 0 778 GND G GND C POSITIVE BRUSH CONNECTED n 261 5 CONTROLI 76B i TO SLIP RING NEAREST 8 d q GND D JA 9 9 9 9 9 TO THE LAMINATION ROTOR 2 low c contacton 909 758 D SF 2c 28 2A uu N Cie D gt 48 4 Sow 212A me 5 a s ineo Pus 5 10 BUTTON CB7 SHOWN N 1 BUTTON GROUND B 5 223A PCB2WELD CONTROL PC BOARD 13 AMPHENOL 1 0 20986 3 22 155 15A 15A 210 210 GND R 7 510 2108 2108
29. sse B 9 o 2 0 i c 5 Return to Master TOC RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 5 2 G 5 Return to Section Return to Master TOC o 0 5 2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Ranger 305D SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operating and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e e Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection 5 28 WARNING ENGINE EXHAUST can kill Use in open well ventilated ar
30. VOLTAGE FEEDBACK CIRCUIT TOUCH START TIG CIRCUIT 213 2 XA 0 9 8 390 E CUR SENSE 1413 K V FEEOBACK 44V ev 8 10 VOLTAGE FEEDBACK 1 SHUNT IN POSITIVE LEAD SENSE PR iK 10 approx 60 ocv amp Return to Section Return to Master TOC uB IN PIPE AND STICK HIGH IN WHEN WELDING REMOTE WELDING CONTACTOR CONTROL CIRCUT 2 amp SENSE CIRCUIT 2 amp 4 CLOSURE FROM AMPHENOL amp TERMINALS CONTROL l 46 IDLE SWITCH SENSE CIRCUIT 4F Ser 0 400 CUR AMP L HLIDLE_SENSE 128844405 1 ula R33 R98 773 SHUNT INPUT pn 181 SHUNT IN POSITIVE LEAD eo
31. o 5 9 lt 818 ES 43 9 c G 31 SCHEMATIC WELD CONTROL PC BD ALL CODES G4108 1 PG OF 5 ELECTRICAL DIAGRAMS G 31 c 5 JA FOR ICS IE D o METER ENABLE feo asv 050 I 4 4 E a L 1 6 6 4 6 6 6 4 1 1 1 B 25 Vee vec
32. 13 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK RAED 4 AMMETER NO CONNECTOR ON RANGER 250 WHITE 1 REMOTE OTHER MODES 15 VOLTMETER NO CONNECTOR ON RANGER 250 YAELLOW 1 CONTROL 16 SHUNT CURRENT FEEDBACK 12 6 LABELS 000000 17 OUTPUT CONTROL FORCE MODE SELECT V cono ARTN FT 12 77 FRAME GROUND EARTH GROUND VIEW OF CONNECTOR ONPC BOARD EX 12PIN CONNECTOR THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC DESIGN INFORMATION JREFERENCE EQUIPMENT RANGER 305D CE UK DRAWNBY MAP L11946 DOCUMENT DOCUMENT ENGINEER SCALE SUBJ ECT MACHINE SCHEMATIC NUMBER REVISION Ri WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED NONE DATE 6 2003 CRM3363 112039 Return to Master Return to Section TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOL RANGER 305D G 19 SCHEMATIC ENTIRE MACHINE CODE 11122 L12213 PAGE 1 OF 2 ELECTRICAL DIAGRAMS G 19 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED A 02 FROM X MA
33. BOARD 1 VANTAGE ONLY J ARC CONTROL 1 CONTROL CIRCUITRY o E t 812 lt gt 9 5 ply 9 c t T TOUCH START OUTPUT VARIABLE CONTROL 4 PIPE FORCE VARIABLE ARC FORCE 4 15 f FIEDARC FORGE SELECT SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON HS MOD ISTHE SETTING OF THE LOCA Y WHAT PARTS OF THE 64107 64109 USED IN EACH T COMPONENT VALUE NTS S PRESET PRESET CONNECTORS BH CONNECTORS JUMPER APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIME CAPACITOR MEOWOLTS 12 ENGINE 12V CONTROL FUNCTIONS ORANGE RESISTOR OHMS WATTS IN EVERY OTHER MODE THE REMOTE IG MODE 410V REMOTE POT WILL SET MACHNETO MAX OUTPUT 13 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK RAED 4 AMMETER NO CONNECTOR ON RANGER 250 WHITE 1 REMOTE OTHER MODES 15 VOLTMETER NO CONNECTOR ON RANGER 250 YAELLOW 1 CONTROL 16 SHUNT CURRENT FEEDBACK 12 6 LABELS 000000 17 OUTPUT CONTROL FORCE MODE SELECT V cono ARTN FT 12 77 FRAME GROUND EARTH GROUND VIEW OF CONNECTOR ONPC BOARD EX 12PIN CONNECTOR THIS DOCUMENT CONTAINS PROPRIETARY INF
34. DIODEONLYON E Ble FRAME IS COMMON FOR ENGINE CONTROL CIRCUITS xx TonEPUuLCaLgOwD HGH PULLTOLOWIDLE MACHINE IDENTITY TABLE J212 lt 124 PINS JUVPERED TOSH ECT MACHNE 1 jrs n z ns MACHINE TOME FORHGHIDLE L4 lt RANGER 250 G amp D 4 x FRAME RANGER 305 660 VANTAGE 500 9 0 PULL OIL d BOARD VANTAGE 575 pe AIR VANTAGE 500 STARTERBUTTON METER 4 INPUT 0 2V 1V 1000 CNIVETER 0 METRO INPUT 12V when stating the machine RUNswitch ON and gt e PH Sart Button Pressed and held OV when the machine 5700 METERS OPTIONAL ONVANTAGE is not CN 40V or more when the machine is running SONRANGER 250 1 154 La o 12 8 lt Return to Section TOC Return to Master TOC 05 0 BLINK PULLED LOWANDHGH S L 153 a 4 FUELSHUTDOWN 210 lt 12V when the RUN switch is ONand the START Button is held IN If externally shorted the PTC will change to high impedance e 157 4 158 2 159 METER INPUT 0 2V 1V 1000 CV MODE 1510 METER INPUT
35. i Y M 23 2 een m CAPACITOR SMD CERAMIC 0 20072095 WEILE LM Q 2 s E x FOO ort g c atte EE 2 sn T I ey s nds 25 3 Jos can eras CAPAGITOR SHD CERAMIC 500 105 SRO RTT IST RR RESISTOR SUD ETAL LA ONDE CT z CAPACITOR SUD CORAM 2700p SOR T 101 525000 35225MT RMT ROURU RESISTOR SMD METAL S323 25 e ge 0 ks Cel 27 17 05 CAPACITOR CERAMIC 0 100055 0 TT 0 El 2 x s 8 28 52502155 2 05007 CAPACITOR SHO CERAMIC 4700pF 509 S86 C is ROS 2023 ROW r oot wl Le CAPACITOR SHD CERAMIC sez 2 15 240 nostre Ros Rot RGIS IRESISTOR SMD METAL FILM HG 4 00K 1 Ew T 307 S25020 1 5MT 1 jos CAPACITOR SNO CERAMIC 00V 55 Ras dae RD Nu LS eet 2 8 4 84 525020245 CAPACITOR SMD CERAMIC 28V CS 7 R377 R426 RID RAT 0 x IN ost TEC tee 32 SiS SSH 2101501752003 DIODE SMO DUAL ZA 70V UDR CC SOT Read Rar ROT REST 103 sosooo eenosMr 6 RESISTOR SMD METAL FILM HON 68 1 1 0 CR 62 55 04 05 06 07 08 08 4 u Su 3s 8 65 48 j014 025 032 025
36. ALL CASE COMPONENTS SHOWN VIEWED FROM REAR 9 5 LINCOLN ELECTRIC xs olo ELECTRIC CLEVELAND OHIO US A BIS il lm Em 0 9 ojo NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOL RANGER 305D 6710 ELECTRICAL DIAGRAMS alis WIRING DIAGRAM ENTIRE MACHINE CODES 11190 11315 G4573 1
37. PULL OIL BOARD 12V when starting the machine RUN switch ON and La o 12 8 lt PH PTC FUELSHUTDOWN 210 lt 12V when the RUN switch is ONand the START Button is held IN If externally shorted the PTC will change to high impedance BATTERY POSITIVE p BATERY 123 1 e ROTOR Stat Button Pressed and held OV when the machine is not ON 40 or more when the machine is running 1 PAMSIGNAL 12V ON MULTIMETER PAMSIGNAL 412V ER CHOPBR G 22 5700 BOARD VANTAGE ONLY J ARC CONTROL CIRC UITRY o EE s HIE lt gle ES ply 9 ojo 5700 TOUCH START VARIAB LE PINCH PIPE ARCF ORCE oa SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON 1 WHAT PARTS OF THE G4107 G4109ARE USED IN EACH CONNECTORS APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIVE FIXED HOT START J1 AMPHENOL amp MACHINE ID JUVPER 42 ENGINE 12V CONTROL FUNCTIONS 43 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK NO CONNECTOR ON RANGER 250 45 VOLTVETER NO CONNECTOR ON RANGER 250 46 SHUNT CURRENT FEEDBACK J7 OUTPUT CONTROL ARC FORCE MODE SELECT COWPONENT VALUE UNTS CAPACITOR MFD VOLTS RESISTOR OHVSWATTS
38. 10V_REF VEARATARSAT 018 n AVE CURRENT BUFFER ew CIW E gt 177 olo gu rm E FO gt T 8160 ov gt 2 12 018 2 ie d XS JB of Mls ou pe 5 15 1 man ZAK E ES D Riz 7 1716W 4066BPW6 019 Aw Sax 019 90 a 8 C54 cn aye iw gus BD gov 05 TIMED AVG CUR RAZ 10 ENABLED Vi 5 327 Coy 7 154 Ed HM va CN LOCAL WIPER 12V 18 un 4 EA 0225W 04 7 Oe GND HE r gt MD 1 Ga K 1 kogsePw 4 IR xr iaa 1 13 MACHINE MIN SETPOINT 0 29 6 9 E 205 10 GND 01 RE b e Era IKO 73 8345 74A0T ZAK R28 1 QUK E TK 019 Bi PRE SETPOINT SCALE 2 146 176 014 Dein i Veo B MAX MIN E a A gt SETPOINT tpga gt 8 fin SA min E iN ger Ms vuU i CON Bx Bin GU 50 AN i MAGNE PRESET 29 8251 48 1107 1 4 1716W IN SERIAL DATA fpga gt 10K 8 2 xl Ai SETPOINT CTRL tpga 4 dls L
39. 15VCOM 5700 hee AY HGH PULLTOLOWIDLE MACHNE IDENTITY TABLE T lt PINS JUVPERED TO SELECT MACHINE 7 11511171 18 TOME FORHGHIDLE L4 gt lt RANGER 250 G amp D i FRAME RANGER 305 G amp D dU VBATERY VANTAGE 500 T E 0 PULL OIL d BOARD STARTERBUTTON METER 4 INPUT 0 2V 1V 1000 CNIVETER 12V when starting the machine RUN switch CN and gt 1410 METRO INPUT L lt E gt Sart Button Pressed and held OV when the machine 9700 METERS OPTIONAL ONVANTAGE is not ON 40V or me when the machine is running NFL NOJ 40RJ 5ONRANGER 250 1 15 1 gt gt PASHON 20 lt d erem o 153 12V when the RUN switch is ONand the Cp BRUSH Return to Section TOC Return to Master TOC START Button is held IN If exermally shorted BLINK PLLLED LOWANDHGH m 154 za the PTC vill change to high inpedance LOCKBACK TO FLASH 55 ree PONT 22 ROTOR L 157 158 2 35 159 METER INPUT 0 24 1V 1000 CV MODE 1510 METER INPUT CURRENT AY EE eeose 127 lt ABSOLUTE amp FOLDBACK
40. 6 16 6 s Vs E 007 87 asi SW SY 9 x p 6 1 5 x E E X5 Em Sle E m AR x12 2m x5 Me 54 c 224P A HCTA066PW 353 ZU v tel 7 pISE X 5v 1 4 t 1 if 4 IR Vec 28 137 66 108 584 86 99 515 ay OP 15 mar uu s TAE 4066BPW 3B074ADT 4066BPW 224P 29010 24 2244 20 55 33074ADT SV 0 7 T 7 T aV cls i 2 4 4 4 4 57 210 olo 5 Cle 5 pit 5 E LE LSU c N SW Xi x 22 GND Sv Go 9 av 58609 4 4 1 c5 89500127253 i Ww Xs WW olo B i Ee Lg E 50V 1 1123 38 1964 77 88 50 E E 5 20 10000 qom OPERATIO 4 4 57 5 64109 17510 1 550129 5 9 ac 16 PIN MACHINE SELECT REMOTE AMPHENOL Y STARL HW INPUT SENSE 12 BIN BATTERY LOMMDN FUNCT
41. Meters display setpoint vol Meters display actual volts Hold function displays actual volts and mps for approximately 5 sends a During this hold display theright most decimal point wil ts amps when rot welding and ams when welding er welding stops WELD VOLTMETER 209 2 TURNS THRU 210 SWITCH 52 212 START BUTTON SHOWN IN RUN 210 FUELSOLENOID PULL 1724 72 2 232 ZINC blink FERRITE COILIS ENERGIZED BY HOUR METER 3l STARTER SOLENOID 5 9 LOW 77 2 NO CONNECTION TE 231 134 25 1 4040439 82 9734 4 SOLENOID P74 CIRCUIT 12 VOLT PULL ELECTRIC BATTERY QUEM 4 5 PUMP 3 PULL COIL MOTOR ALTERNATOR 11 OHMS PCBOARD STARTER HOLD FRAME REL OILPRESSURE COOLANT Battery GROUND SWITCH TEMPERATURE 1 12 6 volts at rest ANDFLEL 174 CLOSES SWITCH eir st to AMPHENOL 14 volts engine PUMP LOWOIL CLOSES ON HIGH control board gt running 777 77 ENERGIZED PRESSURE TEMPERATURE FUEL SENDER ABOVE 2307 ROPRIETARY 8 CONFIDENTIAL D OCUME NTC ONTAINS PR OP RIETARY INF ORMATION OWNEDBY LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU NICATE D STARTER SOLENOID REMOTE
42. red wht 5 8 6 10 REEN W YELLOW STRIPE POSITION 2A SW ow ENGINE FUEL ln 86 1 8 IOLI 95990996 L2 L3 RF CHOKES aow GND H olL coll PCB3 b ooooo E PLUGS ENGINE COMPONENTS 71 2 9 gt 6 FRAME FUEL SOLENOID IDLE SOLENOID PULL COIL BD ELECTRICAL SYMBOLS PER E1537 GND GROUND j O CONNECTORS VIEWED FROM INSERTION END e ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR i 0 810 D 0 12 olg C pir c E CLEVELAND OHIO U S A 64571 lm 45 9 ojo RANGER 305D ELECTRICAL DIAGRAMS Ga WIRING DIAGRAM ENTIRE MACHINE CODES 11188 11275 G4571 1
43. ENGINE 1 ENGINE CIRCUIT ALTERNATOR D SOLENOID PULL HOLD COIL COIL PULL COIL PC BOARD PLUG 12V BUTTON BATTERY nn ah STOP SWITCH Weld Power and Control Weld Power Approximately 90VDC power as described earlier under the heading Generating Power is supplied to the IGBT s See IGBT Operation and to the control cir cuitry in the power module as well as the weld control PC board The IGBT s control the weld output by switching the weld power on and off using a 20 Khz PWM Pulse Width Modulation signal from the control PC board This PWM signal varies the ratio of on and off time thereby controlling the power passing through to the welding arc See Pulse Width Modulation AMP DISPLAY VOLT DISPLAY WELD CONTROL BOARD OUTPUT MODE WELDING CONTROL SWITCH TERMINAL IDLE SWITCH ARC CONTROL The DC power that is being controlled by the IGBT s is now applied to the choke The choke is a heavy con ductor wound around an iron core This device stores power and tends to resist any change to current flow During the IGBT off cycle the choke begins to dis charge through a freewheeling diode on the power module This diode provides the necessary current path allowing the choke to use its stored power to maintain a smooth flow of current to the welding arc during the IGBT s off times Weld Control and Feedback The operator provides input to
44. SHOWN IN HGH POSITION L THERMOSTAT F Usi 43 5 ED THERMAL SENSE if used T MACHINE IDENTITY TABLE PINS UMPERED TO SELECT MACHINE Jr6 17 J1 8 MACHINE RANGER 250 JI 18 RANGER 305 G amp D VANTAGE 500 VANTAGE 575 AIR VANTAGE 500 EW A J1413 amp 9 J112 8 EW ANN 7 KEW MACH SEL 1 MACH SEL 2 MACH SEL 3 J1 6 lt J1 5 lt MACH SEL 4 716 TIG MODE 9 MODE SELECTOR swrcH L a AUSTRAILIAN VANTAGE 575 USES 3 POSITION TOGGLE SWITCH J7 15 lt PIPE MODE 314 6 TROTRIRLUSLE DV VANTAGE 575 J743 N A J7 12 lt N A CV MODE ROCV ENABLE ANN A ANN ANN 9 AAN ANN WN AAA 9 ANN ANN TFOR AUSTRALIAN VANTAGE 575 1 4 THERMAL LAMP IDLE CONTROL ELECTRICAL DIAGRAMS TRANSFORMER lt CONTROL BOARD POWER FROM 40100VDC CHOPPER BOARD INPUT J3316 lt 253 SILVER 36 THERMAL PROTECTION gt gt 8 13 2 INDICATOR XV ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT 12V Battery Supply to 15V COM IDLE CONTROL THERMAL SHUTDOWN if used CURRENT LIMITS REGULATION MODE ON OFF
45. or depend ing on the polarity chosen 7 ARC control to 0 initially and adjust to suit 8 Adjust wire feed speed at the wire feeder FIGURE C 1 Ranger 305D K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM 14 PIN AMPHENOL K867 UNIVERSAL ADAPTER PLUG TO WORK ELECTRODE CABLE TO WIRE FEED UNIT RANGER 305D LINCOLN 5 ACCESSORIES CONNECTION OF THE LN 25 TO THE 5 Attach the single lead from the LN 25 control box RANGER 305D ACROSS THE ARC to the work using the spring clip on the end of the SEE FIGURE C 2 lead This is only a control lead it carries no welding current 1 Shut the welder off 6 Place the IDLER switch in the AUTO or HIGH position as desired 2 Connect the electrode cable from the LN 25 to the terminal of the welder Connect the work cable to the terminal of the welder CAUTION If you are using an LN 25 without an internal contac NOTE Figure C 2 shows the electrode connected for tor the electrode will be HOT when the Ranger negative polarity To change polarity shut the welder 305D is started off and reverse the electrode and work cables at the Ranger 305D output terminals Return to Section TOC Return to Master TOC 7 Place the WELD TERMINALS switch in the NOTE Welding cable must be sized for current and WELD TERMINALS position duty cycle o
46. 2 Routine and Periodic D 2 Engine Maintenance NN 0 3 Engine Oil Change EE D 4 Oil Fiter CHANGES ERES D 4 Service Instruction amp Installation Tips nennen D 5 Cooling SY StS D 6 Tighten the Fan D 6 e 52 11 11 0 7 Battery 0 7 8 Welder Generator D 8 ir s D 8 GIS a EM D 8 2 65 554 2252550 5 52 442552 ERE D 8 Cable Connections ieie a in E a E AE EE E E E EEE D 8 Brush Removal and D 8 Receptacle Testing and Resetting Procedure sse D 9 Major Component 4 0 aan aeaaeai D 10 Q p 9 5 Return to Master RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC o 0 5 0 2 5 WARNING qualifi
47. 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC F 55 TROUBLESHOOTING amp REPAIR STATOR SHORT CIRCUIT amp GROUND TEST WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there are undesirable electrical connections between the stator windings and chassis ground or between individual windings within the stator This test should be performed if flashing voltage is present at the rotor slip rings Rotor resistance field bridge rectifier field capacitor and all associated wiring are proven to be good but the stator output voltage fails to build up to normal levels or is too high in one r more but not all of the windings MATERIALS NEEDED Miscellaneous hand tools Ohm meter RANGER 305D LINCOLN 5 F 55 Return to Section TOC Return to Master
48. B2 T 768 11 8 2104 75 t 2 101 102 2258 Bl 82 B3 B4 7 223 x m L E gt 9 48 50 UE GND K 231 210 GROUND F e GND B 5 223 210 215 GND SCREW ON 7 2 M 4 FAN BAFFLE T CONTACTOR 4 2094 GND L 7234 oo LEAD COLOR CODE CONTROL th 728 zs 209 4 aaa 1 1 1 4 5 B BLACK OR GRAY 53 5 0000 R RED OR PINK d ut aoao looooo W WHITE SHOWN IN 5 6103 Hol blk 2 8 WELDING ON PRES red wht 5 g 6 1 G GREEN W YELLOW STRIPE POSITION SW TP 0 _ GROUND Q JO 1 6 1 m GND H 23 EN 25009959 60000000 12 L3 RF CHOKES Gan PCB3 00000000 PLUGS ENGINE COMPONENTS T cx d2 4 16 STARTER FUEL SOLENOID IDLE SOLENOID PULL COIL BD c ELECTRICAL SYMBOLS PER E1537 GND J GROUND J OJS CONNECTORS VIEWED FROM INSERTION END 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR 9 5 LINCOLNS A olo ELECTR CLEVELAND OHIO U S A Bl x il lm pio 0 9 ojo NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOL RANGER 305D 6 11 ELECTRICAL DIAGRAMS G 11 SCHEMATIC ENTIRE MACHINE CODE 10926 L11946 PA
49. E 8 FIGURE E 1 RANGER 305D BLOCK LOGIC DIAGRAM Return to Master TOC SHUNT POWER A ENGINE Y CHARGING LIGHT SYSTEM LIGHT CODE 10926 ONLY ENGINE PROTECTION ENGINE CIRGUIT ALTERNATOR T E ROTOR STATOR AMP DISPLAY L 120 240 VAC 42 VAC WELD CONTROL INDING AUX WINDING WINDING TOU come mm P C BOARD CURRENT DISPLAY SENSOR AMPHENALS S 0 gt ke 5 IDLE SOLENOID PULL HOLD COIL COIL FLASHING PLUG 12V BUTTON PULL COIL BATTERY PC BOARD IDLE un RUN 1 STOP OUTPUT MODE WELDING SWITCH CONTROL SWITCH TERMINAL ARC CONTROL Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 ci gt 23 cic 515 ply oO ajo Return to Section TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 BATTERY ENGINE ENGINE PROTECTION CHARGING IDLE CONTROL ENGINE PROTECTION LIGHT ENGINE PROTECTION ENGINE CIRCUIT ALTERNATOR PUMP FUEL SOLENIOD 10 IDLE SOLENOID PULL HOLD COIL COIL qn at STOP SWITCH GENERAL DESCRIPTION The Ranger 305D is a diesel engine driven welding power source capable of prod
50. E Dc Bus VOLTAGE 2 Ocated on output panel jac POLARITY CAPACITORS 4 904 10VDC HIIDLE 6010 65 VAC PHASE TO PHASE betweenterminas 777 SWITCH BETWEEN W1 W2 AND W3 2 IGBT 8 AT HIGH IDLE NEGATIVE __ ourPUT E Bl TWO POLE 3600 RPM ALTERNATOR CHOKE OUTPUT RN PWM Signal to Chopper i THRU TERMINAL end FERRITE Power Supply 15 volt 20 kHz Return to Section TOC Return to Master TOC IGNAL Open CircuitVolts Deon Tol Max Mi 2TURNS 7 ist and D3 locatel f fan baffi CC 58 THRU TWISTED Ep Rotor Flashing 12 volts lt 3 OAN SAINE 1 on left side of machine CV 38 WISTE pag G0Sams TO AUX 120 V AC SLIP RINGS Pipe 58 PAIR until generator builds up located a front of fan taffle 200 1 2 then 50 volts 0 amps on left side nea bottom of 50 V DC Control Board senses Weld Output 1303 8 14 346 25 39 23 J 3 10 R3250HM machine OUTLETS 200A from Current Feedback Shunt 2045 61 ROTOR FLASHING to activate idler 2065 62 2 1 2001 AND 2 5 215 LOW IDLE SOLENOID HOLD COIL 0V LOW IDLE 12088 1345 Control board common is AMPHENOLS 42 VOLT AC at welder positive output 15V LOW IDLE TO PULL COILBOARD WIRE FEEDER 17 7 1 and shunt 2 4 404 3 VIA CIRCUIT POWER 030V 156 074 Svich dosed for high B
51. F 102 o 2 0 i c 5 z 3050 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 5 5 9 815 4353 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into four main categories Output Problems Function Problems Engine Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may c
52. G 33 SCHEMATIC WELD CONTROL PC BD ALL CODES G4108 1 PG 5 OF 5 ELECTRICAL DIAGRAMS G 33
53. V BATTERY L Em 428 lt b FUEL SHUTDOWN 12 10 lt 12V when the RUN switch is ON and the START Button is held IN If externally shorted the PTC will change to high impedance V BATTERY 427 lt PULL COIL BOARD 12V when starting the machine RUN switch ON and Start Button Pressed and held OV when the machine is notON 40V or more when the machine is running BATTERY POSITIVE BATTERY NEGATIVE 22 3 lt 15V P 4 eO a ROTOR J22 1 BATTERY CHARGE Uwe g 0211 15V when the battery charge light is OFF Machine running alternator charging battery 41 5V when battery charge lightis ON Battery Low Not charging and for a few FRAME seconds when machine is turned off 47 5 ohm 339 PWM SIGNAL 12V ON MULTIMETER pam PWM SIGNAL 42V L11943 M 4841 475 ohm PWM COMMON 4840 415 ohm PWM COMMON 43 12 1 CHOPPER BOARD ALL MACHINES 32 d CHOPPER BOARD WANTAGE ONLY SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON WHAT PARTS OF THE G4107 G4109ARE USED IN EACH APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIME RANGER 305D LEAD COLOR CODE COMPONENT VALUE UNITS B BLACK CAPACITOR MFD VOLTS G GREEN O ORANGE RESISTOR 5 5 R RED U BLUE CONNECTOR PIN NUMBERS W WHITE EX
54. a2 ELECTRICAL DIAGRAMS GAR SCHEMATIC ENTIRE MACHINE CODE 11039 L12038 PAGE 2 OF 2 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X 660211 MANUFACTURER TRANSFORMER 2 AUXILLARY i AUXILIARY CURRENT SENSE SENSE TOROID WELDING 5 338 TERMINAL CONTRO BOARD 40 100 j CONTROL POWER FROM INPUT SWITCH CHOPPER BOARD som n 4 12 HA ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS ON POSTION IDLER NOT ALL MACHINES USE EVERY CIRCUIT CONTROL IDLE SWITCH SENSE PROTECTION V BATTERY SEN Battery Supply to SHOWN IN HGH POSITION uERH LLARE X 313 22 0 INDICATOR Idle Hold Solenoi IDLE GOLD li IDLE HOLD COIL SOLENOID 5 4 DIODE ONLY ON E HOLD J3 15V COM r 1 THERMOSTAT IF USED fraie FRAVEIS COMVONFOR Otherside ofthe Idle Hold Solenoid ns cot T 2 IDLE CONTROL IDLE CONTROL ENGINE CONTROL CIRCUITS 30V when energized LOW IDLE 12V 3 THERMAL SHUTDOWN if used when notenergized HIGH IDLE os S m CURRENT LIMITS 5 REGULATION MODE TO IDLE PULL COIL BOARD Alte HIGH PULLTO LOW IDLE MACHINE IDENTITY TABLE MACH SELI ONIOFF GS ON SS 212 6 3 424 PINS JUMPERED TO SELECT MACHINE WOD HVO S ya FOR AUX USE CONNECT 1 J1 5 1 6 J1 7 1 8 MACH SEL 2 MACHINE S TO FRAME FOR HIGH IDLE MODE
55. 204537 1028 ZENER DIODE SMD SIN 15V 56 SMB E EASA 3 DIODE SD SWB2V 58 SNE 215 825000 10038MT R188 R199 R41 R25 RISO RESISTOR NITE A KA 2 R200 R203 RESISTOR SMD 12 10HMS 14W 1206 136 TR TESTPT FUNTOO M FUNCTIONAL TEST POINT R204 R205 RODS RIOT 1 4 ROBE RS NB 35 255 3 CONNECTOR MOLEX MIN POB T6 FIN TIN LECCE 20 iD 228555 ncessroR SMDAT SoH 16 206 167 50 62020 1 17 CONNECTOR MOLEX T2 PIN TIN east RABE 21 sao CONNECTOR 316 1 RESISTOR SHO METAL FLM TONS U 3 1520020 1 15 CONNECTOR AO LESENE EE T19 152801 1801541 7 RESISTOR SMD 1 82K 1AN 1200 1 TR 784 POWER 225 625000 87525MT 3 RESISTOR SND METAL FILM UIGNAT SIT 2 Iu 5 15 2 707 1825000 58 5 RESISTOR SMO METAL FILM 1108 68161 TRANSISTOR 60123053 40 MM 12 RESISTOR SMO 7 amp 0 YAW 206 16 TR 122 1520000 39225 2 RESISTOR METAL FIM 1 100 39 2K 1 sr ME TRANSISTOR ADV SOT 20M 324 25000 28RTSMT 1 RESISTOR SMD METAL FIM 17108 2878 ASECY T T2704 05 862088 x EH 5 pee I Ex ne vu 52 1 02 TRANSISTOR SOT 250 15A 60V E 50
56. ROCV ENABLE VFORALSTRAUANVANTAGE 575 KR KR KR KR N nb CURRENTFEEDBACK amp 1 BATERY 123 5700 64107 ONLY NNGDLPHSIVINHZHL PAMSIGNAL 12V ON MULTIMETER FEEDBACK PWM 5700 FORWELDCONTROL PAMSIGNAL 12 arans REG ULATING CHOPPER VOUTAGE FEEDBACK AMPLIFIER CONTROL PAMOOMVEN c m sq 2 CIRCUIT CHOPBR d BOARD VANTAGE ONLY ARC CONTROL CIRC UITRY o EE s HIE lt gle ES ply 9 ojo 5700 TOUCH START VARIAB LE PINCH PIPE ARCF ORCE oa SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS WHAT PARTS OF THE G4107 G4109ARE USED IN EACH PHESET CONNECTORS APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIME G MODE 10V FIXED HOT START AVPHENOL amp MACHINE ID JUMPER Sve 42 ENGINE 12V CONTROL FUNCTIONS 43 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK CONNECTOR PIN NUVBERS NO CONNECTOR ON RANGER 250 EX 12PIN ONNECTOR REMOTE OTHER MODES 45 VOLTVETER NO CONNECTOR ON RANGER 250 3 CONTROL gt 46 SHUNT CURRENT FEEDBACK 5 2 J7 OUTPUT CONTROL ARC FORCE MODE SELECT COMMON 000000 7 12 77 FRAVEGROUND LATCH gt EARIHGFROUND VEW OF CRCBOARD
57. ibi TROUBLESHOOTING amp REPAIR ii Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE AND IDLE PROBLEMS 1 Check circuit breaker CB7 RECOMMENDED COURSE OF ACTION PROBLEMS SYMPTOMS 1 Check wiring and connections Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC 2 0 5 The engine will not crank when start button is pushed The battery does not stay charged Reset if tripped Make sure the run stop switch is in the RUN position Check for loose or faulty battery cable connections See wiring diagram The battery may be low or faulty If the battery is low recharge it If the battery will not accept a charge replace it Check for loose corroded or faulty connections at the bat tery Check for loose or damaged alternator drive belt The battery may be faulty A CAUTION at the starter motor glow plug button CB7 circuit breaker run stop switch and the start button See wiring diagram Check the chassis ground con nections between the engine block and the negative battery terminal Place the run stop switch to the RUN position Press the start button whil
58. receptacles 1 12 308 i ALSO FUNCTIONS AS AN ENGINE Control board circuits associated with J 2 ae part 023 411910 015 1 010 olL ENGINE d of engine electrical system and are common to 305 1 D J UMPER Part 223 PROTECTION frame ground negative battery terminal WELDAMMETER WELD VOLTMETER of amphenol plug and EUN RELAY 9 lead assembly Meters display setpoint volts amps when mot welding CIRCUIT BREAKER 20 Meters display actual volts and when welding 209 Hold function displays actual volts and mps for approximately 5 seonds after welding stops 210 During this hold display theright most decimal point wil blink START BUTTON SWITCH S2 ot e s 3l FUELSOLENOID PULL 2 bo CONNECTION COILIS ENERGIZED BY HOUR METER 209 STARTER SOLENOID 15V LOW IDLE 77 231 YELLOW 229 404 43 8 82 CONTROL CHARGING STARTER LIGHT SOLENOID 1 INPUT x 12 VOLT ELECTRIC CIRCUITI AMPHENOL rd BATTERY FUEL STARTER PUMP PULL COIL OTOR PC BOARD ALTERNATOR FRAME TEMPERA OIL PRESSURE P N 111768 E 22 SWITCH TEMPERATURE t Battery charge lamp wil be 12 6 volts at rest CLOSES ON SWITCH Located next to on whenever RUNSTOP 14 volts engine 7 LOW OIL CLOSES ON HIGH control board switch is in RUN position and running PRESSURE TEMPERATURE altemator is not charging ABOVE 230F Located on wiring behind 1 7 305 4 GLOWPLUG GLOWPLU
59. t FUEL GAUGE 5 oo 208 185 IDLER CONTROL 760 9 1 1 LINE 5A x 650 251 2 oo 305 Amphenol TERMINALS i p PS Model 56 200 200 03 252 Select 5 22 7 SHOWN IN 75A Hot Start e gt 1 AUTO POSITION an 5 i NE mad 2 GND N 210F Er Arey 32 GND SCREW ON RIGH Y 210E 1 4 w 4 c avacl ZOT 4 INSIDE CASEFRONT 5 POSITIVE BRUSH CONNECTED Engine Protection 210F 2088 o o 04 03 20A TO SLIP RING NEAREST Light PLI 2333 Alt WORK FRAME GND Cup BLACK A TO THE LAMINATION ROTOR 2106 Sense o Sel E 5 3 6B 2100 2298 224 N 20 13 z gt 2 768 229A 5322 X contactor SO e 57 GLOW 25 N 13 2 01 48 50 PLUG S IRUNSTOP 212 gis SUN A SWITCH S2 START ase Back In n SHOWNIN 51 BUTTON cic GROUND cun J 1190 ou RUN POS PCB2WELD CONTROL PC BOARD 5 Sip AMEHENOLL o TERMINALS BLACK 2098 5 3 20 Cr 2 4 68 prm WHITE sc WHITE 7 17 210 2104 2108 76A TERM 7 2100 GND R CONTROL 8244 PETSA NA 210 1 CONTACTOR 2 2258 9 9 4 3 GND K 1 fof GROUND gt GND B us 223 231 P op GND SCREW ON AMPHENOL2 o o P43J43 FAN Lm 209A 111131 i 1 4 1 5 LEADCOLOR ODE CONTROL 228 229A 209 P3 4
60. PROTECTION BYPASS UNTIL OIL PRESSURE BUILDS UP 15A BATTERY CIRCUIT BREAKER 212 P SWITCH N RUN ENGINE ELLOW PROTECTION ENGINE RELAY 210 START BUTTON 210 SWITCH 52 FUELSOLENOID PULL 209 OO COILIS ENERGIZED BY STARTER SOLENOID YELLOW BATTERY CHARGING LIGHT INPUT TO Battery charge lamp wil be on whenever RUNSTOP Switch is in RUN position and altemator is not charging 231 AMPHENOL Y PL2 a 228 ALTERNATOR Battery voltage 12 6 volts at rest 14 volts engine running NZ STARTER HOUR METER 15V LOW IDLE E 9 4 229 SOLENOID 50 12 VOLT PULL BATTERY STARTER MOTOR FUEL LENOID HM HOLD PUMP OHMS RED ELECTRIC FUEL FRAME GROUND OILPRESSURE COOLANT CLOSES ON LOW OIL SWITCH CLOSES ON ABOVE 230F SWITCH TEMPERATURE 404 43 8 B2 m PULL COIL PC BOARD P N L11768 1 Located next to pnm HIGH control board PRESSURE TEMPERATURE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLIC
61. gt GENERAL INFORMATION ELECTRICAL SYMBOLS PER 1537 CAPACITORS MFD 022 59 UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 0805 UNLESS OTHERWISE SPECIFIED DIODES 2 200V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 7 7 FRAME CONNECTION EARTH GROUND CONNECTION 5 SCHEMATIC USED FOR BOARD ARTWORK IN 64197 AND 54109 CONT ARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL PARES On USED ANT WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL C EQUIPMENT TYPE COMMON ANALOG CONTROLS SUBJECT SCHEMATIC ANALOG CONTROL PCB DOCUMENT DOCUME Am APPROVED sies HORA 117272006 cues s G4108 1E7 THERMAL ate 1200 V FEEDBACK K R39 Veo Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 3 3 RANGER 305D
62. ueso 12750 5 5 xe na na 62 n clock Xt SHR ad L AZ SETPONT CTRI toga g 100 8 aA 197 SLOM SETPONT CS SETPOINTS 10995 FIXED START 1 ya 50 eR Ls x VAR START 15 v sit 5 i uci i iot 5 PIPE_AF_SETPOINT VAR ARE FORCE xs 1 33074ADT HA FIXED TOUCH START D Ti 3 5 gt FIXED ARC FORCE 5 rl SETPOINI c mau 11 11 45V T 2L wh 7535 e RIS T A Uy D 13 tie TAK 8 E 5 gt FIXED MIN ENABLE 01 ps TUM P i x 37 start 990 3 5 88 27 RL SELECT 1 A 8 3 150 552 9354 T 8 toca AL 91W view Ves aw 1 51 5 aly m LL 8 Vso xs 5 ao POT 50 20 0 1 5 6 aitov 10 ct 835 1A6w E 4 17140 072 2 102V BUF 9 41 1 33074407 Gs 5 mw 8 JIK 100 5 02258 Sov 018 iA V 4 66 A 4 Jum E TOUCH START n e Q 072 R389 Sw i L DO 5760 SU 8 ba g
63. 1206 162 2 41 e 2 5 215 LOW DLE SOLENOID HOLD COIL 0V 8 LOW IDLE AND 2088 315 Control board common is 42 VOLT AC at welder positive output 15V LOW IDLE TO PULL COILBOARD WIRE FEEDER 177 andshunt 24040 AMPHENOLS POWER 0 10V T 76 7 4 Swich closed fcr high idle 42 WELD CONTROL 3 14 252 IDLER SWITCH oY 5075 pc BOARD 3 7 251 4 2 42 VOLT AC REVOLVING FIELD OY maga PAN G40 AMPHENOL BOWER TOR FIELDRESISTANCE TO AMPHENOL REMO 25 WO 114 013 4 5 ROTOR FELD CIRCUIT 9 Located on front of fan TO AMPHENOL Y e 75A 1 1 10 7 9 214 110 ET top of ban 218 Relay CR1 and 04 on fron 279 7 6 baffle onright side of machire ROL 10K 2 278 7 7 7 15 220 7 16 222 VOLTAGE FEEDBACK SIGNAL Return to Section TOC Return to Master TOC 1217 7 8 TOROID SENSES AC POWER TO 260A 034 412 to 14V NORMAL OIL PRES INPUT 2 0 2248 ACTIVATE 261A 33 LOW IDLE IDLER 2 7 2108 12t014V RUN INPUT o 210 ELECTRIC FUEL PUMP AND FUEL GLOWPLUGS SOLENOID HOLD COIL THRU D4 IT CLOSE CR1ENERGIZES OPENING CONTACTS SHUTTING OFF FUEL DLENOID TO STOP ENGINE
64. 4 VANTAGE 500 BLINK PULLED LOW AND HIGH gt gt i VANTAG 575 MACH SEL 3 IN LOOKBACK TO FLASH gt us RANGER OIL PRESSURE g V BATTERY AIR VANTAGE 500 LOGIC DECIMAL POINT HMETED VBATTERY 70 PU 446 EN 0 MACH SEL 4 47 3 DISPLAY 8 4 v J4 9 METER INPUT 0 2V 1V 1000 ON METER STARTER BUTTON 47 16 5 1 A 12V when starting the machine RUN switch ON and t L 0 0 28 lt P Start Button Pressed and held OV when the machine TIG MODE STUD METERS OPTIONAL ONVANTAGE is notON 40V or more when the machine is running ON OFF 5V ON y NOJ 40RJ 5ONRANGER 250 4241 454 1 HOLD 5V HOLD 5 FRAME PIPE MODE 52 FUELSHUTDOWN 42 10 LP75 POSTE e 22223 Wei 1 1 Return to Master TOC Return to Section TOC i 47 15 Return to Section Return to Master TOC i 116 3714 4 MODE SELECTOR G SAR switcH L a AUSTRAILIAN 47 12 VANTAGE SS USES A V DD SWITCH VANTAGE 575 START Button is held IN If externally shorted BLINK PULLED LOW AND HIGH 54 the PTC will change to high impedan
65. 8 1 DISPLAY WELD VOLTS PWM SIGNAL 412V ON MULTIMETER CHOPPER 47411 ANN AAN ANN AAN AAN AAAC ANN 9 ANN Wo ANN 1 FEEDBACK BOARD STUD FOR WELDCONTROL PWM 47 5 ohm gt SIGNAL 3124 ALL MACHINES E bx REGULATING CHOPPER STUD VOLTAGE FEEDBACK gt t AAA AMPLIFIER 47 5 ohm CONTROL POINT CONTROL gt 33 10 PWM COMMON 7 CIRCUIT aum BOARD 1 VANTAGE ONLY J ARC CONTROL 1 CONTROL CIRCUITRY o E t 812 lt gt 9 5 ply 9 c t T TOUCH START OUTPUT VARIABLE CONTROL 4 PIPE FORCE VARIABLE ARC FORCE 4 15 f FIEDARC FORGE SELECT SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON HS MOD ISTHE SETTING OF THE LOCA Y WHAT PARTS OF THE 64107 64109 USED IN EACH T COMPONENT VALUE NTS S PRESET PRESET CONNECTORS BH CONNECTORS JUMPER APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIME CAPACITOR MEOWOLTS 12 ENGINE 12V CONTROL FUNCTIONS ORANGE RESISTOR OHMS WATTS IN EVERY OTHER MODE THE REMOTE IG MODE 410V REMOTE POT WILL SET MACHNETO MAX OUTPUT
66. Hold function displays actual volts and mps for approximately 5 seonds a During this hold display theright most decimal point wil ts camps when rot welding and ams when welding er welding stops 2 TURNS THRU WELD VOLTMETER 209 od 212 210 SWITCH S2 IL START BUTTON SHOWN IN RUN 210 FUELSOLENOID PULL 1724 72 2 232 NC blink FERRITE COILIS ENERGIZED BY HOUR METER 3l STARTER SOLENOID 5 9 LOW 77 2 NO CONNECTION TE 231 77 134 229 404 043 8 82 STARTER SOLENOID REMOTE SL 9734 732 12 VOLT J PULL COIL NOTOR D p ALTERNATOR 11 OHMS PCBOARD PN 1 12 6 volts at rest ANDFLEL CLOSES ON SWITCH Located next to FUELSENDER ABOVE SE FUE BATTERY FRAME REL OILPRESSURE COOLANT AMPHENOL 14 volts engine 777 LOW OIL CLOSES ON HIGH contol board ROPRIETARY amp CONFIDENTIAL D OCUME ONTAINS PR OP RIETARY INF ORMATION OWNEDBY LINC OLN GLOBAL INC A NDMAY NOTBED UPLICATE D COMMU NICATE D Jm SOLENOID CIRCUIT 1 STARTER HOLD Battery voltage GROUND SOLENOD SWITCH TEMPERATURE running ENERGIZED PRE
67. Ranger 3050 For use with machines having Code Numbers 10926 11121 11188 11275 Domestic 11027 11122 11189 11314 UK 11039 11123 11190 11315 EUROPE Return to Master TOC View Safety Info Safety Depends on You o 5 Lincoln arc welding and cutting 2 equipment is designed and built z 8 with safety mind However 3 z your overall safety can be in p 5 2 creased by proper installation D e and thoughtful operation on c your part DO NOT INSTALL OPERATE OR REPAIR THIS ANGER non EQUIPMENT WITHOUT 1 READING THIS MANUAL AND 5 CONTAINED THROUGHOUT And most importantly think before you act and be careful 9 5 21 gjo 2 ali p SERVICE MANUAL View Safety Info Tete 0 0 2007 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth def
68. Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 ENGINE CONTROLS Figure 1 1 OPERATION FIGURE B 1 NOTE Layout and appearance vary between models RUN STOP SWITCH RUN position energizes the engine prior to starting STOP position stops the engine GLOW PLUG PUSH BUTTON when pressed this button activates the engine glow plugs to preheat the engine for starting This but ton also temporarily powers the fuel solenoid hold coil On codes 10926 and 11121 the electric fuel pump is also temporarily activated START PUSH BUTTON Energizes the starter to crank the engine and activates the fuel solenoid pull coil A In the HIGH position the engine runs at the high idle speed controlled by the engine governor B In the AUTO position the idler operates as follows a When switched from HIGH to AUTO or after starting the engine the engine will operate at high speed for approx imately 12 seconds and then go to low idle spee
69. SA 02 bax XO o aE lt 2 2 AE ply 0 9 ojo SENSING gb CUR AMP 835 gy E 332 OK 435 15v Av 15 15 piov m 8 E sx S cox R260 gx R baz 010 5 01 8262 332 5 CURSI CURRENT ENGINE 21K 221K 4 221K CR m 221K NOCTES TRE 2 1716W 3 8 1716W 10 O1W 2 p 11698 9 18 x36 nm xx bz uel hz ue xu us xzz gt i 13 45 143 4 3 3 4 41 57 is i SLOPE 128 90066 32 9 0916 SLOPE 5 AL SLOPES g SLOPE 2 t 1 4 AU66BPW 8 A0668PW 1 40668PW 1 A066BPW 4 0668 8 4066BPW 46668Pw
70. available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Return to Master Return to Master TOC o 9 lt 5 Return to Master PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une gr
71. contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC o Fle 5 5 9 G gt 813 5 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC F 19 F 19 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will not go to high idle when using auxiliary power Auxiliary power is normal when the idler switch is in the HIGH posi tion And the automatic idle func tion works properly when welding The engine will not go to high idle when striking an arc The automat ic idle system functions normally when using auxiliary power Welding and auxiliary outputs are normal when the idle switch is in the HIGH IDLE position POSSIBLE AREAS OF MISADJUSTMENT S ENGINE AND IDLE PROBLEMS The load on the auxiliary recep tacle may be too low The auto matic idle system will not func tion reliably if the load is less than 100 watts The device connected to the auxiliary power may be defec tive try using another device Make sure that the connections to the auxiliary devices are tight Some devices are designed to sense for adequate input power Products of this type may not turn on due to the
72. x 12 VOLT ELECTRIC CIRCUITI AMPHENOL rd BATTERY FUEL STARTER PUMP PULL COIL OTOR PC BOARD ALTERNATOR FRAME TEMPERA OIL PRESSURE P N 111768 E 22 SWITCH TEMPERATURE t Battery charge lamp wil be 12 6 volts at rest CLOSES ON SWITCH Located next to on whenever RUNSTOP 14 volts engine 7 LOW OIL CLOSES ON HIGH control board switch is in RUN position and running PRESSURE TEMPERATURE altemator is not charging ABOVE 230F Located on wiring behind 1 7 305 4 GLOWPLUG GLOWPLUG SWITCH ENERGIZES IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITC SWITCH 57 ND N 210 o EE s HIE lt gle ES ply 9 ojo THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC FACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE EQUIPMENT TYPE RANGER 305D CE UK PAGE 1
73. 12 CONNECTOR Y YELLOW 12 6 LABELS 0090000 COMMON 000000 To 12 77 FRAME GROUND E EARTH GROUND VIEW OF CONIECTOR ONPC BOARD HIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED O OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC INFORMATION REFERENCE EQUIPMENT TYPE MATERIAL TOLERANCE 17 TO AGREE ENGINEER WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING APPROVED SCALE SUB ECT MATERIAL APPROVAL NONE DATE 2 5 03 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual MACHINE SCHEMATIC PROJECT NUMBER CRM33549 DOCUMENT NUMBER REVISION L11946 A DOCUMENT SOUD EDGE G 12 RANGER 305D os ELECTRICAL DIAGRAMS SCHEMATIC ENTIRE MACHINE CODE 11121 112212 PAGE 1 OF 2 ENGINEERING CONT 1 216011 MANUFACTURER Rectifier mounted to generator support IGBTS FLYBACK DIODES AND Shunt on back of positive P islocated on front of 2 FILTER CAPACITORS ARE INTEGRAL above output chole POSITIVE SHUNT output terminal i tan near TO CHOPPER MODULE AND NOT 50MV 400 AMPS machine INDIVIDUALLY REPLACEABLE D1 THREE PHASE BRIDGE RECTIFIER OUTPUT TERMINAL 68 2065 2045 WELD CURRENT Chopper is mounted on the back side of
74. 2 PLACE DECIMALS IS UI N2 02 Eo ASIN N 3 PLACE DECIMALS 15 002 DRAWN BY L11946 DOCUMENT DOCUMENT VERAS dC HER ENGINEER War SUBJ ECT MACHINE SCHEMATIC NUMBER REVISION ITH PUBLISHED STANDARDS MATERIE DO SCALE THIS DRAWING APPROVED NONE Joisposition UF 6 2003 J numser CRM3365 L12039 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D oe ELECTRICAL DIAGRAMS es SCHEMATIC ENTIRE MACHINE CODE 11027 L12039 PAGE 2 OF 2 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X 6 0cV1 MANUFACTURER No TRANSFORMER 2 AUXILLARY i AUXILIARY CURRENT SENSE SENSE TOROID WELDING 5 338 TERMINAL CONTRO BOARD 40 100 j CONTROL POWER FROM INPUT SWITCH CHOPPER BOARD som n 4 12 HA ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS ON POSTION IDLER NOT ALL MACHINES USE EVERY CIRCUIT CONTROL IDLE SWITCH SENSE PROTECTION V BATTERY SEN Battery Supply to SHOWN IN HGH POSITION uERH LLARE X 313 22 0 INDICATOR Idle Hold Solenoi IDLE GOLD li IDLE HOLD COIL SOLENOID 5 4 DIODE ONLY ON E HOLD J3 15V COM r 1 THERMOSTAT IF USED fraie FRAVEIS COMVONFOR Otherside ofthe Idle Hold Solenoid
75. 42 225 69 3600 18 75 23 150 46 225 69 350 107 600 183 240 4800 Conductor size is on maximum 2 0 voltage drop 137 18 100 76 RANGER 305D B 10 NOTES RANGER 305D LINCOLN amp B 10 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes Section C 1 Section C 1 TABLE OF CONTENTS o ACCESSORIES E AGCOSSOMIOS CET Section C 3 Options Accessories nnns tnnt 2 5 Field Installed 2 TIG Welding ACC SSONES PE 2 Semiautomatic FCAW and Welding C 2 Connection of Lincoln Electric Wire 5 C 3 Connection of the K867 Universal 3 Connection of the LN 25 Across the 1 C 4 Connection of the LN 25 with 42V Remote Output Control Module C 5 9 Connection of the LN 25 with K857 Remote C 6 5 Connection of the LN 7 Using the K584 Control C 7 8 Connection of the LN 8 Using the K595 Control
76. 54 located on font of FILTER CAPACITORS ARE INTEGRAL above output chole POSITIVE SHUNT output terminal hi TO CHOPPER MODULE AND NOT 50 400 AMPS INDIVIDUALLY REPLACEABLE D1 THREE PHASE BRIDGE RECTIFIER B2 B5 ate 2045 WELD CURRENT 1000 x4 Chopper is mounted on the back side of fan 206A FEED BACK SIGNAL baffle near top machine 206 FLYBACK A 60 65 PHASE TO PHASE BY PASS DIODES 6 WIREFEEDER DC BUS VOLTAGE BETWEEN W1 W2 AND W3 Located on back of PC BOARD VOLTMETER FILTER 904 10VDC HI IDLE AT HIGH IDLE output panel POLARITY CAPACITORS 4 9 between terminals 7 SWITCH Return to Section TOC Return to Master TOC 2 IGBT 8 NEGATIVE __ QUTPUT E B1 INPUT TWO POLE 3600 RPM ALTERNATOR L1 CHOKE Choke is beneath bearing end PWM Signal to Chopper TERMINAL of generator on support Power Supply d 15 volt 20 kHz Open CircuitVolts m S D C3 and D3 locatal on rear of fan baffle s mere TWISTED TED dad 12 volts located front of fan ba TO AUX AC 4O0VAC 3PH on left side of machine T PAIR until generator builds up on left side neg bottom of lt 85 SLIP RINGS i 230 VAC 1 PH then 350 volts 0 amps machine es ERE 50 V DC 13038 1403 16 253 9 23 3 10 E TISNAC 200A 2045 161 24 ROTOR FLASHING y ANNA OUTLETS pe CENTER TAP
77. 698 Ibs 317kg 1 120 240VAC Dual Voltage Two 50AMP for Dual Voltage 15AMP for 42V Wire Feeder Power Full KVA 14 50R 1 Output rating in watts is equivalent to volt amperes at unity power factor Top of enclosure add 6 in 152mm for exhaust pipe Output voltage is within 10 at all loads up to rated capacity When Engine warranty may vary outside of the USA See Engine warranty for welding available auxiliary power will be reduced details RANGER 305D A 3 A 3 INSTALLATION TECHNICAL SPECIFICATIONS RANGER 305D CE K2279 1 UK Code 11027 11122 11189 11314 9 9 8 2279 2 11039 11123 11190 11315 5 5 INPUT DIESEL ENGINE JE cu in cu cm System 8 53 3 cylinder 12VDC Battery amp Fuel alz 4 stroke starter 45L 12 US gal c 15 9 HP High Idle 3100 Bore x Stroke inch mm Oil Kubota 12 KW 3 2L 3 4 US Qts D722 Net intermittent Full Load 3000 2 64 x 2 68 Group 58 550 Radiator Coolant 3000 RPM 67 x 68 mm cold crank amps 3 6L 3 85 U Qts naturally aspirated Low Idle 2200 Battery Charge water cooled engine RATED OUTPUT 40 C 104 F WELDER Welding Process Welding Output Output Range Max Weld OCV Current Voltage Duty Cycle Rated Load RPM DC Constant Current 250A 30V 100 20 TO 305 AMPS DC Pipe Current 250A 30V 100 40 TO 300 AMPS Touch Start T
78. ALTERNATOR FUEL PUMP FUEL SOLENIOD D SOLENOID PULL HOLD COIL COIL 12V BUTTON PULL COIL STOP SWITCH Generating Power Flashing The battery supplies 12VDC power to the control PC board When the engine protection light shuts off the control board allows the 12VDC flashing voltage to be applied to the now rotating generator field winding first passed through a current limiting resistor then through the brushes and slip rings to frame ground Building Output The flashing current produces a weak magnetic field in the rotor This rotating magnetic field begins to gener ate AC output from all of the stator windings Output form the 42 VAC exciter winding is rectified by a diode bridge then filtered by a capacitor and fed back into the rotating field winding through the brushes making the magnetic field stronger This stronger magnetic field then produces higher voltage from the stator windings which feeds back to the rotor making its magnetic field even stronger This process of strengthening the magnetic field through feedback from the output continues to increase CHARGING SYSTEM LIGHT CODE 10926 ONLY FLASHING SHUNT HERE TT gt WINDING STATOR XCITER 120 240 VAC 42 VAC WELD CONTROL AUX WINDING WINDING Umm rmm P C BOARD CURRENT SENSOR AMPHENALS OF cs D
79. Both the 6 and 14 Pin amphenols are connected to a remote control auto sensing circuit that transfers all or par tial output control functions from the front panel output con trol dial to the remote output control device When in TOUCH START TIG mode a remote output con trol device will vary the output from MIN up to the value set with the front panel output control dial In all other modes the front panel output control is completely disabled and full MIN to MAX control is transferred to the remote output control device Both Amphenols also connect to an electronic output con tactor circuit When the Weld Terminals switch is in the remotely controlled position the weld terminals are Switched on an doff by the device connected to either amphenol CV WIRE DOWNHILL PIPE CC STICK NOTE Both the 6 pin and 14 pin Amphenols share the same TOUCH STARTING output control auto sensing and contactor circuitry for 11 ARC CONTROL The ARC CONTROL dial is active in the CV WIRE CC STICK and DOWNHILL PIPE modes and has different functions in these modes This control is not active in the TOUCH START TIG mode CC STICK mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick weld ing to adjust for a soft or crisp arc Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can
80. For gasless welding Includes 15 feet of cable K470 2 MAGNUM GUN CONNECTOR KIT For gas shielding welding K466 1 MAGNUM GUN CONNECTOR KIT For con necting the Magnum 300 to the feeder for gas shielding welding RANGER 305D LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC o 7 5 ACCESSORIES K18161 FULL KVA ADAPTER KIT Plugs into the 120 240 NEMA 14 receptacle the casefront which accepts 4 prongs plugs and con verts it to a NEMA 6 50R receptacle which accepts 3 prong plugs CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill 9 Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts MOVING PARTS can injure Keep guards in place Keep away from moving parts Only qualified personnel should install use or service this equipment 3050 WIRE FEEDERS USING K867 UNIVERSAL ADAPTER SEE FIGURE C 1 NOTE When you use the Ranger 305D with non Lincoln Electric wire feeders or with certain earlier models of Lincoln wire feeders you will require the K867 Universal Adapter The following
81. Handle only at ouch an unpainted grounded Static Safe part of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either con ductive anti static or static dissi pative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag f the PC Board uses protective shorting jumpers don t remove them until installation is complete you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all elec trical components can reach their operating tempera ture 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the con
82. NNECTOR OTHER MODES 12 6 000000 COMMON T 17 77 FRAVEGROUND LATCH gt EARIHGFROUND VEW OF CRCBOARD REMOTE 10K CONTROL 5700 JHIS D NTC ONTAINS RIETARY INF ORMATION LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU D PROPRIETARY 8 CONFIDENTIAL HERPARTIESO USE DF OR ANY PU RP OSEWIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN COLN GLOBAL INC MANUFAC TURN G TOLERANCE PER EOS 6 DESIGN INFORMATION REFERENCE EQUIPMENT PAGE 20 2 ON 3 PLACE DECIMALS IS 007 DRAWN BY DEO SUBJECT DOCUMET DOOUVENT ON ALLANG _ LES IS 50F A DEGREE NUMER REVISION ENGINEER BAM 112213 MATERIAL APPROVAL PROJECT UF pate 12 1 203 NUMBER CRM3537 MATERIA LTOL 1 TO AGREE WITH PUB LISHED STANDARDS 50 NOT SCALE THIS DRAWING EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 305D LINCOLN 8 G 21 SCHEMATIC ENTIRE MACHINE CODES 11189 11314 L12213 1 PAGE 1 2 ELECTRICAL DIAGRAMS G 21 ENGINEERING CONTROLLED CHANGE DETAIL NEW 610011 MANUFACTURER R4 is located front of fan baffle near top of machine ER PC BOARD Rectifier mounted to generator support
83. Note Different models appearance may vary slightly Note Output stud covers not shown Code 11275 and above RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC o 2 0 5 8 8 INSTALLATION In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the ground symbol is provided on the front of the welder WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output terminals The welding process dictates the polarity of the electrode cable These con nections should be checked periodically and tightened with a wrench Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased
84. S Bjo PEN 813 5 4353 Return to Section Return to Master TOC Return to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine welds but it will not maintain a steady output The arc may suddenly get hotter or colder Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELD OUTPUT PROBLEMS This condition may be normal in the Downhill Pipe Mode The Downhill Pipe Mode allows the arc current to increase and decrease slightly as the arc length changes Check that the electrode used is of good quality dry and free of contamination Try using some new Lincoln electrode and setting the machine per the Lincoln s recommendations for that product If shielding gas is used check that the correct gas is being used and that the gas flow is set correctly Check the gas system for damaged pinched or leaking hoses Check for loose or faulty con nections at the weld output ter minals and welding cable con nections Check for adequate connection between the work cable and the work piece work cable should be attached to clean meta as close to the weld area as practical The weld clamp must be in good condition and have adequate spring tension The weld cables may be too long and or too small causing excessive voltage drop b
85. The engine shuts down shortly after starting The engine shuts down shortly after starting and trips the battery circuit breaker CB7 POSSIBLE AREAS OF MISADJUSTMENT S Check for adequate supply of clean fresh fuel Check fuel and air filters replace if necessary Check oil level add oil as required and look for oil leak age Check for loose or faulty battery cable connections resetting circuit breaker If it trips again do not attempt to use the machine Contact a Lincoln Authorized Field Service Facility Note Repeated tripping and reset ting of the circuit breaker can dam aged it or alter its trip point If the breaker has been tripped and reset many times it should be replaced ENGINE AND IDLE PROBLEMS TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The oil pressure switch coolant temperature switch may be faulty Check for faulty run stop switch or engine protection relay Check for damaged insulation in the wiring between the engine projection relay and the oil pres sure and coolant temperature switches See wiring diagram Check for poor electrical con nections at the run stop switch the engine protection relay the D4 diode bridge and the fuel solenoid See wiring diagram The fuel solenoid may be faulty Perform ind Fuel Solenoid Test Examine the CB7 circuit breaker run stop switch stop button Shut down and idle solen
86. The engine will run at high idle speed for approxi mately 12 seconds and then drop to low idle speed Allow the engine to warm up at low idle for several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather NOTE If the unit fails to start repeat step 4 through step 7 after waiting 30 seconds CAUTION Do not allow the starter motor to run continuously for more than 20 seconds Do not push the START button while the engine is running because this can damage the ring gear and or the starter motor the Engine Protection or Battery Charging Lights do not turn off shortly after starting the engine shut off the engine immediately and deter mine the cause aR NOTE When starting RANGER 3050 for the first time or after and extended period of time of not oper ating it will take longer than normal because the fuel pump has to fill the fuel system STOPPING THE ENGINE 1 Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine 2 Stop the engine by placing the RUN STOP switch in the STOP position NOTE A fuel shut off valve is located on the fuel pre filter RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fle 5 9 813 4353 o o 1 Return to Section TOC Return t
87. When pre setting voltage the AMPS display will be off and while pre setting amps the VOLTS display will be off While welding the machine display both the actual voltage VOLTS and current AMPS RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC o 0 5 6 OPERATION ENGINE OPERATION WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the Ranger 305D is 3650 RPM no load Do NOT adjust the governor screw the engine Severe personal injury and damage to the machine can result if it is operated at speeds above the maxi mum rated speed Read and understand all safety instructions included in the engine operator s manual that is shipped with your Ranger 305D BEFORE STARTING THE ENGINE Check and fill the engine oil level 1 Be sure the machine is on a level surface 2 Open the right side facing control panel engine door and remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dipstick 3 Addoil if necessary to bring the level up to the full mark Do not overfill Close the engine door 4 Open the left side engine door and check the coolant level in the coolant recover
88. amp E 208A 3 WINDING GND E Arc Cont Mode ojo 42 41 21 WRAP TWO TURNS Select LEADS 3 D B amp C IN N CB5 DIRECTION B SHOWN THROUGH TOROID 56 7 us STATOR GND R 9K 42 SHOWN IN CASEFRONT DATOR 2248 4008 METER 0 Engine amp POSITIVE WINDING 2248 POSITION 5 4 GND N GND R 12 VAC 00 Function e 206 GND SCREW ON 2001 200 INSIDE LEFT CASE FRONT 53 9 FILTER SN 5 FUEL GAUGE 3M ASSEMBL GND K 5M 2 e 208 5H 4008 T o o o P1 J1 50 IDLER CONTROL R 315 Amphenol 254 Cah Model 23 TIA Sel C3 54 4 5 elect Olo CBA sk 800uf 210 1 4 252 BA Hot Start NOTE LEADS 31 AND32 NOT USED Z 150 e Key IO 201A SHOWN IN 12 E TAPE LEAD ENDS AND SECURE FUEL SENDER AUTO POSITION J gt 31 200A 200 AR ic 115VAC 0 32 GND N Engine Protection 5 2 og RISE CASPERONISUT 58 16 18 13 4 201 Light PLI 210E 3 B N e Bln 42VAC ps 0000 24 2088 210 GND A OO OO 2298 15 52 251 8 P3J3 gt WORK H e43 21 FRAME GND GND B CBI 5H 27 Sense 5270 7778 gt GND G GND C 20 POSITIVE BRUSH CONNECTED 261 i 1 2 0 1 768 4 GND D TO SLIP RING NEAREST 229A o PWM
89. appropriate Magnum Parts Kit and argon gas SEMIAUTOMATIC FCAW AND MIG WELDING ACCESSORIES LN 25 WIRE FEEDER K449 This portable unit pro vides CC CV for flux cored arc welding FCAW and metal inert gas welding MIG Includes a gas solenoid and an internal contactor that allows across the arc operation with no control cable The LN 25 provides a cold electrode until the gun trigger is pressed For voltage control at the feeder a 444 1 Remote Voltage Control Kit or K857 Remote Control is required Refer to connection instructions later in this section LN 7 OR LN 8 WIRE FEEDER Semiautomatic con stant speed wire feeders NOTE Gas shielding welding requires a Magnum Gun Gasless welding requires an Innershield Gun LN 742 WIRE FEEDER A semiautomatic wire feeder with cold electrode Refer to connection instructions later in this section MAGNUM SPOOL GUN K487 25 A lightweight semiautomatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the handle Requires the K488 SG Control Module Refer to connection instructions later in this section SG CONTROL MODULE K488 Controls wire speed and gas flow Provides the required control interface between the Ranger 305D and the K487 25 Magnum Spool Gun Requires the K691 10 Input Cable K444 1 REMOTE VOLTAGE CONTROL Provides voltage adjustment control at the feeder Includes 25 feet of cable K126 2 INNERSHIELD GUN
90. contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if there s a problem with the remote receptacle control wiring relating to electrical tracking between other control conductors power conductors or ground This test also checks the function of the weld terminal switch Return to Section TOC Return to Master TOC MATERIALS NEEDED Ohm Meter Wiring Diagram Control Inner Connection diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 5 5 9 815 43 oO 1 Return to Section Return to Master TOC Return to Master TOC F 80 TROUBLESHOOTING amp REPAIR REMOTE RECEPTACLE RESISTANCE TEST continued FIGURE 18 AMPHENOL 1 TEST PROCEDURE 1 2 Turn the machine off Perform the Case Cover Removal Procedure Make sure that there are no devices of any kind plugged into either Amphenol recepta cles Remove Molex plug P1 from the control PC board see Control Inner Connection Diagram Examine the Molex plug and the receptacle on the control PC board for dirt corrosion damaged or out of position pins Repair or replace any damaged components Positio
91. is a telltale sign 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 don t 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 The filter should be removed gently to reduce the amount of dust dislodged There will be some initial resistance similar to breaking the seal on a jar Gently move the end of the filter back and forth to break the seal Remove any cause of leaks before installing new filter aN Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end which is the sealing area 7 NEVER install a damaged filter Avoid Dislodging Dust from the Filter Gently pull the filter off the outlet tube and out of the housing Avoid knocking the filter against the housing Insert the New RadialSeal Filter by Hand Insert carefully Seat the new filter by hand Donaldson filters with RadialSeal Sealing Technology are self aligning self centering and self sealing A new filter has a dry lubricant to aid installation The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal ap
92. o lt 5 5 lt 2 EE o F c 3 5 lt t x 2 2 Lt gt o 9 o 9 0002 4 lt lt 5 gt lt gt E L 5 2295 194 6 z co f se 9 5 lt 0 t 6 O 4 o z o o o lt lt 2 o m M T mmm ui 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 uonoes 0 901 uonoes NOL uonoes NOL uonoes 0 Section E 1 Section E 1 TABLE OF CONTENTS o THEORY OF OPERATION SECTION Theory of Section E 9 General 2 5 Battery Engine Rotor Stator and Engine Protection E 2 2 Engine Idle SYStOM E 3 Generating POW E 4 Weld Power and nennen entren rens intern nennen E 5 Remote Output Control Output Contactor Digital Meters E 6 Chopper Technology E 7 Pulse Width ModulatlOn E 8 Insulated Gate Bipolar Transistor IGBT Operation
93. place the probes directly into receptacle or connect to leads 30 and 5 See Figure F 12 See wiring diagram For the lower receptacle place the probes directly into the receptacle or connect to leads 6 and 5B Figure F 12 See wiring diagram 21 WORK SENSE 3 Start the engine and run it at high idle 3650 RPM 4 Checkthe AC voltage reading It should read between 120 and 135 VAC To test the 240 VAC auxiliary winding 1 Connect the meter probes to leads 6F and 3E where they connect to the 120 240VAC receptacle or insert the probes into the 240 VAC connection slots in the front of the receptacle See Figure F 12 See wiring dia gram 2 Start the engine and run it at high idle 3650 RPM 3 Checkthe AC voltage reading It should read between 236 and 252 VAC 4 f these voltage readings are not within the specified limits check for tripped or defective circuit breakers loose connections or bro ken wires between the test points and the stator windings lf there are no wiring prob lems and the circuit breakers are not tripped or defective the stator is defective and should be replaced RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 2 amp x 3 Return to Section TOC Return to Master TOC o p 0 5 53 TROUB
94. 09 24 ANIS 3440 o o 89 193 094 543013 ANION 10 9 0 92201 15815 89 70424 SO 20 10 11 4 82 000515 3 166 Z0SE dWH N33HO Pe E LS9ELL 2081 1331 Q3A33TS V8 0 256 L HWO L 340HO 21818814 1 INIOd 1531 1 191331 edit tals WISZPNI 958406 ML 86 201211 820 1201 VOPLPNT 958 ABL 3000 YIN Sv zo zLL 9201 B SESNI S A0Z MS 2 52207211 2 VONT SAOL ML 22204211 220 VEELPNI 1 6 ME 10 28 201211 120 009 65 50 21 ISV4 VELIN A009 901 2921 3000 1950721 7 185 52507211 166121 AS A001 doce OW3O HOLIO Vd VO 8899918 220 3602 9 zz 131v dvO 18106015 120 3 601 AOG d00 OW3O HOLIO Vd VO 9 899918 619 810 710 5602 AOS zz0 HOLIO Vd VO 9 899915 520 910 9608 1001 00001 1419 512 069615 LLO 7010 60 020 910 510 9017706 F O OWIO HOLIOYAYO 11899915 0 90 SO EO 550 1 AE9 O L JW3d HOLIO Vd VO 51 06615
95. 10K Ohms values should sweep smoothly from 10K to 0 when ARC CONTROLis P7 8 277 TO P7 7 278 turned from Min to Max Resistance should be very low The Ohmmeter should read about the same value as one would get by touching the two meter probes together If the resistance readings are not as specified in the table replace the potentiome ter and mode switch plug and lead assembly or replace the defective component See the Wiring Diagram if testing is complete plug P7 back into the control PC board and perform the Case Cover Replacement Procedure RANGER 305D LINCOLN 5 78 5 3050 LINCOLN amp F 78 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes 79 79 TROUBLESHOOTING amp REPAIR REMOTE RECEPTACLE RESISTANCE TEST 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely
96. 20 19602 169 89 TA HOLIO Vd VO 902 06015 10 HN 1 341200 30 39vd IV8O 19 NOISSIINH3d NALLIYM SS3HdX3 1 50 CASN S3ILYWd OL 1 38 LON NIOONIT GANMO AHV L3IHdOHd SNIV LNOO SIH Nid S H3MOd IVNIWH3IL HOLO3NNOO 1 900525 68 tH 2818 58 19 40 2174 0016 1866 20 211 96 00 9 11 zy ON LV d LA duls NOISIASY 1430209 SOLID EDGE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the PC BOARD ASSEMBLY CHOPPER PC BD ALL CODES L11845 1 NOTE machine G 38 LINCOLN DOL 491se A DOL 4215 901 491se WQ 901 4215 DOL 082
97. 3 61 naturally aspirated Idle 2450 water cooled engine RATED OUTPUT 104 F 40 C WELDER Current Voltage Duty Cycle Rated Load RPM DC Constant Current 305A 29V 10096 20 TO 305 AMPS DC Pipe Current 300A 29V 10096 40 TO 300 AMPS Touch Start TIG 250A 30V 10095 20 TO 250 AMPS 60 Volts DC Constant Voltage 300A 29V 10096 14 TO 29 VOLTS RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 10 000 Watts Peak 9 500 Watts Continuous 60 Hz 120 240 Volts Sound Levels Sound Power 104 2 dB Lwa Sound Level 80 6 dBA 23 ft 7m PHYSICAL DIMENSIONS 30 00 in 21 50 in 52 25 in 762 0 mm 546 0 mm 1327 0 mm LUBRICATION EMISSIONS Full Pressure Electric Fuel Pump Code 10926 11121 or Mechanical Mechanical with Full Flow Filter Certified to EPA Tier Fuel Pump Code 11188 11275 Auto air bleed Governor system Electric shutoff solenoid Indirect fuel injector AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure amp engine Made from long life aluminized steel temperature ENGINE WARRANTY 2 year complete parts and labor 3rd year major components parts and labor RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS 2 120VAC Duplex 5 20R Two 20AMP for Two Duplex Receptacle 25AMP for Battery Charging Circuit
98. 5700 VANTICEON ARC CONTROL CIRC UITRY FE is HIE ols gle ES ply 9 ojo TOUCH START VARIABLE PINCH PIPEARCF ORCE ROL VARIAB LE ARCF ORCE NT SELECT SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON 1 WHAT PARTS OF THE G4107 G4109ARE USED IN EACH PRESET PRESET CONNECTORS APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIME FIXED HOT START J1 ANPHENOL amp MACHINE IDJUVPER J2 ENGINE 12V CONTROL FUNCTIONS 48 CHOPPER PUM PONER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK para AMVETER NO CONNECTOR ON RANGER 250 OTHER MODES J5 NO CONNECTOR CN RANGER 250 YYB1ON REMOTE 10K 09 4 gt 46 SHUNT CURRENT FEEDBACK 11255 d J7 OUTPUT CONTROL ARC FORCE MODE SELECT 885504 110 Te 17 lt 77 FRAVE GROUND ALL ae EARTHGROUND VEW CORSTOR 5700 COVPONENT VALUE UNTS CAPACITOR MFD VOLTS RESISTOR OHVSWATTS 6 MODE REMOTE CONNECTOR PIN NUVBERS EX 12PIN NNECTOR 79 1111 lt JHIS D NTC ONTAINS OP RIETARY INF ORMATION OWNEDBY LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU D PROPRIETARY amp CONFIDENTIAL OT HER PARTIESO USE DF OR ANYPU HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN
99. 5M ASSEMBLY 5 5M e 208 5H Tus 1 ls TERMINALS FRAME GND 2 A Model 58 2 20 200 S4 Select 3 oT 252 Hot Start 20 SHOWNIN e BLACK A 201 FUE SENDER AUTO POSITION tet 1 L GND N 120VAC 2 5H SP CASERO avae KS e aea 3 POSITIVE BRUSH CONNECTED hz FRAME 20A TO SLIP RING NEAREST ig um n WORK BLACK TO THE LAMNATION ROTOR Sense ES eire o 6B 2100 2298 Idler lt EONIROLL Fers i 7 un gt G e4 758 j contactor 0 e TERMINALS Slow m GND A 5 S1RUN STOP 2 8 Coe 7 BLACK BUTTON Som GROUND 3 5 53 amp elc BION auo bd UNOS PCB2WELD CONTROL PC BOARD 5 AMPHENOL 1 Back 920 208 5 2 i 210 zi A gt etie WHITE 1 210 2108 2108 REMOTE 76A 1 GNDR a cc CONTROL B 768 T5 CONTACTOR 2 25 2258 1 2 B3 B4 pope 223A zm 23 2 018 GND K gt 4 IGROUND F GND B 223 I 404 GND SCREW ON 2 4 FAN BAFFLE oo GND L LEAD COLOR CODE CONTROL T 4 229 204 1 PA La 21 p73 199 1 1 4 1 5 GRAY 8311 4 BH o l T SHOWN IN 2 GHD HO 5 Mi 2 i WELDING ON PRES
100. 5V ON HOLD 5V HOLD MACHINE MODE LOGIC BLINK PULLED LOW AND HIGH IN LOOKBACK TO FLASH DECIMAL POINT 443 gt 44 2 444 45 48 4 gt 4 6 gt gt 47 45 AMMETER DISPLAY STUD ON OFF 5V ON gt J4 9 METER INPUT 0 2V 1V 21000 ON METER gt 44 10 METER INPUT METERS CPTIONAL ONVANTAGE 5 250 HOLD 5V HOLD J gt 15 2 BLINK PULLED LOW AND HIGH IN LOOKBACK TO FLASH DECIMAL POINT my 453 454 455 P k Be mk SELECT CONTROL POINT 357 7 458 4 t gt 45 9 METER INPUT 0 2V 1V 100 0 ON METER 3 456 VOLTMETER DISPLAY J5 10 METER INPUT CURRENT FEEDBACK CURRENT FEEDBACK DISPLAY 2065 50mV 400 AMPS CURRENT FEEDBACK STUD FOR WELDCONTROL 5 8 15 STUD PRESET DISPLAY PRESET VALUE VOLTAGE FEEDBACK DISPLAY WELD VOLTS FEEDBACK E VOLTAGE FEEDBACK ARC 10K ARC CONTROL CONTROL CIRCUITRY OUTPUT 10K CONTROL POT TOUCH START VARIABLE PINCH PIPE ARC FORCE THE TOP END OF THE REMOTE POT IN TIG MODE IS THE SETTING OF THE LOCAL OUTPUT CONTROLPOT IN EVERY OTHER MODE THE POT WILLSET
101. 63 63 TROUBLESHOOTING amp REPAIR CHOPPER MODULE FUNCTION TEST continued TEST PROCEDURE CONTINUED 16 If the 20 kHz signal is present the chopper module is defective Replace 17 If the 20 kHz signal is not present perform 13 If about 58 VDC is present at chopper mod the Weld Control Board PWM Gate Drive ule terminals B2 to B3 and B5 to B6 but not at the output terminals there is a problem between the chopper module and one of the 18 If the weld control board is producing PWM Return to Section TOC Return to Master TOC output terminals Check for damaged con gate signal check th e 23 and 25 leads for ductors or faulty connections on leads 7 damaged conductors and faulty connections W8 W9 and W10 Also check the shunt the between the control PC board and the chop choke and the connections at the back of the per module output terminals See the wiring diagram 19 If testing is complete Perform the 14 If the voltage at terminals 2 to B3 and Cover Replacement procedure B54 to B6 of the Chopper module is signifi cantly higher than 58 VDC check for an open R4 load resistor See the Control Inner Connection diagram Also check for dam aged conductors or faulty connections at leads 302 and 302 See wiring diagram Return to Section TOC Return to Master TOC 15 If the voltage at terminals 2 to B3 and B5 to B6 of the chopper module is very low or not present use the freq
102. 65 VAC PHASE TO PHASE BY PASS WIREFEEDER DIODES 6 2 0 DC BUS VOLTAGE BETWEEN W1 W2 AND W3 Located on back of BOARD VOLTMETER FILTER 90410VDC Q HI IDLE AT HIGH IDLE output panel 208C 1 POLARITY CAPACITORS 4 between terminals 77 SWITCH Return to Section TOC Return to Master TOC 2 IGBT 8 NEGATIVE __ Bl TWO POLE 3600 RPM ALTERNATOR Tl CHOKE OUTPUT 2 PWM Signal to i THRU TERMINAL 3l end FERRITE Power Supply 15 volt 20 kHz IGNAL Open CircuitVolts d rol 2TURNS 7 ist and D3 locatal on rear of fan baffle THRU TWISTED gp Rotor Flashing 12 volts T A B C 400 VAC 3PH on left side of machine CV 2TURNS FERRITE 0 5 ocated m front of fan ba TO AUX i 58 WISTED 05 amps on left side nea bottom of lt A SLIP C5 THRU FERRITE PAIR until generator builds p is 230 VAC 1 PH then 450 volts 0 amps OUTLETS 3 8 79 50 V DC Control Board senses Weld Output 1303 8 1403 16 25 39 2303 10 8325 OHM 200 from Current Feedback Shunt 2045 161 ROTOR FLASHING to activate idler 2 1 200N AANAA AND lt 1156 62 2065 62 1125 08 IDLE SOLENOID HOLD COIL v 8 LOW IDLE 12088 1345 Control board common is AMPHENOLS 42 VOLT AC at we
103. CONNECTOR LEAD ENTRY VIEW olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 28 5 3050 LINCOLN amp F 28 901 J91Se N 01 UuunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC F 29 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION If the machine output is low or high this test will determine whether the engine is operat i
104. Cleaning slip rings In the event that the slip rings have become dirty discolored or mildly pitted it will be necessary to clean them using very fine 500 or 600 grit emery cloth or a 220 or 320 grit commutator stone Seating Brushes 1 3 If brushes have been replaced repositioned or are not making full contact with the slip rings it may be necessary to re seat them This can be done by placing a strip of 180 grit sandpaper between the 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 Use a low pressure compressed air to thor oughly blow the carbon commutator stone and sandpaper dust from the machine before operating Perform the Case Cover Replacement Note See Figure F 9 for general locations RANGER 305D 39 39 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE AND GROUND TEST STATIC WARNING 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 or 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 ma
105. Cont BI Mode wv 42 41 21 WRAP TWO TURNS OF V Select ojo LEADS A 3 D B amp CIN DIRECTION SHOWN THROUGH TOROID 3 5G 224A 215 259 2 2 BOTTOM GND STATOR GND R 5K 83 b o 1 CB5 SHOWN IN parse one EXCITATION 2248 008 METER 404 Y Engine amp 4 POSITIVE WINDING 2248 pt 154 POSITION 55 18 Battery GND N GND R Function 42A TOP GND SCREW ON 42 VAC 2008 1 INSIDE OF CASE FRONT 222 i R3 S M 5N 5k 5M 5 T F FUEL GUAGE BYPASS J 5H 1 1 FILTER 5N gt IDLER CONTROL ASSEMBLY 5 36 Amphenol 23 251 Model e 208 54 Select 01 252 Hot Start NOTE LEADS 31 AND 32 NOT USED Ke SHOWN IN y e TAPE LEAD ENDS AND SECURE C B 1 FUEL SENDER SHOWN IN TION 200 C it 115 GND N Engine Protection g i die 2 GRP SCREWON LEFT 5B 1C 1B 1A 2 5 Light PL1 210E 13 e u 42VAC 24 2088 31 L ketsa 2106 251 945 FRAME GND D SND OPP 252 ov 733 6 WORK H e 2 GND A Sod ian CB1 ni 20 5 Sense avor E29 778 GND G GND C 20A PIENE 2100 2298 260 oH gg EUR w 0009 Qoo rm E C ks 5b 2C 28 2A i 211 D 25 lob gt e pL 2124 9 um S1RUN STOP ge 43 Bla C2 e 28 12 i SARIN 223A 4 7
106. DETAILS ON 1 WHAT PARTS OF THE G4107 G4109ARE USED IN EACH CONNECTORS APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIVE FIXED HOT START J1 AMPHENOL amp MACHINE ID JUVPER 42 ENGINE 12V CONTROL FUNCTIONS 43 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK NO CONNECTOR ON RANGER 250 45 VOLTVETER NO CONNECTOR ON RANGER 250 46 SHUNT CURRENT FEEDBACK J7 OUTPUT CONTROL ARC FORCE MODE SELECT COWPONENT VALUE UNTS CAPACITOR MFD VOLTS RESISTOR OHVSWATTS G MODE CONNECTOR PIN NUVBERS 12 NNECTOR OTHER MODES 12 6 000000 COMMON T 17 77 FRAVEGROUND LATCH gt EARIHGFROUND VEW OF CRCBOARD REMOTE 10K CONTROL 5700 JHIS D OCUME NTC ONTAINS RIETARY INF ORMATION LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU D PROPRIETARY 8 CONFIDENTIAL HERPARTIESO USE DF OR ANY PU RP OSEWIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN COLN GLOBAL INC MANUFAC TURN G TOLERANCE PER EOS 6 DESIGN INFORMATION REFERENCE EQUIPMENT PAGE 20 2 ON 3 PLACE DECIMALS IS 007 DRAWN BY DOCU SUBJECT ON ALLANG 1 5 5 DEGREE NUMER MATERIAL APPROVAL PROJECT DATE 07 5 204 587 L12212 1 MATERIA LTOL 1 TO AGREE
107. Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 98 98 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX CONTROL POT HIGH IDLE NO LOAD Return to Section TOC Return to Master TOC CH1 HHHH 0 volts Return to Section TOC Return to Master TOC 50V 5ms This is the typical DC open circuit out put voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time NOTE Scope probes are connected at weld output terminals Fle 5 5 gt 8 43 21 a SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 99 99 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM STICK CC MACHINE LOADED TO 300 AMPS AT 27 VOLTS Return to Section TOC Return to Master TOC Trig 15V CH1 O volts Return to Section TOC Return to Master TOC 20V 1ms This is the typical DC output vol
108. Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 101 101 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM WIRE CV MACHINE LOADED TO 300 AMPS AT 28 VOLTS Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 20V 1ms This is the typical DC voltage gener ated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 1 millisecond in time The machine was loaded with a resis tance grid bank to 300 amps at 28 volts Fle 5 5 gt 8 43 21 a NOTE Scope probes connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div Coupling DC TAGGET Internal Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 102 102 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics If you repair or replace any electrical component
109. E GROUND B UNPOS PCB2 WELD CONTROL PC BOARD 1 cma Slow 22 77 i u 15 BUTTON CB7 2025 nemore 2 91 18g 2100 2108 2108 2 617168 777 2 92 n 81 TE 210H N GND R CONTACTOR E 2A A J101 4 l 1 81 3 83 02 6 8 2 Jon GE 223 Zi 232 gt 6 8 50 GND K 2258 8 4 GROUND F 4 GND 8 23 210C 231 Ai 404 GND SCREW ON 9 OP p4343 AMPHENOL 2 a 2 xx di m o o P434 CONTROL 4 29 2794 209 ESTE Presa cm TT EE 1225 1 1 5 83 m enom i oo ooo J HO blk blk 2 2 ME SUN ON 2 N wt PRES red wht red wht 5 8 6 0 POSITION e SN G SUM gt 5 ENGINE f GND H m 6960696 L2 L3 RF CHOKES SERIA OR ERA GROUND e 8 2 Em y x PLUGS ENGINE COMPONENTS T 2 6 M EE NS STARTER FRAME FUEL SOLENOID IDLE SOLENOID PULL COIL BD ELECTRICAL SYMBOLS PER E1537 G GREEN W YELLOW STRIPE GROUND CONNECTORS VIEWED FROM INSERTION END ALL CASE COMPONENTS SHOWN VIEWED FROM REAR LI N C Q L N ELECTRIC CLEVELAND OHIO U S A G4572 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram s
110. MACHINE TEST SWITCH fpga 18 USED POPULATED AR P3 NOT USED SWITCH 2A 5 BY SERIALDATA sx 28 JU ic wp JUMPER TO ENABLE ER Go AER 81 n TOUCH START lt o aE lt 2 2 AE ply 0 9 ojo P4 NOT USED SWITCH R67 EK 1 16 RESET OE DATA SERCEN n TOUCH STICK SWITCH Go REPLACED WITH XC17S20XL PROM WHEN CODE IS JUDGED STABLE amp LAST NO USED GENERAL INFORMATION _ Rm Ti ELECTRICAL SYMBOLS PER 1537 XS Li CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED bom mcm RESISTORS Obes 0805 UNLESS OTHERWISE SPECIFIED LABELS DIODES 2A 200V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET C POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION 5 SCHEMATIC USED FOR BOARD ARTWORK IN 64107 AND G4109 IMENT PROP
111. MACHINETO MAX OUTPUT 4 10V lt REMOTE CONTROL ALL OTHER MODES EN 168 1 VARIABLE ARC FORCE FIXED ARC FORCE PRESET PRESET gt FIXED HOT START TROL NT SELECT REGULATING AMPLIFIER CONTROL POINT CONNECTORS 1 AMPHENOL amp MACHINE ID J UMPER 12 ENGINE 12V CONTROL FUNCTIONS CURRENT LIMITS AVERAGE ABSOLUTE amp FOLDBACK PWM CHOPPER CONTROL CIRCUIT 13 CHOPPER PWM POWER IN THERMAL OVERLOAD IF USED VOLTAGE FEEDBACK 4 AMMETER NO CONNECTOR ON RANGER 250 5 VOLTMETER NO CONNECTOR ON RANGER 250 6 SHUNT CURRENT FEEDBACK 11 OUTPUT CONTROL FORCE MODE SELECT PROPRIETARY amp CONFIDENTIA MANUFACTURING TOLERANCE PER E2056 ON ALL GIES S 5 OF A DEGRE DRAWN STUD 15V COM m fakme FRAME IS COMVONFOR ENGINE CONTROL CIRCUITS V BATTERY DIODE ONLY ON E VERSION AND ABOVE FRAME the Idle Hold Solenoid IDLE IDLE HOLD COIL 5 di 5 Other side ofthe Idle Hold Solenoid vt 1 30V when energized LOW IDLE 12V when not energized HIGH IDLE 5 E SOLENOID a uJ TO IDLE PULL COIL BOARD COIL HIGH PULL TO LOW IDLE J2 12 lt FOR AUX USE CONNECT TO FRAME FOR HIGH IDLE FRAME RANGER OIL PRESSURE y g lt a STARTER BUTTON
112. ME S 92K 1 R85 R36 R68 R69 4 45 2 8253655180 RESISTOR STAND UP WW SW 51 0 5 EE di 4 855 856 57 R58 R59 R61 R62 4 R63 aes e R64 R65 R65 R67 2 5194008252 RESISTOR ME 4W 82 5 1 gen xi 1 815128 11 IC COMPARATOR QUAD 2901N fs 2 4 e DESCRIPTION 5 ay Q PCB BLANK E 2 1194363 1 POTTING TRAY B E NE SELF TAPPING SCREW alz 4 E2527 1129 EPOXY ENCAPSULATING RESIN olo _5 E3539 ASREQD ELECTRICAL INSULATING COMPOUND 23 4 4 5 Ner 4 4 oO 9 ojo NOTES UNLESS OTHERWISE SPEGIFIED MAKE AS CAPACITORS MFD VOLTS CAUTION ruis DEVICE 5 SUBJECT TO DAMAGE BY STATIC ELECTRICITY RESISTORS 1 4W OHMS LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING INDUCTANCE HENRYS N B SECURE P C BOARD ASSEMBLY IN PLACE WITH ITEM 4 2 PLACES L1768 1E0 N C PRINT L11768 LATEST DASH NUMBER AND 1 0 CODE ON LABEL 222 PART MAY TILT 10 FROM PERPENDICULAR THE BOARD ENCAPSULATE PER E1911 E TO DEPTH SUCH THAT ALL COMPONENT PART IDENTIFICATION CODE LEADS ARE COVERED N G ALL CONNECTORS MUST BE GREASED WITH ITEM 5 PRIOR TO COATING PER E1911 TEST PER E4050 SCHEMATIC REFERENCE G4117 1E0 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONF
113. P3 9 9 If the 20KHz gate signal is present place the weld terminals switch in th LY CONTROLLED position The gate sig nal should turn off 10 If the 20 KHz gate signal responds as described above this test is complete 11 If there is no 20 KHz gate signal test for the presents of 80 to 100 VDC at leads 134 P3 8 to 14 P3 16 of the weld control PC board 12 If voltage is very low or not present check leads 13 and 14 for faulty or damaged wiring or connections between the control PC board and the chopper module 13 14 15 16 17 18 19 20 Test for 80 to 100 VDC at the terminals where the 13 and 14 leads connect to the chopper module See the wiring diagram there is no voltage at the chopper module perform the chopper module function test If the 80 to 100 VDC supply voltage is pre sent at the weld control PC board but there is no PWM gate signal check the voltage between leads 72 4 1 4 and 4 P1 3 See figure 1 The voltage should be about 0 VDC If about 5 VDC is detected the welding ter minal control circuit is open Check for damaged leads for faulty connections at leads 2 and 4 also check for a defective welding terminal switch See the wiring dia gram If the PWM signal remains after the welding terminal switch has been placed in the REMOTELY CONTROLLED position check the voltage between leads 2 P1 4 and 4 P1 3 a
114. RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 5 2 5 Return to Section Return to Master TOC o 2 0 5 88 88 TROUBLESHOOTING amp REPAIR CHOPPER MODULE REMOVAL AND REPLACEMENT continued FIGURE F 19 EXCITER LEADS 11 T2 51302 5113 51301 5114 PROCEDURE Removal 1 2 Turn the engine off 7 Remove the Power Module assembly from the machine Perform the Case Cover Removal Perform the Power Module Capacitor Discharge procedure TERMINAL LEADS Disconnect leads 23 and 25 at their in line Heavy lead W11 small couplings lead 14 Using the 7 16 socket wrench remove the HL WS SL 13 following leads Label the leads before removal Cut cable ties as needed Note HL W8 placement of leads and fasteners screw lock washer flat washer small lead heavy HL W6 lead Using a 3 8 socket wrench remove the three screws holding the power module assembly to its brackets on the vertical baffle Remove B3 HL W9 SL 302 the plastic strip with the top two screws Be sure to support the Power Module as you remove the last screw RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
115. TOC i 47 15 Return to Section Return to Master TOC i 116 3714 4 MODE SELECTOR G SAR switcH L a AUSTRAILIAN 47 12 VANTAGE SS USES A V DD SWITCH VANTAGE 575 START Button is held IN If externally shorted BLINK PULLED LOW AND HIGH 54 the PTC will change to high impedance IN LOOKBACK TO FLASH 355 DECIMAL POINT gt FRAME t 22 458 VOLTMETER ta DISPLAY 58 42 COM S gt 159 METER INPUT 0 2V 1V 1000 ON METER CV MODE gt 4540 METER INPUT 22 CURRENT BATTERY SELECT CONTROL POINT LIMITS CHARGE 427 lt ROCV ENABLE BATTERY POSITIVE UMP 74 TOR AUSTRALIAN VANTAGE 575 CURRENT FEEDBACK AVERAGE 9 ABSOLUTE Ss v CURRENT FEEDBACK J DISPLAY WELD AMPS amp FOLDBACK BATTERY NEGATIVE 923 lt 15V when the battery charge light is OFF 5700 Machine running alternator charging battery 1 5V when battery charge lightis ON Battery Low Not charging and for a few DISPLAY PRESET PRESET seconds when machine is tumed off 2085 x MAr VALUE VOLTAGE ONLY 4 t 50mV 400 AMPS a A 475 ohm
116. TOC Return to Section TOC O10 Fle 515 gt 813 4353 Return to Section Return to Master TOC Return to Master TOC F 56 TROUBLESHOOTING amp REPAIR STATOR SHORT CIRCUIT amp GROUND TEST continued FIGURE F 14 WELD CONTROL BOARD CONTACTOR 5 CONTROL REMOTE CONTROL 14 2 TIMES THRU FERRITE LEADS 75 76A amp 77 TEST PROCEDURE 1 Perform Case Cover Removal Procedure 2 Perform Capacitor Discharge Procedure 3 Unplug anything that may be connected to the auxiliary receptacles or the 14 pin amphenol 4 Disconnect and isolate GND E lead from the bottom ground screw inside the left case front See control Inner Connection diagram See Figure F 14 5 Disconnect the 7 and 9 leads from the field bridge rectifier See Wiring Diagram 6 Using an ohmmeter check the resistance between chassis ground and each of the fol lowing points Resistance should read very high 500 000 500K ohms minimum 1 Pin 1 at the 14 pin amphenol and the 5 lead that had been disconnected from the ground screw this checks for a connec tion between the wire feed winding and the auxiliary winding 2 Pin 1 of the 14 pin amphenol and lead 7 or 9 This checks for a connection between the wire feed winding and the exciter winding 3 Pin 1 of the 14 pin amphenol an lead W1 W2 or W3 This checks for a connection between the wire feed
117. TOC Return to Master TOC Return to Section TOC olo O o s olg 2 8 8 tlt 5 5 ply a Return to Section Return to Master TOC Return to Master TOC F 9 F 9 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine welds but it will not maintain a steady output The arc may suddenly get hotter or cold er continued POSSIBLE AREAS OF MISADJUSTMENT S WELD OUTPUT PROBLEMS The weld cables may be coiled or wrapped around metal reels or racks This can cause exces sive electrical inductance in the weld circuit Try welding after uncoiling the cables or discon nect the existing weld cables and attach a set of adequately sized short test cables TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 6 The output control or arc control potentiometers may be defec tive or grounded The mode switch may also faulty Perform the Contro Potentiometer__and__ Mode Switch Resistance Test The Amphenol receptacles may be contaminated or defective Perform the Replace the weld control PC board The weld output cannot be adjust ed with the front panel output con trol knob in one or more weld modes The weld output terminals have normal OCV Open Circuit Voltage The AC auxiliary power is normal and the engine operates normally Remote control devices com p
118. VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 10 000 watts peak 9 500 watts of continuous 60 Hz singe phase power The auxiliary power capacity rating in watts is equiva lent to volt amperes at unity power factor The maxi mum permissible 40 amps continuous current of the 240 VAC output is 42 amps maximum NOTE Machines with code numbers of 11121 and higher are equipped with GFCI duplex receptacles If a GFCI receptacle is tripped it will not reset unless it is receiving nearly full voltage from the generator for this reason the engine must be running at high RPM before resetting a GFCI RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 5 5 9 gt 813 43 oO 1 Return to Section TOC Return to Master TOC Return to Master TOC B 9 B 9 OPERATION The 240 VAC receptacle can be split to provide two separate120 VAC outputs with a maximum permissible current of 42 amps pea 40 amps continuous per out let to two separate 20 amp branch circuits These cir cuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least
119. and solder connections as well as dam aged wiring or insulation See wiring diagram Perform Potentiometer and Mode witch Test 3 The Weld control PC 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 RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 11 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The arc quality is poor with exces sive spatter The arc heat can be controlled and maintained normal ly the auxiliary output is normal and the engine operates normally POSSIBLE AREAS OF MISADJUSTMENT S WELD OUTPUT PROBLEMS The arc Control may be set too high Try using a lower setting The output control may be set too high for the electrode being used Try welding at a lower setting Check that the electrode used is of good quality dry and free of contamination Try using some new Lincoln Electrode and set ting the machine per the Lincoln s recommendations f
120. discussion and connection diagram explain in general how to make the proper connections 1 Shut the welder off 2 Connect the electrode cable from the wire feeder to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K867 Universal Adapter to the 14 pin amphenol of the Ranger 305D as shown in Figure C 1 Make the proper connections for local or remote control according to Figure C 1 and the fol lowing NOTES indicated on the figure 2 T 797 WIRE 4 oT FEEDER A These leads are not used for the Ranger 305D Insulate each unused lead individually B For wire feeders that return a signal for weld ing output use an isolation relay to close leads 2 and 4 C Refer to the Operation section of this manual for maximum wire feeder auxiliary current draw 4 Set the MODE switch to the CV WIRE position 5 Place the IDLER switch in the AUTO position CAUTION Any increase of the high idle engine RPM by chang ing the governor setting or overriding the throttle link age will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuit may be damaged The engine governor setting is preset at the factory do not adjust above RPM specifications listed in this manual 6 Set the VOLTMETER switch to
121. engine cannot maintain this RPM make sure there is an adequate supply of clean fresh fuel Check the fuel filter and the air filter Replace any filter that is dirty or dam aged If this doesn t help the engine should be serviced Compare the volt and amp readings shown on the external meters with the readings dis played on the machine s front panel If these readings differ significantly perform the WELD CONTROL FEEDBACK TEST If the maximum weld output cannot be obtained even though the engine maintains correct RPM and the front panel dis plays are reading accurately Check for damaged conductors and loose or damaged connec tions at each of the large weld current carrying conductors that connect the stator output rectifi er chopper module choke shunt and output terminals See the wiring diagram If all of the these connections Voltage Test Module Resistance Test the POTENTIOMETER AND MODE SWITCH _ RESIS TANCE TEST Perform the 10 Perform REMOTE RECEPTACLE RESISTANCE TEST Replace the weld control PC board CAUTION 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 RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o Fle
122. front to the side to permit access to the Output Rectifier and Choke Removing the Output Rectifier 10 Remove the heavy leads from the output 11 rectifier Carefully mark the leads for accurate re connection and also note the order and position of multiple lead connections Remove the nuts and lock washers hold ing the Output Rectifier to the mounting bracket You will need to reach through the large access holes on either side of the rectifier to reach these nuts 12 Remove the Output Rectifier from the machine RANGER 305D Removing the Output Choke 1 Remove the heavy leads from the choke Carefully mark the leads for accurate re connection and also note the order and position of the leads in multiple lead con nections 2 Remove the three long bolts lock wash ers and nuts holding the choke the mount ing bracket in the machine base Note that there is no bolt in the lower right cor ner of the choke 3 Carefully remove the choke REPLACEMENT PROCEDURE Replacing the Output Choke 1 Place the choke into the machine so that the three mounting holes in the choke line up with the holes in the mounting bracket Insert the three long bolts through the choke and the mounting bracket Place a lock washer and nut on the end of each bolt and tighten Reconnect the choke leads Position the leads bolts washers and nuts exactly as they had been originally connected Ti
123. incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie du LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc TRANSFORMATEUR ET REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou at quand on regarde b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s e
124. is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN RANGER 3050 Return to Section Return to Master TOC G 3 WIRING DIAGRAM ENTIRE MACHINE CODES 11121 G4571 ELECTRICAL DIAGRAMS NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is paste
125. it to the engine mounting bracket Clearly mark all stator leads to insure proper reconnection See wiring diagram Disconnect all of the stator winding leads Note how the leads are routed and connect ed as well as the order and placement of leads and hardware for each connection See wiring diagram and the Control Inner Connection Diagram Unwrap the 3 and 6 leads from the toroidal current transformer and pull all of the stator leads through the hole in the center baffle assembly All of the leads connected to the stator winding should now be clear so noth ing can bind when the stator is removed later this procedure See Figure 21 See Wiring Diagram Remove the two screws and nuts holding the brush holder bracket to the stator frame The brush holder and bracket assembly can now be removed Remove the wiring attached to the alternator side of the engine This includes the con nections to the alternator starter oil pressure switch and engine ground cables and wires Be sure to mark leads for accurate re con nection See Figure F 22 RANGER 305D LINCOLN F 92 93 OIL PRESSURE SWITCH FIGURE F 21 WIRE GUIDE HOLE FIGURE F 22 ALTERNATOR LEADS 210 RANGER 305D LINCOLN H IGNITION BATTERY TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued F 93 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL
126. ld 9 OBST3 SNOLLOHNNOO TIVNIAHaLL LOSdSNI NTHXCTIOS YALAY EN 33S ALIDIHLOGEIS 15 SSW OL 125 fanis SI OX SHL VN lt L L9L ET o SOOONOLVOIJINSXXI HSEIAICIN M OWNT STSILI OWL C6Z6LIA OLIVIWHHOS H2 996 3 1531 1 ANY TIGLA DMN 39NVH3101 1VIB31VIN TIMLA ATEINSSSV CTHVOGS D 200 SI STVINIO3Q 39V 1d NO 20 SI SIVWIOSG 39V ld Z NO 99023 334 3ONVE3101 SNIBLLOVAONVIN 3 9539 92 33101 031319395 JSIMH3HIO 853710 3389v OL 41 vexe3 v Nis3usNuvinsdvoNdAXOd3 om 333934 v 30 9 SI 5819 TIY NO SIHL 11995 LON OG IVILN3GI3NOO 8 fs NIOSH XL eoess v wyg LL ELECTRICAL DIAGRAMS x 29 NoudnDsxi a Wall 65 01 13 50 5 91 810815 3IOWI H3TIOHLNOO WMd Ol 8 ex V N 66 5 L34S0W H3AIHQ SOWO OI 12
127. not restarted before the end of the time delay the idler reduces the engine speed to low idle speed The engine will automatically return to high idle speed when there is welding load or AC power load reapplied WELDING CONTROLS 9 OUTPUT CONTROL The output control dial is used to present the output voltage or current as displayed on the digital meters for each of the four welding modes It can also be used to vary the output while welding This control is disabled by auto sensing circuit if the machine is in CC Stick Downhill pipe or CV wire modes and an accessory device with output control capability is plugged into either amphenol When in Touch Start TIG mode and when an accessory device with output control such as an Amptrol is plugged in to either Amphenol the OUTPUT control dial is used to set the maximum current range of the accessory output control device 10 WELD MODE SELECTOR SWITCH This switch provides four selectable welding modes 12 13 14 AMPHENOL Primarily used for attaching accessories such as a wire feeder spool gun module or TIG module It provides connections to both 120VAC and 42VAC power and to the weld circuit work voltage sensing lead It also provides a connection to the same control cir cuits described in the 6 PIN AMPHENOL section below 6 PIN AMPHENOL Primarily used to connect a remote control device such as the K857 or a TIG Amptrol such as the K870 or K812
128. ns cot T 2 IDLE CONTROL IDLE CONTROL ENGINE CONTROL CIRCUITS 30V when energized LOW IDLE 12V 3 THERMAL SHUTDOWN if used when notenergized HIGH IDLE os S m CURRENT LIMITS 5 REGULATION MODE TO IDLE PULL COIL BOARD Alte HIGH PULLTO LOW IDLE MACHINE IDENTITY TABLE MACH SELI ONIOFF GS ON SS 212 6 3 424 PINS JUMPERED TO SELECT MACHINE WOD HVO S ya FOR AUX USE CONNECT 1 J1 5 1 6 J1 7 1 8 MACH SEL 2 MACHINE S TO FRAME FOR HIGH IDLE MODE 4 VANTAGE 500 BLINK PULLED LOW AND HIGH gt gt i VANTAG 575 MACH SEL 3 IN LOOKBACK TO FLASH gt us RANGER OIL PRESSURE g V BATTERY AIR VANTAGE 500 LOGIC DECIMAL POINT HMETED VBATTERY 70 PU 446 EN 0 MACH SEL 4 47 3 DISPLAY 8 4 v J4 9 METER INPUT 0 2V 1V 1000 ON METER STARTER BUTTON 47 16 5 1 A 12V when starting the machine RUN switch ON and t L 0 0 28 lt P Start Button Pressed and held OV when the machine TIG MODE STUD METERS OPTIONAL ONVANTAGE is notON 40V or more when the machine is running ON OFF 5V ON y NOJ 40RJ 5ONRANGER 250 4241 454 1 HOLD 5V HOLD 5 FRAME PIPE MODE 52 FUELSHUTDOWN 42 10 LP75 POSTE e 22223 Wei 1 1 Return to Master TOC Return to Section
129. of fresh clean fuel The fuel filter may be clogged Replace the fuel filter if neces sary The fuel solenoid may be faulty or not operating properly Check lead Z231 and perform the Fuel Solenoid Test The engine may be in need of mechanical repair The fuel solenoid may be faulty or not operating properly Check lead 225 and perform the Fuel Solenoid Test See the wiring diagram The fuel solenoid bypass circuit may be faulty Check the glow plug button for proper operation Check lead 233A and diode bridge D4 See wiring diagram The engine protection relay may be faulty The engine may have inadequate oil pressure The oil pressure switch or coolant temperature switch may be faulty CAUTION 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 RANGER 305D LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o He 0 5 16 16 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS
130. pounds euruuoe 1eddou5 o 2 9 1 0 512 212 515 43 o o ajo 5 Reconnect all leads 7 Perform the Case Cover Replacement procedure Return to Section TOC Return to Master TOC RANGER 305D LINCOLN B 68 5 3050 LINCOLN amp F 68 901 J91Se N 01 UuunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes 69 F 69 TROUBLESHOOTING amp REPAIR WELD CONTROL BOARD PWM GATE SIGNAL TEST 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the weld control PC board is able to produce the PWM Pulse Width Modulated gate signal needed to control the IGBTs Insulated Gate Bipolar T
131. produce 200 amps apply as much load as you can 7 Compare the readings shown on the exter nal ammeter and voltmeter to the amps and volts displayed on the front panel of the machine 8 If the readings shown on the front panel dis plays are about the same or very close to the reading on the external meters the feedback is probably good and this test is complete 11 If the readings differ significantly continue with this procedure Turn off the engine and release the load from the weld terminals The load bank and ammeter should remain connected but the load should be released Perform the Case Cover Removal Locate plugs P3 and P6 on the control PC board See figure 1 Remove the plugs and check for dirt corrosion damaged expanded or incorrectly positioned termi nals Repair or replace wiring components as needed and reconnect the plugs to the control board Restart the machine and apply a load across the weld terminals that measures about 200 amps If the machine will not produce 200 amps of current apply as much load as you can Using the voltmeter measure and note the DC voltage at the weld output terminals Check the voltage between leads 204S 6 1 and lead 208B P3 15 at the control PC board Molex plugs The voltage should be the same as was measured at the weld terminals RANGER 305D Return to Section TOC Return to Master TOC Return to Section TO
132. side of machire ROL 10K R2 278 7 7 7 15 220 7 16 222 VOLTAGE FEEDBACK SIGNAL 0v REVOLVING FIELD 4 VOLT AC FIELD RESISTANCE APPROX 5 OHMS 75F Return to Section TOC Return to Master TOC 1217 7 8 TOROID SENSES AC 260A 34 POWER 12 to 14V NORMAL OIL PRES INPUT ENERGIZEDFOR ACTIVATE 261A 33 2 9 2248 IDLER 2 7 2108 312 to 14V RUN 4 210 picos GLOWPLUG GLOWPLUG SWITCH ENERGIZES IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITC SWITCHS7 ND P723 2 ELECTRIC FUELPUMP AND FUEL cer imas 11 ae 5K 23 PROTECTION BYPASS UNTIL OIL ENGINE ELLOW PULL PRESSURE BUILDS UP PROTECTION ENGINE 0 2 OHM RELAY HOLD 15A BATTERY 51 7 110 5 CIRCUIT BREAKER P724 P722 WELDAMMETER WELDVOLTMETER 209 stp 212 74 722 Meters display setpoint volts 0 amps when rot welding 232 Meters display actual volts and ams when welding 210 Hold function displays actual volts and mps for 210 approximately 5 seonds after welding stops START BUTTON During this hold display theright most decimal point vill SWITCH 52 fo e binis 2 TURNS THRU FUELSOLENOID PULL FERRE ee COILIS ENERGIZED BY HOUR METER 15V LOW 77 5 CONNECTION STARTE
133. some other PC board compo nents may not be detected Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Digital Ohmmeter Wiring diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 66 66 TROUBLESHOOTING amp REPAIR CHOPPER MODULE RESISTANCE TEST continued TEST PROCEDURE 1 Perform the Case Cover Removal 4 Usea digital Ohmmeter to test the module per Table F 2 2 Perform the Capacitor Discharge 3 Check that all of the leads connected to the chopper module terminals are clearly marked to facilitate reassembly Remove all of the leads from the chopper module and position them so they do not make electrical contact with any part of the module See the wiring diagram Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 5 9 16 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 67 67 TROUBLESHOOTING amp REPAIR CHOPPER MODULE RESISTANCE TEST continued TABLE F 2 DIODE TEST TABLE OHMMETER MN Diode Bias Lead Lead and Expected Test Result Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 6 The chopper module screw connection should be lightened to 50 60 inch
134. sure all terminals are crimped tightly to the flex leads and arc free of corrosion RANGER 305D 49 49 TROUBLESHOOTING amp REPAIR olo O10 FLASHING VOLTAGE TEST continued 8 8 FIGURE 11 EXCITER LEADS T1 T2 5 ENGINE ALTERNATOR 229 ala 818 Ed ul gt lt OIL PRESSURE SWITCH OIL FILTER 2 gt o Hr 5 2 5 Return to Master 17 If battery voltage is present at lead 210 but not present at leads 224B or 200N 21 If testing is completed perform the Case check the engine protection wiring and CR1 excu ym engine protection relay per the wiring dia gram Also check that the oil pressure switch lead lead 229 has not come into contact with chassis ground The engine protection light should be off during this test O10 eile 5 5 16 battery voltage is present at leads 721 0 19 Set the RUN STOP switch to the STOP i and 224B but not present at leads 200N position o The Control PC board is probably defective 20 Re connect lead 229 to the oil pressure 515 switch dc 18 If battery voltage is not present at lead 210H check wiring per wiring diagram and check the run stop switch Also check the ground PC board chassis ground wire lead 5 and the stud where it connects to th
135. that the bridge rectifier and the capacitor be replaced with known good components before replacing the stator RANGER 305D LINCOLN F 45 46 5 3050 LINCOLN amp F 46 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes 47 47 TROUBLESHOOTING amp REPAIR FLASHING VOLTAGE TEST Engine Not Running 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 pro ceed Call 1 888 93 3877 MATERIALS NEEDED O10 55 DESCRIPTION 9 5 This test checks the flashing voltage with the engine stopped by simulating running condi 815 tion 88 dc Miscellaneous hand tools Voltmeter Wiring Diagram olo 515 9 16 gt 8153 43 o o 1 R
136. to read the low 5 Start the engine and place the idle switch in ie RPM the HIGH IDLE position Make sure that If either of the readings is incorrect proceed there is no load on the machine to the THROTTLE ADJUSTMENT PROCE DURE later in this section Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 55 0 9 16 gt 815 4353 Return to Section Return to Master TOC Return to Master TOC F 31 Electric Fuel Pump 31 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 6 SOLENOID Solenoid amp Fuel Pump Bracket codes 10926 811121 only Engine Engine Speed Control Lever Solenoid MOVING ENGINE SPEED CONTROL 2 LEVER 3 INCREASE DECREASE RPM RPM Solenoid viewed from above and shown in High Idle position Frequency Counter Method NOTE A dedicated frequency counter can be used for this test but many high quality digital multimeters also have this function and can be easily utilized See the manufacturer instruc tions for your frequency counter or multimeter 1 Set your frequency counter p
137. u RS m m SN gt 5N 5K FUEL GAUGE 5M ASSEMBLY GND K 5 m e 208 5 1 1 5L i 562 E IDLER CONTROL Amphenol 210F 251 224 54 Select D CBA sk 800 252 Hot Start NOTE LEADS 31 AND32 NOT USED lt 01A T50vdc SHOWN IN TAPE LEAD ENDS AND SECURE FUEL SENDER jr AUTO POSITION ela 20 200 115 GND N i Engine Protection 4 23 RD 58 1C 18 1A 28 2A 201 Light PL1 210 T zz 42VAC 29 0909 zc m x 2 04 GND A 0000 j a P33 FRAME GND RCDI 2298 15 d WORK H 21 GND B Sk Ap 24 30 lo Sense 2 0 1 778 GND G GND C 20 POSITIVE BRUSH CONNECTED 2100 2 261 EONTROL 2 0 1768 GND D TO SLIP RING NEAREST 2294 T T E TO THE LAMINATION r 3 2 9 75 1 7 2A f ROTOR 22221 e 5r 2C 28 13 L2 L1 D D e1 48 Glow sinunstop 212 52 lt gt 2 04 28 50 1 BUTTON CB7 SWHGH 81 SURON GROUND B gt 5 223A PCB2WELD CONTROL PC BOARD AMPHENOL 1 u 2098 6 212 L 12 55 15A 15 15A 20 1 76 7 77 100 2108 H 2108 5493 CONTROLL B2 768 t 11 97 210H Coe 758 a A 81820083 1 2 101 1102 CONTACTOR a r N 2234 Zi 258 H 232 O 5 E gt 50 GND K 4 8 GROUND 5 9 GND B 23 Hie 2
138. 0 cs 1813400484 CAP ALEL 930 100V 20 EIE C6 __ 1 1111577 58_ CAPACITOR CD 0047 3000V 20 5 13490 69 CAPACITOR TAEL 3 9 35V 10 510 51 02 53 3 111270587 DIODE SCHOTTKY AX 407 c 09 512 2 11270529 DIODE AXLDS SA 800V 15406 8 NEO IO riz at e D20021 2 1127047 DIODE AXCDS AA 200V UFR 71 D22 1 11270562 DIODE T218 00A 400V SR SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION DZI 27025 ZENER DIODE DZ 1 12702 25 ZENER DIODE SW 20V 5 1453578 074 075 M ERE ZENER DIODE 1W 15V 5 1N4744A A3 71 624020 8 CONNECTORMOLEXMINLPCB S PIN TIN BLANK PART NUMBER L11768 E Movi 1 71364025 MOV 14VRMS 100 20MM NA Q4 1 111270452 IRANSISTOR NME TO226 195A 60V BS170 SS 07 112 013 3 112704 69 TRANSISTOR PNP TO226 0 5 407 242403 i Q8 17 151839540 516 220 6 150 15031 8 520590 2 5 e Q9 ric NB 014 015 2 51830544 R52 R53 4 15194004751 RESISTOR MF 1 4W A 75K 1 olo 22 7 RO 3 15194001002 RESISTOR ME 1 4W 10 0K 196 t 2 3 R ols R11 R13 R14 R16 R17 8 j919400 1211 alles ms olo 218 519 2 5154003351 RESIS TOR MF 1 4W 3 32K 196 214 R20 R39 R40 R G RAT RAS 9 819400 1000 RESISTOR MF 1 4W 100 1 8 PULL COIL BATIERY R49 R50 R51 R25 iiv R26 RESISTOR MF 1 4W 9 09K 1 c R32 R38 2 5194003921 RESISTOR
139. 0000000 PLUGS ENGINE COMPONENTS 5 y 1 142 g 4b WEWBITE ACIERNATCR STARTER N FRAME FUEL SOLENOID IDLE SOLENOID PULL COIL BD ELECTRICAL SYMBOLS PER E1537 G GREEN W YELLOW STRIPE J GROUND J CONNECTORS VIEWED FROM INSERTION END 4 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR LI N LN ELECTRIC porso nousa Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN RANGER 3050 G 3 ELECTRICAL DIAGRAMS ms WIRING DIAGRAM ENTIRE MACHINE CODES 11123 G4573
140. 035 D37 DIODE SMD DUAL 0 2008 70V UFR 1 038 040 105 5250 452250 1 C1 347 3 OPTERON NIS DUAL ER 2009 607782 1 4 E NA fh Ce HN 1 MORD SCOTS 108 82550 10225 5 m RESISTOR SMD METAL FILM 1 10W 18 2K 1 c c ES can oie fh Lom 38 9567 5 012628 629050094041 1A DV 00 214 RESISTOR SHD METAL E 1 i M barre Se 1 ER E EE DIEA 1 EA RESISTOR GMD METAL FIONS 5 gt Di us 0 PAS ND DUAL S OCA ZON 109 8 EEE RESISTOR SMO METAL FILA GN 20 OK T D 912 2 i pepe bene E RE 316 325000 15035 7 RI RIS RIS RESISTOR SMDMETAT FILM 10111506 1 t snsf 3 CEN 2 fr ems m DIODE SMD 226i 12458 801 23 RESISTOR SMO 20 140 12 6 15 18 0213 0214 02164 4 52 ZENER DIODE SMOD WS TV 86 50542 s2s007 t002sMr RESISTOR SMO PREG MF 1104 10 04 0 1 amp 1 abiit lt e m A3 525044 35 3_ 0280765 ZENER DIODE SMD 3W 12V 5 SMB EEIN 0220122 11 52504 5 ZENER DIODE SMO SWAN 55 SM M 18712 RESISTOR SMD METAL FILM 1 408 90 0K 4 Gece 1 021 ZENER DIODE 540305 555 SMB n i 3 45
141. 11 ENGINEERING CONTROLLED CHANCE DETAIL NEW MANUFACTURER No AUXLLARY WELDING CURRENT SENSE TERMINAL CONTROL 5700 IDLE SWITCH SENSE MACHINE IDENTITY TABLE PINS JUVPERED TO SELECT MACHINE Tie 178 z RANGER 250 G amp D RANGER 305 G amp D VANTAGE 500 VANTAGE 575 AIR VANTAGE 500 MODE ROCV ENABLE KR KR KR KR HR WK 64107 ONLY TFORALETRAUANVANTAGE 579 ELECTRICAL DIAGRAMS ISOLATEDCIRCUITRY FOR ENGINE FUNCTIONS 15V 410 5700 04 S BLINK PULLEDLONANDHGH INLOCKBACK TOFLASH DECIMAL POINT HOLD 45V HOLD 5 153 153 gt gt gt 3 1 19 4 158 2 METER 4 INPUT 0 2V 1V 1000 CNIVETER INPUT METERS OPTIONAL ONVANTAGE 4 5ONRANGER 250 2 154 1540 9 INPUT 0 24 1 1000 CNIMETER INPUT CURRENTFEEDBACK 500 FOR WELDCONTROL 5 FEEDBACK REG ULATING AMPLIFIER CURRENT LIMITS AVERAGE ABSOLUTE amp FOLDBACK NNGDLPHSIVIWHZHL PWM CHOPPER CONTROL CIRCUIT Ble FRAME IS COMMON FOR E
142. 1113 kg of baking soda and 1 quart 0 9461 of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING THE ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is cor rect Improper polarity can damage the charging cir cuit The RANGER 3050 positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do so can result in damage to the internal charger com ponents Follow the instructions of the battery charger manufac turer for proper charger settings and charging time OPTIONAL SPARK ARRESTOR A WARNING MUFFLER MAY BE HOT
143. 2 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 20 BATTERY PLACEMENT Battery Terminals TEST PROCEDURE 10 11 Turn engine off Position the machine on a firm safe work surface with adequate space to work around the machine A hoist will be needed with a reach extending from the lift bale to several feet behind the radiator end of the machine Perform the Procedure Perform the Chopper Module Capacitor Discharge Procedure Remove the four screws holding the battery access panel to the base Disconnect the battery cables REMOVE THE NEGATIVE BATTERY CABLE FIRST and then remove the positive cable Case Cover Removal Loosen the battery retaining nuts and unhook the long carriage bolts from the slotted holes in the engine support bracket Remove the bolts and battery retaining bracket Slide the battery out of the base through access hole in the side See Figure F 20 Drain radiator and disconnect the radiator hoses and the overflow tube Remove the six screws holding the radiator frame to the base Remove the radiator and frame assembly Remove the coolant recovery tank by pulling it straight up and off of its mounting bracket 12 13 14 15 16 17 18 Remove the air filter assembly from its brack et it may remain connected to the engine air intake hose Remove the filter bracket by removing the two nuts and bolts holding
144. 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 89 89 TROUBLESHOOTING amp REPAIR CHOPPER MODULE REMOVAL AND REPLACEMENT continued Replacement 1 Mount the heat sink to the brackets on the vertical baffle with the three 3 8 screws Mount the plastic strip with the top two Screws Connect leads 23 and 25 at their in line cou plers Using a 7 16 wrench attach the heavy leads and small leads as follows Note placement of leads and fasteners screw lock washer flat washer small lead heavy lead Apply a thin coating of electrical thermal joint com pound Dow Corning 340 Lincoln T12837 to the mating surfaces but not the threads Tighten the fasteners to between 50 60 in Ibs TERMINAL 4 Replace any cable ties cut at disassembly 5 When procedures are complete perform the Case Cover Replacement procedure LEADS Heavy lead W11 small lead 14 HL W5 SL 13 HL W8 HL W6 HL W4 SL 301 HL W9 SL 302 RANGER 305D LINCOLN 5 90 5 3050 LINCOLN amp F 90 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes 91 91 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT Service and re
145. 27 112039 Page 2 of 2 G 18 Schematic Entire Machine Code 11122 112213 Page 1 of 2 G 19 Schematic Entire Machine Code 11122 112213 Page 2 of 2 G 20 Schematic Entire Machine Codes 11189 11314 L12213 1 Page 1 of 2 G 21 Schematic Entire Machine Codes 11189 11314 L12213 1 Page 2 of 2 G 22 Schematic Entire Machine Code 11039 112038 Page 1 Of 2 G 23 Schematic Entire Machine Code 11039 112038 Page 20012 G 24 e Schematic Entire Machine Code 11123 112214 Page 1 of 2 G 25 5 Schematic Entire Machine Code 11123 112214 Page 2 of 2 G 26 8 Schematic Entire Machine Codes 11190 11315 112214 1 Page 1 of 2 G 27 9 Schematic Entire Machine Codes 11190 11315 L12214 1 Page 2 of 2 G 28 Schematic Weld Control Bd Codes G4108 1 Page 1 5 G 29 E Schematic Weld Control PC Bd All Codes 04108 1 Page 2 5 G 30 Schematic Weld Control PC Bd All Codes G4108 1 Page of 5 G 31 Schem
146. 3 Pn 1995 5 555 15 BLACK OR GRAY gi 2o oo 59090 R REDORPINK SHOWN IN i i 2 5 2 8 6 4 10 W WHITE MELDING EY H20 ENGINE wht id og d G GREEN WNELLOW STRIPE 2 LEMP i GROUND Kors aud 989066 12 13 CHOKES T soo aMLLLLA CE ENGINE COMPONENTS PULL COIL BD 7 2 9 26 H ALTERNATOR STARTER FRAME FUEL SOLENOID IDLE SOLENOID 10 VIEWED FROMNSERTIONEND 4 2 ALL CASE FRONTCOMPONENTS SHOWN VIEWED FROM REAR 5 T N A ONMACHINE CODE BELOW 11275 CBS WAS TWO SINGLE POLEBREAKERS SES 4 4 9106 gt 8 8 LINCOLN ELECTRIC CLEVELAND OHIO U S A 64571 1 5 pe 0 c NOTE This diagram is for reference only It may be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside of the enclosure panels of your machine LINCOLN RANGER 305D G 5 ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE CODES 11027 G4226
147. 31 aU s op GND SCREW ON AMPHENOL 2 u UR 1 o o gg ns bean 211 eo 1 1 4 1 5 LEAD COLOR CODE 229A 209 PIS T Pr 1 5 2555 nU B BLACK OR GRAY 3 m BATTERY 4 ok o ED OR PINK SHOWN IN 2 HO 27 Qoam akapo Best ENGINE wh cB G GREEN W YELLOW STRIPE POSITION L 2A 1 4 sw 8 h IGN n GND H rod 00000000 L2 L3 RF CHOKES aow L Ey PLUGS ENGINE COMPONENTS 5 T cx 16 STARTER FUEL SOLENOID IDLE SOLENOID PULL COIL BD ELECTRICAL SYMBOLS PER E1537 GND GROUND J CONNECTORS VIEWED FROM INSERTION END M 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM A LINCOLNE ELECTRIC 5487221 CLEVELAND OHIO U S A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine RANGER 305D Gs ELECTRICAL DIAGRAMS md WIRING DIAGRAM ENTIRE MACHINE CODES 11039 G4409
148. 7 1 ENGINEERING CONTROLLED CHANGE DETAIL RE
149. 78 Q POSITIVE BRUSH CONNECTED 2100 ave M 261 CONTROL gt 9 768 i TO SLIP RING NEAREST 2294 2 5 gt 758 TO THE LAMINATION 22 lo 5 D CONTACTOR D e ROTOR 212 m 52 01 8 5 GROUND B UNPOS PCB2WELD CONTROL PC BOARD AMPHENOL 1 GND B 6b Slow 212 5 BUTTON 15A 210 JF E CB 210 2108 2108 76 55 ae 210H S 75 2098 o o nE CONTACTOR 2 B1 B2 B3 2234 232 0O EDT GND K 4 8 GROUND 23 206 21 404 GND SCREW ON 9 AMPHENOL 2 FAN BAFFLE m CONTACTOR 209 GND L J73 4 229 1234 229A 209 PTT P74 P73 P72 1 5 1 1 1 5 3 BATTERY GNDM tlo oooo 56069 SHOWN IN 2 GND HO ru blk blk 22 90 VUE WO m m sw Spe 2 24 PUMP m ENGINE GND H e 255099 1213 RF CHOKES GRAY Gon GROUND e PCB3 PLUGS ENGINE COMPONENTS 7 d 9 5 6 Te STARTER GNDJ FRAME FUEL SOLENOID IDLE SOLENOID PULL COIL BD ELECTRICAL SYMBOLS PER E1537 G GREEN W YELLOW STRIPE 1 GROUND CONNECTORS VIEWED FROM INSERTION END 2 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR LN A ELECTRIC CLEVELAND OHIO U S A G4250 NOTE This diagram
150. 810515 31 25 e 16171 193805 3dAL LNAWdINOS NOLLISOdSIQ TTTTT 2 e V Mr L JWHOLSIS3H 1121 00615 LSH 9 1 01 91534 1065 62692 05 15153 26 00615 675 Lez My L3WHOLSIS3H 0122 00 615 8v4 961 HOO 81539 8001 0086 S 298 2189 00615 6 1281 00615 8122 00 615 2051 00 615 seu 1292 0061 ved 0001 0096 8 1 3e U SZ MEE JINHOLSISSH 9927 00615 vse ezu LZH 951 We ve 53 Zevt 00v6LS Led 629 51536 0925 00615 220 961299 0299 00615 zj 06 91539 1929 00615 SIH wj 1 0 01 1515 2001 00 616 J ay 9 8111 N Yl AS LY My UJWHOLSIS3H 2515 00615 ely 6H 8H 36 V 0 0L Mr L JW HOLSIS3H 0 009615 9 ZY 961400 M L JWHOLSIS3H 1001 00615 81H lH 65 0984 1008 V8 Ozc 1 JWN HOLSISNVHL 51 701 N in avd WAOUddY 00 1811355 93
151. 85 E Vaw 9 Se DET 59 GENERAL INFORMATION 957 ELECTRICAL SYMBOLS PER E1637 wy 5 59 23 45 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 01 PROGRAMMABLE RESISTORS Ohma 0805 UNLESS OTHERWISE SPECIFIED LABELS gt me DIODES 2 209V UNLESS OTHERWISE SPECIFIED 4 SUPPLY VOLTAGE NET Viso 10K POWER SUPPLY SOURCE POINT 1 sno 102488 57 COMMON CONNECTION 64107 FRAME CONNECTION THIS DOCUMENT PROPRIETARY INFORMATION pen F LINCOLN GLOBAL INC my DUPLICATED COMMUNICATED 4 CONFIDENTIAL OTHER FOR ANY PURPOSE WITHOUT THE LINCOLN ook INC EQUIPMENT TYPE COMMON ANALOG CONTROLS SUBJECT SCHEMATIC ANALOG CONTROL FOUND ne 117272006 un 1172 2006 CRM38474 INCE COMPONENTS OR CIRCUITRY ON A Y CHANGE 272588 95 OF 5 iw 64 4308 167 RANGER 305D BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER gt o ix lt 12 8 cle lm 43 9 a NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 ot ELECTRICAL DIAGRAMS ee PC BOARD ASSEMBLY WELD CONTROL PC BD ALL CODES G410
152. 9 IDLE SWITCH OUTPUT MODE WELDING CONTROL SWITCH TERMINAL SWITCH ARC CONTROL the output of the main generator until the design volt age is reached The output of the machine depends on engine RPM and rotor current The field voltage is now considerably higher than the flashing voltage that was used to start the generating process Circuitry in the control PC board blocks that higher field voltage from intruding into the 12VDC bat tery system AC output The generator is now producing sufficient AC power from all four of the windings These windings consist of 60 to 65 VAC three phase weld winding a 120 240 VAC auxiliary power winding a 42 VAC exciter winding and a 42 VAC wire feeder power winding DC output The output from the three phase weld winding is con verted to DC by a three phase output rectifier then fil tered by four large capacitors located on the power module assembly This produces about 90VDC power that supplies the IGBTs on the power module and the weld control PC board RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 5 5 8 5 9 0 12 2 2 S 2 Return to Section Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 5 WELD POWER amp CONTROL SHUNT POWER IGBTs MODULE CHARGING SYSTEM LIGHT CODE 10926 ONLY
153. 925050 15MT 1 ur TRANSISTOR SD NPN JA 200 SOT 73 P 1 RESISTOR SMD METAL 1 08 TRANSISTOR PHF 5 0621 B RESISTOR SMDPREC ME AMOR IS OR OS 3 5 52051 15 Y je TRANSISTOR 100V 38 RESISTOR SMD METAL __ 525010 35 3 RESISTOR SMD MF 1W20 0K 1 SURGE E 1 RESISTOR BMO 1206 34 S25003 4TRSSMT RESISTOR SMD WAT SOHMS 1 191 RESISTOR SMO MP 2 216448 V SURGE 5 22503508 108MT 1716 RESISTOR SMD TWO OHMS 196 192 E RESISTOR SMD METAL FILM THOVELSDKT 250 25 1 RS TRIMMER SMD MT 1102 10 LINEAR KE 1 RESISTOR SMD METAL 100K 4 SVO MT T7650 055 LINEAR 134 i jn TRANSFORMER 589091 0 53 3 RRS THERMISTORPTC SO0OHMS 28 nA ETE 2 Um 138 92067 8508 IG SHON G2 BANI 33 1 O s2sono tzt0SMT 8 RARE RBRR RS RESISTOR SHO tW 1210HMS 1 war 915128 295 5 5 JOP AMP SNO QUAD TSSOP M GEN PURPOSE 2 0 70 5183803 6 THERMISTOR PTC 03 0 19 OHMS 1 SA xas amp Zi sz800 12115MT 3 Cei RESISTOR SMD T 2TICTAW 1206 156 TR 498 19102 45 1 2 IG ARRAY DRIVER PERIPHERAL NPN DARLIN gt 333 47 IE OPAMP SMT QUADIH GH PERF 23074801 98806172 173 140 865128 10541 2 exu VOLTAGE REF ADJ P
154. 96 DOL 08296 DOL 08296 DOL 08296
155. AC operation The auxiliary power capacity is 10 000 watts Peak 9 500 Watts Continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equiva lent to volt amperes at unity power factor The max permissible current of the 240 VAC output is 42 amps The 240 VAC output can be split to provide two sepa rate 120 VAC outputs with a max permissible current of 42 Amps per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity Auxiliary power is protected by circuit break ers The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two 120 V circuits but are of opposite polarities and cannot be paralleled STANDBY POWER CONNECTIONS The RANGER 3050 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The RANGER 305D can be permanently installed as a standby power unit for 240 VAC 3 wire single phase 50 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical c
156. AL Open CircuitVolts d rol 2TURNS 7 ist and D3 locatal on rear of fan baffle THRU TWISTED gp Rotor Flashing 12 volts T A B C 400 VAC 3PH on left side of machine CV 2TURNS FERRITE 0 5 ocated m front of fan ba TO AUX i 58 WISTED 05 amps on left side nea bottom of lt A SLIP C5 THRU FERRITE PAIR until generator builds p is 230 VAC 1 PH then 450 volts 0 amps OUTLETS 3 8 79 50 V DC Control Board senses Weld Output 1303 8 1403 16 25 39 2303 10 8325 OHM 200 from Current Feedback Shunt 2045 161 ROTOR FLASHING to activate idler 2 1 200N AANAA AND lt 1156 62 2065 62 1125 08 IDLE SOLENOID HOLD COIL v 8 LOW IDLE 12088 1345 Control board common is AMPHENOLS 42 VOLT AC at welder positive output 15V LOW IDLE TO PULL COILBOARD WIRE FEEDER Qv 177 7 1 and shunt 2 4 404 POWER 0110 V Swich dosed for high BREAKERS 76 7 4 5 0 WELD CONTROL 0324 252 SWITCH 75 7 5 BOARD 3 7 251 _ 22 21 THRU FERRI 2A TO AMPHENOL 1 11 1 1 POWER FOR TO AMPHENOL REMO 1 25V POT 114 LD TERM SW ROTOR FELD CIRCUIT CON Located on front of fan TO AMPHENOL 21111 75A 140 baffie near top of 7 9 214 Relay CR1 and 04 locatel on fron 279 76 Machine 1744 218 baffle onright
157. ARTS OF THE G4107 G4109ARE USED IN EACH CONFORENTVALEUNTS PHESET CONNECTORS APPLICATION NOT ALL CIRCUITS ARE USED ALL THE TIME CAPACITOR 5 awone FIXED HOT START J1 amp MACHINE ID JUVPER OHVSWA J2 ENGINE 12V CONTROL FUNCTIONS 43 CHOPPER PWM POWER IN THERMAL OVERLOAD USED VOLTAGE FEEDBACK CONNECTOR PIN NUVBERS NO CONNECTOR ON RANGER 250 12 ONNECTOR 45 VOLTVETER NO CONNECTOR ON RANGER 250 REMOTE 10K OTHER MODES E 135223 CONTROL 46 SHUNT CURRENT FEEDBACK J7 OUTPUT CONTROL ARC FORCE MODE gt COMMON 200209 1 77 FRAVEGROUND LATCH gt EARIHGFROUND VEW OF CRCBOARD 5700 JHIS D NTC ONTAINS RIETARY INF ORMATION LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU D PROPRIETARY 8 CONFIDENTIAL HERPARTIESO USE DF OR ANY PU RP OSEWIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN COLN GLOBAL INC MANUFAC TURN G TOLERANCE PER EOS 6 REFERENCE EQUIPMENT TYPE RANGER 305D CE EUROPE DRAWN BY DEO SUB ECT MACHINE SCHEVATIC NMER WITH PUB LISHEDS TANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING 121 203 357 112214 SOLID EDGE EN 168 Return to Sect
158. ATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UN RWI PECTI PACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE EQUIPMENT TYPE N 2 PLACE CECIMALS IS 02 N DRAWN BY L11943 0 UI 2 3 PLACE DECIMALS 15 002 NGIES IS 50F A DEGREE TERIAL TOLERANCE 1 AGREE ENGINEER SCALE WITH PUBLISHED STANDARDS MATERIAL pa APPROVAL DISPOSITION DATE 2 5 03 DO NOT SCALE THIS DRAWING APPROVED NONE 3050 PAGE 1 oF 2_ ACHINE SCHEMATIC NUMBER DOCUMENT REVISION PROJECT CRM33549 L11946 A NUMBER EN 168 SOUDEDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 RANGER 305D Return to Section TOC Return to Section TOC Return to Master TOC o EE s HIE lt gle ES ply 9 ojo Return to Section TOC Return to Master TOC Return to Master TOC G 12 SCHEMATIC ENTIRE MACHINE CODE 10926 L11946 PAGE 2 OF 2 96111 AUXILIARY SENSE TOROID ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X MANUFACTURER AUXILLARY WELDING TERMINAL CONTROL SWITCH SHOWN IN ALWAYS ON POSITION 2 4 SENSE IDLER CONTROL IDLE SWITCH SENSE
159. Allow the engine to cool before installing the spark arrestor Clean the spark arrestor after every 100 hours of use RANGER 305D WELDER GENERATOR MAINTENANCE STORAGE Store the RANGER 305D in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always firm BRUSH REMOVAL AND REPLACEMENT It s normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary A CAUTION Do not attempt to polish slip rings while the engine is running A WARNING Service and Repair should only be performed by 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 ELECTI MAINTENANCE GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To properly test and reset the GFCI
160. C olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC F 73 16 17 18 19 TROUBLESHOOTING amp REPAIR WELD CONTROL FEEDBACK TEST continued If the voltage readings are different check the wiring and connections between the welding terminals and the control PC board See the wiring diagram Connect the millivolt meter probes between lead 206S P6 2 and lead 2045 6 1 See Wiring Diagram If the machine is cur rently producing 200 amps the millivolt meter should read about 25 millivolts If the machine cannot produce 200 amps of weld current the correct millivolt signal will need to be calculated by dividing the read ing displayed on the external ammeter by 8 See the following explanation The shunt used in this machine will produce 50 millivolts at a load of 400 amps or 8 amps per millivolt 20 21 22 To calculate the correct millivolt signal for a given load you divide the number of amps displayed on the ammeter by 8 Example If your ammeter reads 75 75 8 9 4 If the shunt is working correctly and th wiring between the shunt and the control PC board is in good condition the meter con nected at the control PC board should be reading about 9 4 millivolts If the millivolt reading is incorrect check the wiring between the shunt and the control PC board for damage grounds and faulty co
161. COLN GLOBAL INC UNLESS OTHERW ISE SPEC IFIED TOLERAN CE 3 MANUFAC TURIN G TOLERANCEPEREXS 6 DESIGN INFORMATION EFEFENCE EQUIPMENT PAGE 20F 2 ON2PLAC EDECIMA 5 5 02 ON 3 PLACE DECIMALS 16 002 DRAWN BY DEO DOCUMET DOCUVENT NUMER REVISION MATERAL APPROVAL PROJECT L12212 A UF pare _ 12 1 203 NuMBER CRM3587 ON ALLANG LES S 5 OF A DEGREE SUBJECT MATERIA LTOL t TO AGREE ENGINEER BAM WITH PUB LISHED S_TANDARDS DO NOT SCALE THIS DRAWING SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 305D LINCOLN 8 es ELECTRICAL DIAGRAMS alia SCHEMATIC ENTIRE MACHINE CODES 11188 11275 L12212 1 PAGE 1 OF 2 ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURER PC BOARD Rectifier mounted to generator support IGBTS FLYBACK DIODES AND Shunt on back of positive 2 5 0 8180 on font of FILTER CAPACITORS ARE INTEGRAL above output chole POSITIVE SHUNT output terminal hi TO CHOPPER MODULE AND NOT 50MV 400 AMPS INDIVIDUALLY REPLACEABLE D1 THREE PHASE BRIDGE RECTIFIER 206B 2065 2045 WELD CURRENT 85 10 000uF x4 Chopper is mountet on the back side of fan Q 206A FEED BACK SIGNAL baffle near top of machine Requires added 206 FLYBACK baffle for cooling flow Latis inccr
162. Check your state and local requirements A double pole double throw transfer switch in conjunction with the properly rated double pole double throw circuit breaker is connected between the generator power and the utility meter Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 9 Section 1 Section 1 TABLE OF CONTENTS o e OPERATION SECTION ie vrl Section 5 Operating EE 2 Sisi a B 2 E B 2 DE B 3 Controls and Settings ettet ensured 3 Engine COMMONS ipa 4 T Welding 5 Engine QDS AUON mS B 6 2 Before Starting the 6 gt Starting 25 525442 5410 EPI 6 DLOPPING AMES ENGINE EE 6 5 Stick Welding tues 7 c Constant Current CC Stick 222 204 40 B 7 Pipe 7 TG 8 Wire Welding CV 8 fremere B 8 Auxillary B 8 Simultaneous Welding and Auxiliary Power Loads
163. Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instructions RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 G 5 Return to Section Return to Master TOC o 2 0 5 INSTALLATION PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Keep hands away from the engine muffler or HOT engine parts Stop the engine and allow it to cool before fueling not smoke when fueling Fill the tank at a moderate rate and do not overfill Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel
164. E CONNECTOR KEYING PLUG OVER HEADER PIN IN 10 613090797 1 i CAPACITOR ALEL 3 200 2075 36 500 68115 RAT R TB R2ST RIGS RAIS RESISTOR SMD METAL FILM IHOWE 81K 1 us LOCATION SHOWN PLUG SHOULD BE INSERTED BELOW 11 525024 25 0163011620 0152 CAPACITOR SMD TANTALUM 0 159 1056 R45 RB1 882 189 8123 8125 CONNECTOR TOP SURFACE 2 PLACES CACCE RI37 v 46 005008007013 CAPACITOR SMO CERAMIG 0 AMF 0V 10 X SD HON RB RSS FESISTORISDIETALFRM E 9 146 148 0148 0150 0153 ed SECURE BOARD ASSEMBLY IN PLACE WITH ITEM 4 S poser CAPACITOR ALEL SESS 2096 LOWES RAS RBLRESROTRTR TA ec 2 PLACES 5 3 IN LBS 147760502 CAPACITOR PPM 0047 1000V B0X R28 R145 R47 RISO ACL 5 3 6503 CAPACITOR TANTALUM ION 18V 1096 RIZ RTTARISA 82218222 ms LOE AV 10 g8 s25012 100 6MT E RESISTOR SMO METAL FILM ATTON f00K 1 NF PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND E 1 5 CAPACITOR SHD TANTALUMAG ENE SON 10 R237 RA 92458268 BARCODED SERIAL NUMBER IDENTIFICATION IN AREA SHOWN NB 17 505024 55 i 012 CAPACITOR SMD TANTALUM 22M 16 105 5 R270 R293 R297 R344 345 18 1525024 35 3 1 11045 085 CAPACITOR 5 22 20V 1036 1 1 R380 387 R428 RAJ2 R33 CSEE CAPACITOR ALEL O00 36V 2059 LOWESR RSI
165. ENGINEER BAM WITH PUB LISHED STANDARDS 50 NOT SCALE THIS DRAWING EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual RANGER 305D LINCOLN 8 ELECTRICAL DIAGRAMS SCHEMATIC ENTIRE MACHINE CODE 11027 112039 PAGE 1 OF 2 6 0211 Noo CHANGE DETAIL RELEASED FROM X CHOPPER PC BOARD Rectifier mounted to generator support L11845 1 IGBT S FLYBACK DIODES AND Shunt on back of positive located on font of FILTER CAPACITORS ARE INTEGRAL above output chole POSITIVE SHUNT output terminal hi TO CHOPPER MODULE AND NOT 50 400 AMPS INDIVIDUALLY REPLACEABLE D1 THREE PHASE BRIDGE RECTIFIER B2 B5 ate 2045 WELD CURRENT 1000 x4 Chopper is mounted on the back side of fan 206A FEED BACK SIGNAL baffle near top machine 206 FLYBACK A 60 65 PHASE TO PHASE BY PASS DIODES 6 WIREFEEDER DC BUS VOLTAGE BETWEEN W1 W2 AND W3 Located on back of PC BOARD VOLTMETER FILTER 904 10VDC HI IDLE AT HIGH IDLE output panel POLARITY CAPACITORS 4 9 between terminals 7 SWITCH Return to Section TOC Return to Master TOC 2 IGBT 8 NEGATIVE __ QUTPUT E B1 INPUT TWO POLE 3600 RPM ALTERNATOR L1 CHOKE Choke is beneath bearing end PWM Signal to Chopper TERMINAL o
166. EVER USE A SHORTING STRAP TO DIS CHARGE CAPACITORS the Lincoln rec ommended resistor or an equivalent resistor is used the capacitors can be discharged by holding the resistor with insulated pliers and using the resistor terminals to bridge Chopper Module terminals B1 to B2 and to B5 DO NOT TOUCH THE TERMINALS OR METAL PARTS OF THE PLIERS WITH YOUR BARE HANDS Hold the resistor in place for about 10 seconds If another type of resistor is used jumper leads may need to be attached to the resis tor The leads can then be used to connect terminals B1 to B2 and B4 to B5 4 Usingthe volt ohmmeter check the voltage across B1 and B2 then B4 and B5 It should be zero volts in both cases RANGER 305D 25 25 TROUBLESHOOTING amp REPAIR FUEL SHUTDOWN SOLENOID TEST WARNING 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 or 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 Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you procee
167. EYES AND SKIN Wear gloves and eye protection and be careful when working near a battery Follow the instructions printed on the bat Use caution as the electrolyte is strong acid that can burn skin and damage eyes The RANGER 305D is shipped with the negative bat tery cable disconnected Make certain that the RUN STOP switch is in the STOP position Access the neg ative post of the battery by opening the left side engine cover Attach the negative battery cable to the negative battery terminal and tighten using a socket or wrench NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity See battery charging instructions in the MUFFLER OUTLET Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned to direct the exhaust in the desired direction Tighten using a sock et or wrench SPARK ARRESTER Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain loca tions where unarrested sparks may present a fire haz ard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester must be installed and properly maintained See the Accessories section for more inform
168. Engine hour meter for scheduled maintenance e Output at welding terminals controlled by electronic contactor Can be switched to On or to Remotely Electric start Controlled Oil drain valve no tools required Many wire feeder combinations 14 pin connector for Lincoln wire feeders LN 25 LN 23P LN 7 LN 8 oper See spec pages for watts of continuous duty AC gen ates when using a Lincoln wire feeder with the appro erator power priate control cable Smart machine Remote operation and Magnum See spec pages for Amp and voltages output specs spool gun 42VAC for LN 742 and Cobramatic wire Circuit breaker protection feeders See spec pages for receptacle information 12 gallon fuel capacity allows you to run an extended CONTROL AND SETTINGS Easily check fuel level during operation and refuelling with highly visuable fuel gauge Return to Section TOC Return to Master TOC The diesel engine stop start and idler controls are Some models have gauge located next to fuel cap on located on the case front panel The welder controls case top are also located here See Figure 1 Some models have gauge located on front panel Voltmeter and ammeter display actual volts and amps at output terminals when welding olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 Return to Section Return to Master TOC
169. F 32 33 33 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST WARNING 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 or 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 Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the idler solenoid resistance values are normal and also deter mine if it will function normally when it is energized with 12VDC Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools External 12VDC supply 30 amps automotive battery works well Wiring Diagram Volt Ohmmeter o Fle 5 5 o 9 2 3 2 o Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 5 2 5 Return to Section TOC Return to Master TOC
170. G SWITCH ENERGIZES IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITC SWITCH 57 ND N 210 o EE s HIE lt gle ES ply 9 ojo THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC FACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE EQUIPMENT TYPE RANGER 305D CE UK PAGE 1 2 PLACE DECIMALS IS UI N2 02 Eo ASIN N 3 PLACE DECIMALS 15 002 DRAWN BY L11946 DOCUMENT DOCUMENT VERAS dC HER ENGINEER War SUBJ ECT MACHINE SCHEMATIC NUMBER REVISION ITH PUBLISHED STANDARDS MATERIE DO SCALE THIS DRAWING APPROVED NONE Joisposition UF 6 2003 J numser CRM3365 L12039 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D
171. GE 1 OF 2 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROM X 996111 MANUFACTURER R4 is located front of fan baffle near top of machine CHOPPER PC BOARD pin L11845 1 Rectifier mounted to generator support IGBT S FLYBACK DIODES AND above output choke FILTER CAPACITORS ARE INTEGRAL TO CHOPPER MODULE AND NOT INDIVIDUALLY REPLACEABLE Shunt on of positive SHUNT output terminal 50MV 400 AMPS POSITIVE OUTPUT TERMINAL TS 206 BY PASS Located on back of PC BOARD output panel between terminals 7 2 NEGATIVE _ OUTPUT L1 CHOKE TERMINAL Choke is beneath bearing end of generator on support D1 THREE PHASE BRIDGE RECTIFIER O 2 206S 204S WELD CURRENT B5 10 000uF x4 FEED BACK SIGNAL Chopper is mounted on the back side of fan baffle near top of machine FLYBACK WIREFEEDER DIODES 6 VOLTMETER FILTER POLARITY CAPACITORS 4 SWITCH Return to Section TOC Return to Master TOC DC BUS VOLTAGE wt 90 10 HI IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 W3 AT HIGH IDLE IGBT 8 E OUTPUT TWO POLE 3600 RPM ALTERNATOR Signal to Chopper 15 volt 20 kHz Power Supply em to Control Open CircuitVolts Board B 58 TWISTED TWISTED 0 58 26 PAIR PAIR Tig 12 12 lt D3 locatal on rear of fan baffle 1 1
172. HENOL WELD TERM SW 13 4 7 9 214 7 14 218 017 15 2201 7 16 222 AMPHENOL 12 to 14V NORMAL OIL PRES INPUT G AND 42 VOLT AC AMPHENOLS power i 150vde 20 ds 42 VOLT AC POWER FOR ROTOR FELD CIRCUIT REVOLVING FIELD FIELD RESISTANCE APPROX 5 OHMS 75F Relay CR1 and D4 on fron baffle onright side of machire 2 9 2248 2 7 2108 12 to 14V Q RU N INPUT 210 IDLE SOLENO ENEGIZED FO LOW IDLE 1 7 305 112 305 of engine electrical system and are common to GLOWPLUG SWITCH 57 LL GLOWPLUGS frame ground negative battery terminal WELD AMMETER WELD VOLTME ER REMOTE gcONTROL AMPHENOL Hold func blink Meters display setpoint volts 0 amps when rot welding Meters display actual volts and ams when welding approximately 5 seonds after welding stops During this hold display theright most decimal point wil tion displays actual volts and mps for 115VAC 42VAC 305 1 0 J UMPER Part of amphenol plug and lead assembly 209 5 223 GLOWPLUG SWITCH ENERGIZES ELECTRIC FUELPUMP AND FUEL SOLENOID HOLD COIL THRU D4 IT IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH CLOSE CR1ENERGIZES OPENING CONTACTS SHUTTING OFF FUEL S LENOID TO STOP ENGINE ALSO FUNCTIONS AS AN ENGINE
173. IAGRAMS ISOLATEDCIRCUITRY FOR ENGINE FUNCTIONS 15V 410 5700 04 S BLINK PULLEDLONANDHGH INLOCKBACK TOFLASH DECIMAL POINT HOLD 45V HOLD 5 153 153 gt gt gt 3 1 157 4 158 2 METER INPUT 0 2V 1V 1000 0N METER INPUT METERS OPTIONAL ONVANTAGE 4 5ONRANGER 250 2 154 1540 9 INPUT 0 24 1V 1000 INPUT CURRENTFEEDBACK 500 WELDCONTROL 5 FEEDBACK REG ULATING AMPLIFIER CURRENT LIMITS AVERAGE ABSOLUTE amp FOLDBACK NNGDLPHSIVIWHZHL PWM CHOPPER CONTROL CIRCUIT Ble FRAME IS COMMON FOR ENGINE CONTROL CIRCUITS NOT ALL MACHINES USE EVERY CIRCUIT 12 Battery Supply to qo ide Hold Solencid 5 26 gt 125 5 Other side of the Ide Hold Solenoid 30V when energized LOWIDLE 12V DIODEONLYON E when not energized HGH IDLE hee AY HGH PULLTOLOWIDLE 1242 lt FORALXUSE CONNECT TOFRAVEFCRHGHIDLE RANGER OL PRESSUFE lt p VBATERY 0 d rt STARTERBUTTON
174. IDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC DESIGN INFORMATION y REFERENCE EQUIPMENT TYPE ENGINE WELDERS 1 or 1 Dae WO SUBJECT PULL BATTERY BD ASSEMBLY ogg wom cem ENGINEER NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN amp ine LINCOLN machine RANGER 305D Ot ice CiFIEO TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS 15 002 ON ALL ANGLES 5 t 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING EN 168 SOLID EDGE o ix lt 12 8 cle lm 43 9 a G 37 ELECTRICAL DIAGRAMS G 37 217 SCHEMATIC CHOPPER BD ALL CODES 19792 1 55 O n V From R
175. IG 250A 20V 100 20 TO 250 AMPS 60 Volts DC Constant Voltage 250A 27V 100 14 TO 29 VOLTS RATED OUTPUT 40 C 104 F GENERATOR Auxiliary Power 0 Sound Levels Auxiliary 8 500 Watts Peak 8 000 Watts Continuous 50 Hz 115 amp 230 Volts 1 Phase Sound Power 98 dB Lwa 8 500 Watts Peak 8 000 Watts Continuous 50 Hz 400 Volts 3 Phase PHYSICAL DIMENSIONS 762mm 546mm 1524mm Return to Section TOC Return to Master TOC 341kg 752lbs GOVERNOR Mechanical Governor O10 o s gt 23 cic 5 5 ply o ajo 30 0 21 50 in 60 0 in LUBRICATION EMISSIONS FUEL SYSTEM Full Pressure Electric Fuel Pump Code 11027 11039 11122 11123 or Mechanical with Full Flow Filter Certified to EPA Tier system Electric shutoff solenoid Indirect fuel injector NI NI PRO ON ENGINE WARRANTY 2 year complete parts and labor 3rd year major components parts and labor RECEPTACLES AND CIRCUIT BREAKERS Fuel Pump Code 11189 11190 11314 11315 Auto air bleed Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure amp engine Made from long life aluminized steel temperature MODEL NUMBER K2279 1 UK K2279 2 EUROPE Receptacles 400V 3 Ph x 1 400V 3 Ph x 1 230V 1 Ph x 1 230V 1 Ph x2 115V x 100 14 Pin Connector 14 Pin Connecto
176. IGBT S FLYBACK DIODES AND above output chole FILTER CAPACITORS ARE INTEGRAL TO CHOPPER MODULE AND NOT INDIVIDUALLY REPLACEABLE Shunt on back of positive SHUNT output terminal 50 400 AMPS 2068 2065 2045 CURRENT 85 10 000uF 4 OQ 206A FEED BACK SIGNAL 206 FLYBACK POSITIVE D1 THREE PHASE BRIDGE RECTIFIER Chopper is mounted on the back side of fan baffle near top of machine Requres added baffle for cooling flow W1 60 10 65 VAC PHASE TO PHASE BETWEEN W1 W2 W3 AT HIGH IDLE Return to Section TOC Return to Master TOC BY PASS PC BOARD WIREFEEDER DIODES 6 VOLTMETER FILTER POLARITY CAPACITORS 4 SWITCH 2 1881 8 NEGATIVE OUTPUT E OUTPUT L1 CHOKE 2 TURNS DC BUS VOLTAGE 904 10VDC HI IDLE Located on back of output panel between terminals 77 29 Bl aweur TWO POLE 3600 RPM ALTERNATOR PWM Signal to Chopper FERRITE Power Supply 15 volt 20 kHz to i lt D Rotor Flashing 12 volts TO AUX CV 58 FERRITE R 0 5 amps R3 located a front of fan ba te THRU FERRITE PAIR un until generator builds up on left side nea bottom of lt then 450 volts 0 amps machine OUTLETS 25 Control Board senses Weld Output 13 3 8 14 J316 25 3 9 23 3 10 8325 OHM lt E from Current Feedback Shunt 2045 61 L 206S J62 12088 J315 Control board commo
177. IN COLN GLOBAL IC 20 35 OHMS FULL REFERENCE 1 5 DESIGN INFORMATION EQUIPMENT TYPE RANGER 305D CE EUROPE PAGE lor 2 DRAWN BY MAP L12214 1 DOCUMENT DOCUMENT saa MACHINE SCHEMATIC EU REVISION WITH PUB LISHED STANDARDS MATERIAL APPROVAL PROJECT 70 WOTSCALE THIS DRAWING NONE M 0752004 _Jnumper CRM35578 L12214 1 A 404 043 8 82 EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D G 28 ELECTRICAL DIAGRAMS 0 28 SCHEMATIC ENTIRE MACHINE CODES 11190 11315 L12214 1 PAGE 2 OF 2 ENGINEERING CONTROLLED CHANCE DETAIL NEW MANUFACTURER No AUXLLARY CURRENT SENSE Return to Section TOC Return to Master TOC WELDING TERMINAL CONTROL ISOLATEDCIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT 12 Battery Supply to IDLE SWITCH SENSE VBATTERY Supply t 9 22 gt 15 FRANE IS COMMONFOR adc side ofthe Idle Hold Solencid ENGINE CONTROL 5 40V when energized LOWIDLE 12V when not energized HGH IDLE
178. INE COMPONENTS PULL COIL BD OIU 7 9 6 W WHITE STARTER FRAME FUEL SOLENOID IDLE SOLENOID Bt ELECTRICAL SYMBOLS PER E1537 G GREEN W YELLOW STRIPE Jo GROUND p Ola CONNECTORS VIEWED FROM INSERTION END ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM LINCOLN ELECTRIC 4 CLEVELAND OHIO US A 64226 Clic lm 0 0 c NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine RANGER 305D LINCOLN 8 ELECTRICAL DIAGRAMS Gs WIRING DIAGRAM ENTIRE MACHINE CODES 11122 G4572
179. IONS J3 PRIMARY GNO PE 16 PN SWITCH 2 2 NFEEOBALK MW SELECT INPUT POWER 15V_COM 15V COM NOT USED INCLUDED ON ARTWORK ONLY gt 15 COM GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohm 0805 UNLESS OTHERWISE SPECIFIED 0100 5 200V UNLESS OTHERWISE SPECIFIED LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION CONNECTION EARTH GROUND CONNECTION THIS SCHEMATIC USED FOR BOARD ARTWORK IN 64407 AND G4109 PROPRIETARY amp CONFIDENTIAL DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND HAY DUPLICATED COMMUNICATED SUL dec cec ere EQUIPMENT TYPE COMMON ANALOG CONTROLS oraw RS E xt RS ERE COMPLETE BOARD THIS REVISION 11 2 2006 G 5108 1 7 SEND SUBJECT Ter ANALOG CONTROL PCB EN APPROVAL Eg DATE o ix lt 12 8 cle lm 43 9 a NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 RANGER 305D 0 32 ELECTRICAL DIAGRAMS 0 32 SCHEMATIC WELD CONTROL BD ALL CODES G4108 1 PG 4 OF 5
180. L1 CHOKE a Meter Se R2 CONTROL OUTUTCONT olg L 206B O 208C 4 cew mem E t 7 gt B 10K Ola 208 208C 277 279 77 n gt 206 NOTE STATOR LEAD 3 NOT USED 76 75 5 TAPE LEAD END AND SECURE VOLTMETER gio WIRE FEED POWER POLARITY o 7 7 EI WITCH STATOR AUX C Output amp 9 5 E 208A 3 WINDING GND E Cont D 0 42 41 21 WRAP TWO TURNS C Select cc LEADS A 3 D B amp C IN lt DIRECTION B SHOWN THROUGH TOROID 5G 3 224A 215 2 2 BOTTOM GND STATOR GND R 3K o CB5 SHOWN N INSIDE our 90 2248 OUR METER Dm Engine amp POSITION 5 GND R 00 unction 42A TOPGND SCREWON 42 VAC 2001 2001 2 INSIDE OF CASE FRONT 2108 5N 5K 206C EE BYPASS 5H o P1 J1 F S IDLER CONTROL dd B Amphenol ASSEMBLY 9 251 2 305 e 208C 5G m t Select 4 o p HotStart OlO NOTE LEADS 31 AND 32 NOT USED SUN o Key e O TAPE LEAD ENDS AND SECURE CBA 1 AUTO POSITION 31 200 115 GND N e cb 4 5 5 5 284 i 2954 1 2 92 41 NS E t 42 0000 Engine Protection Battery Charge 2088 01 gt 42 ND B 0 0 00 Light PL1 Light PL2 Om 2106 gt WORK H e 2 FRAME G
181. LESHOOTING amp REPAIR STATOR VOLTAGE TESTS continued FIGURE 13 RECTIFIER BRIDGE DETAIL POS W3 W2 W1 W4 W5 W10 To test the 120 VAC wire feeder supply NOTE The wire feeder AC voltage supply tests require that the meter probes be inserted into the Amphenol connection cavities Care should be taken to avoid damaging or expanding the termi nals when inserting the probes NOTE The 120 VAC power supplied to the 14 pin Amphenol connector originates from the same winding that supplies the 120 VAC receptacles If the machine has previously passed 120VAC aux iliary winding test this test can only reveal prob lems in connections or components between the Amphenol and the stator winding NEG W6 W11 FROM SHUNT Connect the voltmeter probes to pins A lead 32 and lead 31 of the 14 pin Amphenol See figure 3 and wiring dia gram Start the engine and run it at high idle 3625 to 3675 RPM The AC voltage reading should be between 120 and 135 VAC If these voltage readings are not within spec ifications check for a tripped or defective cir cuit breaker faulty connections or broken wires between the test points and the stator windings See wiring diagram RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 5 5 9 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to M
182. LINCOLN amp F 86 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes 87 87 TROUBLESHOOTING amp REPAIR CHOPPER MODULE REMOVAL AND REPLACEMENT 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Chopper Module Assembly Note The Chopper Module assembly is removed and replaced as a unit It contains no ser viceable parts Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Electrical thermal joint compound Dow Corning 340 Lincoln T12837 olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC
183. LTMETER switch to or depend ing on the polarity chosen 7 Set the MODE switch to CV WIRE 8 Set the WELD TERMINALS switch to WELD TERMINALS REMOTELY CONTROLLED 9 Adjust wire feed speed and voltage at the LN 8 10 Adjust the ARC control to O initially and adjust to suit FIGURE C 6 Ranger 305D LN 8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM 14 PIN AMPHENOL ELECTRODE CABLE TO WIRE FEED UNIT TO LN 8 INPUT CABLE PLUG K595 CONTROL CABLE TO WORK RANGER 305D LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 ACCESSORIES CONNECTION OF THE LN 742 TO THE RANGER 305D SEE FIGURE C 7 1 Shut the welder off 2 Connect the electrode cable from the LN 742 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Figure C 7 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the output terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K619 Control Cable to the 14 pin amphenol on the Ranger 305D and the input cable plug on the LN 742 4 Set
184. MBER _ APPROVED APPROVAL 98 26 2004 cRM36472 19792 1 0 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D Return to Section TOC Return to Master TOC G 38 RANGER 305D ATANASSY PINIS YaddOHD CHLIH ldAIOD SWHO SONVISISJH SONN LOCXINI SEIIOWNCOHW 013140345 SASMYSHLO SS INO ON HSYNLOVANNVIN CZTITIOHLNO2 ONISHZISINIONSI dadasuadns SHSEINNN SNOWSdd TN HSV 16 11 SASN NOLONGOYd INIYYNO ONLLIOd ASI LON SI 55 SIHL 9NLLLOd NO 38 INO NO YIAWNN H3ACO OL T3ENZ INO S009 LSU HN 9 Wea bw JO 39 OL AOWIYNS WOH 9 SOvaHL ONY SIOV FYNS dOL DN dOLAVHL SOOT NHLM OLALVINSdVONA SHL NI 38 OL 181 NOLIWOISLINACI INTON SSCOD SNELL OL NOLIWWHOSNI SNIENIDVANNW 33S DOS ANY IWYS SHL OL Suv SOA 53000 LYOSS NIHLM OL SI HA SHOLSISNVHL HOS SPA SINS CNV 3000 IWYS IWH OL ATSWASSV D d NOWWOD Y NO SINGOW 2INOHLOHT3 ON YOANI IWYS GANddNS OL NOWIAOO Y NO SINSNOdNOD 3S3HL DN XS3Ov
185. MOVED J50 AND SEALANT WITH NOTE m 7 825001 33208 4 58 5 836 R87 RESISTOR SMD 3320 5 1 4W 1206 176 TR 10179 MANUFACTURER Yes REVISED BUY A8 PART NUMBER IDENTIFICATION CODE AND SCHEMATIC REFERENCE PART NO ary re SOMDREFERENCE DESCRIPTION EE 7 WELD CONTROL BLANK R211 R212 EMOAAN Bd 12 2 Pe RESISTOR FILM THOW2210HMS o o NOTES 2 60050 7 SELF TAPPING SCREW 30 3 RESISTOR SMD METAL FILM I OW AT 0 577 55 Tos EPOXY ENCAPSULATNG RESIN 81 71842 750 8320 97 RAGS RESISTOR SMD METAL FILM 20 5 un gt M 6 1 3539 ASREQ ELECTRICAL INSULATING COMPOUND 82 3 RASRUSRIED 10W 9 09 0 596 CAUTION THIS DEVICE Is SUBJECT TO DAMAGE BY STATIC P C BOARD BLANK INFORMATION 1 277177 3 FILM QU 2 ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING 1 DIE t 50000 a 54 BUY COMPLETE AS G4107 E 6 LAYER BOARD PER E3867 FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS RESISTOR SMD METAL SEE ELECTRONIC FILE FOR INFORMATION NN ESSET RAS RES RTI R253 R397 RESISTOR SMD METAL FILM U10W5110HMS c NB PLAC
186. MPING L RING Install a new bearing on the rotor shaft Assemble the coupling disc and clamping ring to the rotor hub The surface of the disc with the stamping burrs should be against the rotor hub The side of the clamping ring with the radius should be placed against the coupling disc See Figure F 23 Insert the screws with lock washers and evenly tighten to a torque of 17 to 19 Ft Lbs Lift the rotor assembly with the hoist and lift ing straps and recheck the engine flywheel and coupling disc for anything that might prevent proper seating To attach the coupling disk to the engine fly wheel align the screw holes and insert the six screws with lock washers through the dsc clamping bars and the coupling disc and into the engine flywheel Evenly tighten all the screws to a torque of 17 to 19 Ft Lbs RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo 515 9 16 815 4353 Return to Section Return to Master TOC F 96 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued Replacing the Stator T Examine the stator frame assembly Be sure the wiring coils mounting flange and bear ing seat are clean and in good condition Check the engine mounting flange to be sure it is clean and free of nicks burrs or anything that may interfere with the seating
187. ND GND A E E nsn CB1 228 8 an B be Sense 0 778 GND G GNDC 20 POSITIVE BRUSH CONNECTED 2100 i NN 261 oH pd 76 SLIP RING NEAREST 8 4A PONTROL Foe GND D Q 9 9 E TO THE LAMINATION 229A 23 oo et CONTACTOR 9 5 2c 28 2A L3 L2 L1 D ROTOR 25 lov Set S1RUN STOP 212A 52 C e 4 B 12 SWITCH START 5 0 GROUND SHOWNIN BUTTON o o ONDA 2 WELD CONTROL PC BOARD a AMPHENOL 1 GND B osa Slow 77 15 BUTTON 087 2 Remore 2 778 E 15A 210A 2108 2108 768 3 912 11 97 3 ames 2108 4 L GND R I 2 5 25 7 2 101 1102 Bl B2 B3 B4 DeB Jon AA T 2234 zii 232 5 GND 210 231 210 8 F e1 GND B 223 215 404 p GND SCREW ON 43 2 FAN BAFFLE J73 J72 o CONTACTOR 209A 1 GND L T 1231 CONTROL 728 209 Pala 4l pases 5 1 Bees 1 5 83 enom 1 1 292 sown sk 2275 ET UT WELDING ON d FUEL red wht S O 5 8 6 1 POSITION oH WH PUMP 1 6 1 cH ENGINE D H FIFE 65 5 5 6 5 55559555 LLXRFCHOKES GRAN a GROUND mlt RERED OB PINIC PLUGS ENG
188. NGINE CONTROL CIRCUITS NOT ALL MACHINES USE EVERY CIRCUIT 12 Battery Supply to qo ide Hold Solencid 5 26 gt 125 5 Other side of the Ide Hold Solenoid 30V when energized LOWIDLE 12V DIODEONLYON E when not energized HGH IDLE hee AY HGH PULLTOLOWIDLE 1242 lt FORALXUSE CONNECT TOFRAVEFCRHGHIDLE RANGER OL PRESSUFE lt p VBATERY 0 d rt STARTERBUTTON PULL OIL BOARD 12V when starting the machine RUN switch ON and La o 12 8 lt gt FUELSHUTDOWN 210 lt 12V when the RUN switch is ONand the START Button is held IN If externally shorted the PTC will change to high impedance BATTERY POSITIVE p BATERY 123 1 e ROTOR Stat Button Pressed and held OV when the machine is not ON 40 or more when the machine is running 1 PAMSIGNAL 12V ON MULTIMETER PAMSIGNAL 412V 1 G 16 5700 BOARD VANTAGE ONLY J ARC CONTROL CIRC UITRY FE is HIE ols gle ES ply 9 ojo 5700 TOUCH START VARIAB LE PINCH PIPE ARCF ORCE oa SEE SPECIFIC MACHINE SCHEMATIC FOR
189. NUFACTURER R4 is located front of fan baffle near top of machine ER PC BOARD Rectifier mounted to generator support IGBT S FLYBACK DIODES AND above output chole FILTER CAPACITORS ARE INTEGRAL TO CHOPPER MODULE AND NOT INDIVIDUALLY REPLACEABLE Shunt on back of positive SHUNT output terminal 50 400 AMPS 2068 2065 2045 CURRENT 85 10 000uF 4 OQ 206A FEED BACK SIGNAL 206 FLYBACK POSITIVE D1 THREE PHASE BRIDGE RECTIFIER Chopper is mounted on the back side of fan baffle near top of machine Requres added baffle for cooling flow W1 60 10 65 VAC PHASE TO PHASE BETWEEN W1 W2 W3 AT HIGH IDLE Return to Section TOC Return to Master TOC BY PASS PC BOARD WIREFEEDER DIODES 6 VOLTMETER FILTER POLARITY CAPACITORS 4 SWITCH 2 1881 8 NEGATIVE OUTPUT E OUTPUT L1 CHOKE 2 TURNS DC BUS VOLTAGE 904 10VDC HI IDLE Located on back of output panel between terminals 77 29 Bl aweur TWO POLE 3600 RPM ALTERNATOR PWM Signal to Chopper FERRITE Power Supply 15 volt 20 kHz to i lt D Rotor Flashing 12 volts TO AUX CV 58 FERRITE R 0 5 amps R3 located a front of fan ba te THRU FERRITE PAIR until generator builds up on left side nea bottom of lt then 450 volts 0 amps machine OUTLETS 25 Control Board se
190. OID K E ML LENOID P74 CIRCUIT 2 BATTERY UL uM 4 b INPUT T STARTER HOLD gt AMPHENOL L D ALTERNATOR MOTOR OHMS PC BOARD C g E FRAME OILPRESSURE COOLANT F gt Battery voltage GROUND SWITCH TEMPERATURE l 12 6 volts at rest CLOSES ON SWITCH Located nex AMPHENOL AMPHENOL 14 volts engine LOW OIL CLOSES ON HIGH control board running PRESSURE TEMPERATURE ABOVE 230F NTC ONTAINS PR OP RIETARY INF ORMATION OWNEDBY LINC OLNGLOBAL INC A NDMAY NOTBED UPLICATE D COMMU NICATE D 240 265 5 2 20 35 OHMS FULL PROPRIETARY amp CONFIDENTIAL OT HERPARTIESO USE DF OR ANYPU WIT HOUTT HE EX PRESS W RITTE NPE RMISSION LIN COLN GLOBAL INC MANUFAC TURIN EROR ES REFERENCE EQUIPMENT TYPE RANGER 305D PAGE lor 2 i DRAWN BY DEO L11946 DOCUMENT TDOCUMENT MATERIA TOL TO MGREE ENGINEER SCALE SUBJECT MACHINE SCHEMATIC Po WITH PUB LISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING NONE pseosmow UF pere _ 12012003 _CRM35573 112212 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines cov
191. OLENOID HOLD COIL THRU D4 IT 3 SOLENOID HOLD COIL THRU SHUTTING OFF FUEL DLENOID TO STOP ENGINE BE E 023 41010 Control board circuits associated with 2 ae part 05100 ENGINE PULL of engine electrical system and are common to 3 PROTECTION 0 2 OHM frame ground negative battery terminal RELAY 9 DAD 77 ul TIE IM 15 ferrite CIRCUIT BREAKER S SENEC 7 P724 P722 WELDAMMETER WELDVOLTMETER 29 212 RUM 3 1722 Meters display setpoint volts amps when rot welding Meters display actual volts and amps when welding 210 Hold function displays actual volts and mps for 210 approximately 5 seonds after welding stops START BUTTON During this hold display theright most decimal point vill SWITCH S2 binc P 2 TURNS THRU 55 FUELSOLENOID PULL All leads 305 10 JUMPER Part 223 1 time thu of amphenol plug and ferrite lead assembly o E t 818 ols gt 818 5 43 9 c FERRITE SUE COILIS ENERGIZED BY HOUR METER STARTER SOLENOID HNELON IE usvac 231 73 4 bd 229 404 43 8 P73 4 hire 88 STARTER SOLEN
192. OM CIR COM ENGINE POWER SUPPLY Return to Section TOC Return to Master TOC 4V BATT O eR 19 232N 25V REF X 25 PULL COIL 227 y BULL COIL CIR COM CIR COM SHUT BOWN SOLENOIO PULL COIL DRIVE IDLE SOLENOIO PULL COXL DRIVE o aE lt 2 2 AE ply 0 9 ojo IOLE SOLENCID HOLD COIL DRIVE BCARC TO 5 Dow 022 HOLD COIL Di ON BERIPHERAL ARO NA 55 25V REF 7 754 REFERENCE LAST NO USED GENERAL INFORMATIUN a FLEC SYMBOLS PER E1537 boo deis E CAPACITORS MFO 022 50V UNLCSS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED 0100 5 1A 400V UNLESS CTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT v COMMON CONNECTION FRAME CONNECTION the EARTH GROUND CONNECTION 0 14 0 5 THIS DOCUMENT CONTAINS PRCPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND DEN COMMUNICATED PROPRIETARY amp CCNFIDENTIA TO OTHER PARTIES OR USI DR ANY PURPOSE wiTHOU THE EXPRESS WRITTE V ust CIRCUIT BOARD MAY HANGE ESIGN INFORMA
193. ON BYPASS UNTIL OIL ENGINE ELLOW PULL PRESSURE BUILDS UP PROTECTION ENGINE 0 2 0HM RELAY HOLD 15A BATTERY Sl 110HMS CIRCUIT BREAKER P724 P722 WELDAMMETER WELDVOLTMETER 20 stp 212 74 722 Meters display setpoint volts 0 amps when rot welding 232 Meters display actual volts and ams when welding 210 Hold function displays actual volts and mps for 210 approximately 5 seonds after welding stops START BUTTON During this hold display theright most decimal point vill SWITCH 52 fo e pay 2TURNS THRU FUELSOLENOID PULL ee COILIS ENERGIZED BY HOUR METER 15V LOW 77 o CONNECTION STARTERSOLENOD receptacles 11 12 305 i ALSO FUNCTIONS AS AN ENGINE 4 SOLENOID Control board circuits associated with 2 ae part of engine electrical system and are common to frame ground negative battery terminal ul All leads 1 hu E 041010 0511010 All leads 305 1 0 JUMPER Part 223 1 time thu of amphenol plug and ferrite lead assembly 77 ltime ferrite o E t HIE lt gt 9 5 ply 9 c 134 25 404 043 8 82 SL STARTER i SOLENOID FUEL 14 SOLENOID 14 REMOTE cincum CONTROL 121011 ELECTRIC BATTE
194. OR SMD METAL FILM TSW 200 5 gg 515128 555 5 5 11 224 j TET j c 88 eal Nee B Bgm vis NOTE G4109 1 amp G4461 1 MUST BE REVIEWED SN HE BOAR UNLESS OTHERWISE SPECIFIED WHEN MODIFYING THIS BOARD MEE BUY AS SCHEMATIC REFERENCE G4108 1E7 4107 1 7 BUY PER E3867 PART NO IDENTIFICATION CODE TEST PER E4048 TAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMMUNICATED R USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL IN HIS DOCUMENT PROPRIETARY amp CONFIDENTIAL 5 DOCUMENT FRANCE PERE 1 melon MANUFACTURING TOLERANCE PER ERES EQUIPMENT TYPE COMMON ANALOG CONTROL or 1 PLACE DECIMALS IS 002 DRAWN BY 7 63660 ON ALL ANGLES IS 5 OF A DEGREE SUBJECT WELD CONTROL PCB ASSEMBLY MATERIAL APPROVAL PROJECT DATE 41 02 2006 CRM38474 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro LINCOLN D reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality o
195. ORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC DESIGN INFORMATION JREFERENCE EQUIPMENT RANGER 305D CE UK DRAWNBY MAP L11946 DOCUMENT DOCUMENT ENGINEER SCALE SUBJ ECT MACHINE SCHEMATIC NUMBER REVISION Ri WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED NONE DATE 6 2003 CRM3363 112039 Return to Master Return to Section TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOL RANGER 305D nan ELECTRICAL DIAGRAMS mem SCHEMATIC ENTIRE MACHINE CODE 11123 L12214 PAGE 1 OF 2 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED A 02 FROM X 48474 MANUFACTURER PC BOARD Rectifier mounted to generator support IGBTS FLYBACK DIODES AND Shunt on back of positive 545 located on font of FILTER CAPACITORS ARE INTEGRAL above output chole POSITIVE SHUNT output terminal hi TO CHOPPER MODULE AND NOT 50MV 400 AMPS INDIVIDUALLY REPLACEABLE D1 THREE PHASE BRIDGE RECTIFIER 206B 2065 2045 WELD CURRENT 85 10 000uF x4 Chopper is mountet on the back side of fan Q 206A FEED BACK SIGNAL baffle near top of machine Requires added 206C FLYBACK baffle for cooling flow W1 60 TO
196. PEN gt 815 43 oO 1 Return to Section Return to Master TOC Return to Master TOC F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment Turn the machine OFF before working on equipment not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 the problem persists replace the suspect board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shield ing bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment ATTENTION frame Static Sensitive f you don t have wrist strap Devices t h inted ded
197. REAKERS WELD CONTROL 0319 252 SWITCH 755075 3 7 251 LLL 2 TURNS THRU FERRI 2A TO AMPHENOL 11 PNG 4 POWER FOR To AMPHENOL REMO ASV WO POT 1 14 10 TERM SW ROTOR FELD CIRCUIT CON ov Located on front of fan TO AMPHENOL Y e IM 75A 1 10 baffle near top of 7 9 214 Relay CR1 and 04 locatal on fron 279 76 Machine 714 218 baffle onright side of machire ROL 10K R2 28 7 7 07 15 220 716 222 ARC VOLTAGE FEEDBACK SIGNAL 0v REVOLVING FIELD 4 VOLT AC FIELD RESISTANCE APPROX 5 OHMS 75F Return to Section TOC Return to Master TOC 1217 7 8 TOROID SENSES AC 260A 34 POWER 12 to 14V NORMAL OIL PRES INPUT ENERGIZEDFOR ACTIVATE 261A 33 2 9 2248 IDLER 2 7 2108 312 to 14V RUN 4 210 GLOWPLUG GLOWPLUG SWITCH ENERGIZES COOLANT TEMP SWITCH OR OIL PRESSURE SWITC P723 ND 2 SWITCH S7 ELECTRIC FUEL PUMP AND FUEL Located on wiring behind 01 7 305 __ ai GLOWPLUGS SOLENOID HOLD COIL THRU D4 IT 1 1 1 1 receptacles 11 12 305 i ALSO FUNCTIONS AS AN ENGINE SOLENOID Control board circuits associated with 2 ae part 023 4 1 to 10 05140 0 1 UN
198. RECISION A31 TE s RI REISRITS RIS R227 4481 5 5065 175uT 1 pe IC SMC CHOS EEPROM SERIAL SPI 19032 9 8 22 8 ross nori nore axo Rats 142 2 POT DIGITAL SNO JOK QUAD 15809 24 EGER R917 R922 RATS R42 3 1545868 K IG SMD PWM CONTROL 5 RAT 16 1 ee SMD PHM GREE Es a 8 A25 RA25 171 IC PAR CONTROLLER MODE 282A 5010 4 E T sj F27 RGA RS R66 1 IG SMD EEPROM CMOS CONFIGURATION 250K j a xm 75 33215 a RO RIZRIESRMORISSROM RESISTOR SMD METAL FILM 110W3 32K 1 1 IC SHD FPGA XCS2UXL SGF P 100PIN 2 43 GEE nM PEERS 296 302 553 RSS i SMO CMOS SWITCH ANALOG QUAD 406887 9 8 cs cong a Tu 1 IE SMD CMOS SMICH ANALOG QUAD 20 S5 Sg ROS ROSEO RESTOR SOTA TTR T REGULATOR MEDS TERT x Eo m mmm 1 E E ese ee era eM E 92 206 123 1 C SMD VOLTAGE REFERENCE 60V 0 2 50 5 1 6 5 REGULATOR ADJO SALMTTIT 5 og EERE 2 IC SMD COMPARATOR CUAD 01D E 1 C OP ANP SINGLE PRECISION LTIOSTSE Gi T C SMO MULTIPLEXER 2TO 1 SH0 CHOS MUL TPLEXERDEMULTIPLEXER SHO SCHOT TRY BA TOV ENS B5 RESIST
199. REPAIR OUTPUT RECTIFIER BRIDGE TEST continued FIGURE 15 AC2 AC3 TEST PROCEDURE 1 2 Turn the engine off Perform the Case Cover Removal dure Perform the Chopper Module Capacitor 3 Discharge procedure Electrically isolate the three phase input terminals of the output bridge rectifier as follows Mark leads W1 W2 and W3 so they can be properly reconnected after the test is com plete Remove these leads and position them so they do not come in contact with any part of the rectifier See figure F16 See wiring diagram Electrically isolate the DC output termi nals of the rectifier 117 DC Mark the leads connected to the positive and negative terminals of the output bridge recti fier to assure that they can be reconnected properly See figure F 16 Remove leads W4 W5 and W10 from the positive terminal of the Rectifier and remove leads W6 and W11 from the negative termi nal Position these leads so they do not come to contact with any part of the rectifier See Figure F 16 See the wiring diagram RANGER 305D LINCOLN 9 F 58 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 59 59 TROUBLESHOOTING amp REPAIR OU
200. REZ 0 PROGRAM ITEM 141 WITH ITEM 7 88 S25001 10008MT 8 RESISTOR SMD 4000 8 14 1208 156 TR 20 7 343450 109 1 jos CAPACITOR 200 254 205 LOW ESR x RIGS RIT Z1 02 075 1 or CAPACITOR SMD CERAMIC D 27 MF 50 105 R53 R56 RG9 RBS RGB NH PROGRAM 145 WITH ITEM 8 4 99 s25000 7600SMT 48 2 8294 8369 8362 RESISTOR SMD METAL FILM 108 7500HMS 082 633 086 036 368 NJ PARTSSHOWN MUST BE COMPLETELY COVERED 08040068 086 WITH ENCAPSULATION 47 048 048 50 252 53 2 771202 RESISTOR SMD PREC MF 10 0K 0 5 Q 5 7 RM 93 s25001 75025MT RESISTOR SMD 75 0K L4 1208 14 2 9 pus CAPACITOR 50V 2096 8034 Nisi 087 089 080 91 092 083 nd 1 METAL 4 4104 4700 45 h ozi 97 44 93 84 96 97 98 89 95 S25000 10RDSMT RESISTOR GMO METAL FILM A 10W 10 00HM ERES ir e NEA icm ct 6102038 4 44 n 0 35 825 0 22119 5 RIRI RESISTOR SMO METAL 2 21K 1 22 ROBO R313 360 R64 E w 2 He 101 01281128 CD RICE RIOT RIGO R2 16 R245 URS n ARIE E m j 22 2 25 5 oss Rast R24 R266 R30 RESISTOR SUD METAL FILM 1622 11
201. RIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMMUNICATED ARES USED THE EXPRESS WATTEN PERMISSION OF Coe INC 01 0 5 reverence EQUIPMENT TYPE COMMON ANALOG CONTROLS ANALOG E E PCB d mos D EE cmn 54408 17 SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE HOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D 0 30 ELECTRICAL DIAGRAMS G 30 SCHEMATIC WELD CONTROL PC BD ALL CODES 04108 1 PG 2 OF 5
202. RSOLENOD receptacles 11 12 305 i ALSO FUNCTIONS AS AN ENGINE 4 SOLENOID Control board circuits associated with 2 ae part of engine electrical system and are common to frame ground negative battery terminal ul All leads 1 hu E 041010 0511010 Allleads 305 1 0 JUMPER Part 223 1 time thu of amphenol plug and ferrite lead assembly 77 ltime ferrite o EE s HIE lt gle ES ply 9 ojo 2 134 132 529 BOY STARTER SOLENOID la SOLENOID REMOTE CIRCUIT CONTROL 12 VOLT PULL BATTERY 02 OHM INPUT 19 STARTER HOLD PULL 15 AMPHENOL MOTOR 110HMS L Us PC BOARD ALTERNATOR FRAME FUEC OILPRESSURE COOLANT PN ROUND Battery voltage GROUND SOLENOD SWITCH TEMPERATURE i 12 6 volts at rest ANDFLEL CLOSES ON SWITCH Located next to AMPHENOL 14 volts engine 77RMP LOW OIL CLOSES ON HIGH control board FUELSENDER running ENERGIZED PRESSURE TEMPERATURE RUN ABOVE 230F JHISD OCUME NTC ONTAINSPR OPRIETARY ORMATION OWNEDBY LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU NICATE D 741265 OHWS EMPTY ROPRIETARY amp CONFIDENTIAL 0 5 8 USE DFORANYPU RPOSEWIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF L
203. RUSH AND SLIP RING SERVICE PROCEDURE 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure provides guidance in testing and maintaining the brush and slip ring system Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Miscellaneous hand tools 500 or 600 grit emery cloth 180 grit sand paper olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o FIle 5 5 PEN gt 815 4353 oO 1 Return to Section Return to Master TOC Return to Master TOC F 38 TROUBLESHOOTING amp REPAIR BRUSH AND SLIP RING SERVICE PROCEDURE continued TEST PROCEDURE Perform the Case Co
204. RY 02 OHM 6 d gt MOTOR L ALTERNATOR 11 OHMS PCBOARD PN FRAME ME OILPRESSURE COOLANT GROUND 74 ROUND Battery voltage SOLENOID SWITCH TEMPERATURE 1 12 6 volts at rest ANDFLEL pa CLOSES ON SWITCH Located next to AMPHENOL 14 volts engine 77 77 LOW OIL CLOSES ON HIGH contol board FUELSENDER running ENERGIZED PRESSURE TEMPERATURE FORRUN ABOVE 230F JHISD OCUME NTC ONTAINS PR OPRIETARY INF ORMATION OWNEDBY LINC OLNGLOBAL INC A NOTBED UPLICATE D COMMU NICATE D 741265 ONS EMPTY ROPRIETARY amp CONFIDENTIAL parties oR USE DFORANY PURPOSE WIT HOUTT HEEX PRESS W RITTE NPE RMISSION OF LIN COLN GLOBAL INC 20 35 OHMS FULL OTHERW P D TOLERAN REFERENCE 7 EQUIPMENT TYPE RANGER 305D CE EUROPE lor 2 DRAWN BY DEO 112038 DOCUMENT mon MACHINE SCHEMATIC rus REVISION WITH PUB LISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING NONE UF _ 12112003 Jumper 83558 L12214 A EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D
205. Remove the 2 screws from the battery door using a screwdriver or a 3 8 socket Remove the 2 nuts from the battery bracket using a 7 16 wrench or socket Slide the battery out and remove from welder WARNING FROM BATTERY can Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY Disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER Connect positive lead to battery first then connect negative lead to the engine foot BATTERY ACID can burn eyes and skin d Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 8 MAINTENANCE CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0
206. S OPTIONAL ONVANTAGE isnot 440 or more when the madine is runing 4 5 250 154 22 73 Return to Section Return to Master TOC gt 152 FUELSHUTDOWN 210 L 88 12V when the FUN switch is CN ard the START Buttonis held IN If exterelly shorted BLINK PULLEDLOWANDHGH m 154 the PTCwill change to high impedance INLOCKBACK TO FLASH 3 18 DECIMAL gt 1 15 158 2 35 159 METER INPUT 0 24 1V 1000 CV MODE 1510 METER INPUT CURRENT LIMITS a as CUFRENTFEEDBACK AVERAGE ABSOLUTE amp FOLDBACK BATTERY POSITIVE 127 lt lt lt lt lt lt lt lt nb amp 1 BATERY 123 5700 64107 ONLY NNGDLPHSIVINHZHL PAMSIGNAL 12V ON MULTIMETER FEEDBACK PWM 5700 FORWELDCONTROL PAMSIGNAL 412V arans REG ULATING CHOPPER VOUTAGE FEEDBACK AMPLIFIER CONTROL PAMOOMVEN c m sq 2 CIRCUIT PWM COMMON CHOPER BOARD VANTAGE ONLY J ARC CONTROL CIRC UITRY o EE s HIE lt gle ES ply 9 ojo 5700 TOUCH START VARIAB LE PINCH PIPE ARCF ORCE MA EEM SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILSON 1 WHAT P
207. SSURE TEMPERATURE AS ONS ENY 0 HERPARTIESO RUSE DF ORANY PU RPOSEWIT HOUTT HEEX PRESSW RITTE NPE RMISSION OF LIN GLOBAL INC SUMUS E TURI DESIGN INFORMATION REFERENCE EQ IPM ENT TYPE RANGER 305D CE UK DRAWN BY MAP 112213 SUBJECT MACHINE SCHEMATIC ENGINEER SCALE WITH PUB LISHEDS TANDARDS MATERIAL NA PROJECT CRM35578 DO NOT SCALE THIS DRAWING NONE pisposirion NUMBER PAGE lor 2 DOCUMENT DOCUMENT NUMBER REVISION L12213 1 A EN 168 APPROVAL DATE 07 15 2004 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC G 22 SCHEMATIC ENTIRE MACHINE CODES 11189 11314 L12213 1 PAGE 2 OF 2 ENGINEERING CONTROLLED CHANCE DETAIL NEW MANUFACTURER No AUXLLARY WELDING CURRENT SENSE TERMINAL CONTROL 5700 IDLE SWITCH SENSE MACHINE IDENTITY TABLE PINS JUVPERED TO SELECT MACHINE Tie 178 z RANGER 250 G amp D RANGER 305 G amp D VANTAGE 500 VANTAGE 575 AIR VANTAGE 500 MODE ROCV ENABLE KR KR KR KR HR WK 64107 ONLY TFORALETRAUANVANTAGE 579 ELECTRICAL D
208. See Figure F 6 NOTE Low idle RPM must be set and the adjustment nuts tightened before the high idle RPM is adjusted Low Idle adjustment 1 With engine running and no load applied to the machine place the idle switch in the AUTO IDLE position Wait for the idle solenoid to energize and the engine speed to drop and stabilize to low idle RPM 2 If the low idle RPM requires adjustment loosen the low idle adjustment jam nuts Turn both nuts so they are clear of the swiv el fitting Rotate the swivel fitting until the engine speed has been set to between 2400 and 2500 RPM Hold the swivel fitting in position while tightening the first jam nut against the swivel fitting and then tighten the second jam nut against the first Figure F 6 3 Re check the low idle RPM and then ceed to the high idle adjustment High idle adjustment 1 With engine running place the idle switch in the HIGH IDLE position The solenoid should immediately de energize allowing the engine to increase to high idle speed 2 f the high idle RPM requires adjustment loosen the high idle adjustment screw jam nut and turn the adjusting screw until the engine speed is between 3625 and 3675 RPM Hold the adjusting screw in position while tightening the jam nut against the solenoid plunger See Figure F 6 Re check the high idle RPM Close the engine service access doors and shut off the engine RANGER 305D LINCOLN
209. TER Attaches between muffler or exhaust elbow K704 ACCESSORY KIT Accessory set includes 35 ft 10 7meters 2 AWG electrode cable 30 ft 9 1 meters 2 AWG work cable headshield with No 12 fil ter G300 work clamp and Cooltong 300 electrode holder Cables are rated at 300 amps 4096 duty cycle K857 28 ft 8 50 or K857 1 100 ft 30 4m REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120 volt ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 amps The maximum total cur rent from the GFCI Duplex is limited to 20 amps Two kits are required K802 N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps K802 R POWER PLUG KIT Provides four 120 volt plugs rated at 15 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps T12153 9 50 AMP 120 240V POWER PLUG Provides one dual voltage plug for full KVA power TIG WELDING ACCESSORIES K1783 9 TIG TORCH For TIG welding with shielding gas Includes 25 feet of cable K963 2 Hand Amptrol K870 Foot Amptrol NOTE TIG welding requires a Magnum TIG Gun
210. TIL OIL ENGINE NONE PULL of engine electrical system and are common to 305 10 JUMPER Part 223 PRESSURE BUILDS UP PROTECTION ENGINE 0 2 frame ground negative battery terminal All leads All leads fam J 4 RELAY HOLD rH ul 1 time thu 4 1 time thu of amghenol plug an a ferrite ferrite y CIRCUIT BREAKER P724 P722 WELDAMMETER WELDVOLTMETER 20 stp 212 74 72 Meters display setpoint volts 0 amps when rot welding 232 Meters display actual volts and ams when welding 210 Hold function displays actual volts and mps for 210 approximately 5 seonds after welding stops START BUTTON During this hold display theright most decimal point vill SWITCH 52 e e bins 2 TURNS THRU FUELSOLENOID PULL ee COILIS ENERGIZED BY HOUR METER STARTER SOLENOID 5V LOW 77 usvac x IDLE o E t HIE lt gt 9 5 ply 9 c 734 q T 725 42VAC 4040438 B2 STARTER WORK SOLENOID SL 734 e SOLENOID CIRCUIT BATTERY STARTER HOLD PULL 11 AMPHENOL MOTOR FRAME REL OILPRESSURE COOLANT PIN Battery
211. TION EQUIPMENT TYPE MISCELLANEOUS 01 OF 01 N WITHOUT AFFECTING THE INTERCHANGE 0RAWN BY MABE DOCUMENT ABILITY OF A COMPLETE BOARD THIS Si SCHEMATIC PULL COIL BATTERY PCB CIR COM DIAGRAM MAY NOT SHOW THE EXACT ENGINEER eee ats SUBJECT S 5 CIR COM COMPONENTS OR CIRCUITRY CF CONTROLS MATERIAL APPROVAL PROJECT 1 HAVING COMMON CODE NUMBER APPROVED osposition pare 4 4 2006 CRM36599 0 5117 180 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E 3050 eod ELECTRICAL DIAGRAMS G36 PC BOARD ASSEMBLY PULL COIL PC BD ALL CODES L11768 1 17892111 ENGINEERING CONTROLLED CHANGE DETAIL UPDATED COMPONENT DESIGNATORS DESIGNATOR REQ D PART NO DESCRIPTION MANUFACTURER Yes B1 B2 B3 B4 o 5 1 82 13157 24 CONNECTOR TAB QC VERTICAL 1 4 EXTENDED Bla 1 2 7 06 10 11 12 51656811 0 1 50V 1096 D C13 014 2 3 11 15166688 330 100 5 olo CA 1 1513490479 CAPACITOR ALEL 1000 36V 2090
212. TION This procedure will insure that the large capacitors in the chopper module have been dis charged This procedure should be performed whenever work is to be attempted on or near the chopper module Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Volt Ohmmeter Resistor 25 1000 ohms and 25 watts minimum Lincoln part 501404 114 works well for this purpose Jumper leads Wiring Diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 TROUBLESHOOTING amp REPAIR CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 2 CHOPPER MODULE CAPACITOR TERMINAL DISCHARGE INSULATED PLIERS INSULATED GLOVES TEST PROCEDURE 1 Turn the engine off 2 Perform the Case Cover Removal proce dure NOTE It is necessary to remove the fuel cap in order to take the case cover off the machine Be sure the fuel cap is ON when discharging the chopper module capacitors 3 Locate the chopper module and capacitor assembly on the inner machine baffle See Figure F 2 and the Wiring Diagram N
213. TOC Return to Master TOC o HE 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 The engine cranks when the start button is pressed but will not start The engine starts but shuts down immediately when the start button is released ENGINE AND IDLE PROBLEMS The battery voltage may be low This condition will normally result in slow cranking speed The battery should be checked and recharged if it is not pro ducing adequate voltage and replaced if it will not accept a full charge Make sure the glow plug button is pressed while pushing the start button See the operator s manual or the operation section of this manual for the proper starting procedure Make sure the fuel valve on the fuel sediment filter is in the open position Check that the machine has an adequate supply of fresh clean fuel The fuel filter may be clogged Replace the fuel filter if neces sary Check the oil level Make sure the glow plug button is pressed while pushing the start button and held in until the engine protection light turns off 5 SECONDS MAXIMUM AFTER THE ENGINE STARTS See the operator s manual or the operation section of this manual for the proper starting procedure Check the oil level Be certain that the engine is not overheat ed Check that the machine has an adequate supply
214. TPUT RECTIFIER BRIDGE TEST continued 7 Check for grounds by placing of the ohm NOTE A digital Ohmmeter is not recommended meter probes on a clean unpainted metal for this test A typical digital Ohmmeter surface of the machine Touch the other does not provide enough voltage or cur probe to each of the five rectifier terminals rent flow to reliably test the diodes used in The resistance to chassis ground from each this rectifier terminal should be very high 500 000 500 ohms minimum the resistance reading is 10 Test all of the diode groups per the Table 1 less than specified the rectifier is grounded and should be replaced 8 If using diode checker a multimeter with diode check functionality read and under stand the instructions that accompany your test equipment 9 If using an analog ohmmeter the forward bias test will indicate low resistance and the reverse bias test will indicate high resistance Precise ohm values for this test will vary depending on a test equipment used FIGURE F 16 SHUNT RECTIFIER LEADS 7 TOP W1 wa 7 Z CENTER W3 7 BOTTOM OUTPUT RECTIFIER BRIDGE W10 FROM SHUNT RANGER 305D LINCOLN 5 TROUBLESHOOTING amp REPAIR TABLE F 1 DIODE TEST TABLE Lead Lead and Expected Test Result AC1 DC FORWARD BIAS Low Resistance AC2 DC FORWARD BIAS Low Resistance Return t
215. The engine will not idle down to low RPM machine has normal weld output and auxiliary power POSSIBLE AREAS OF MISADJUSTMENT S The fuel may be old or contami nated Supply the engine with fresh clean fuel The fuel filter may be clogged replace the filter if necessary The air filter may be clogged replace if necessary Make sure the idle switch is in the AUTO IDLE position Make sure there is no external load on the weld terminals or the auxiliary power receptacles Check for mechanical restric tions in the idler solenoid link age ENGINE AND IDLE PROBLEMS TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The engine may be in need of adjustment or repair 1 Perform the Idle Solenoid 2 Check for damaged wiring or faulty connections at idle sole noid the pull coil PC board the run stop switch and the start button Check for loose or damaged wiring or faulty connections at leads 404 and 215 Control PC Board P2 4 and P2 5 See Wiring diagram Set the idle switch in the AUTO position Set the mode switch to the CC STICK posi tion Make sure that no lead is applied to either weld output or the auxiliary output Start the machine and allow it to run for about 30 seconds Manually move the idle solenoid plunger to the idle position f the solenoid engages and holds in the idle position the pull coil PC board is probably defective replac
216. Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools o Hr 9 2 5 Return to Master TOC away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running AX To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work dis
217. a 218 50 a O 2008 W3 O16 m md Lt CHOKE H Meter EJ c R2 CONTROL R1 OUTPUT CONT olg 206 206 Cow gt Ha 8 NOTE STATOR LEADS D AND E USED gio 208 C 208 TAPE LEAD ENDS AND SECURE 279 77 206A 277 76 75 85 278 9 8 WIRE FEED POWER POLARITYTS FTT clc 2 3 SWITCH STATOR AUX Output amp 5 Taz vag 208A 34 WINDING GND E M Arc Cont 43 42 41 21 WRAP TWO TURNS OF V Select ac LEADS A 3 D B amp CIN x DIRECTION 8 SHOWN THROUGH TOROID 224A 215 2592 2 2 BOTTOMGND STATOR GND R 5K sy 45 E J CB5 SHOWN IN POTTO GND E EXGHATION 2248 00 METER amp 1542 POSITIVE WINDING 5k SI Battery 9 POSITION 1 GND N GND R Function 42 SCREW ON 42 8 2004 9 INSIDE OF CASE FRONT 5 1 9 S 5N 5K 206 GND K BYPASS 5H 2008 1 1 REM 5 IDLER CONTROL Amphenol 251 Model e 208C 5G C3 54 A Select NOTE LEADS 31 AND 32 NOT USED 4 8004 252 Hot Start 150vd e e TAPE LEAD ENDS AND SECURE 2014 15049 ci SHOWNIN E AUTO POSITION 200A 200 clo 115VAC m GND N ANANAS o g IDE CASE BONE 58 1C 1B 1 2c zm 210E 210F 5H Engine Protection B 2 ah cabs Lig
218. a clean unpainted chassis ground The resistance should be very high 500 000 Ohms or more If any of the above resis tance values are incorrect the solenoid may be faulty Replace SHUTDOWN SOLENOID IDLE SOLENOID 6 Using an external 12VDC supply apply voltage to the pull in coil leads black to white The solenoid should activate REMOVE THE VOLTAGE immediately to avoid damaging the solenoid Apply 12VDC to the hold coil leads black to red While the voltage is applied manually move the solenoid to the fuel on position The solenoid plunger should hold this position until the voltage is removed If either coil does not operate as described check for mechanical restric tions or other problems with the linkage If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied the solenoid may be defective Replace Re connect fuel solenoid and replace any previously removed cable ties If finished testing close the engine ser vice access doors Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 27 27 TROUBLESHOOTING amp REPAIR FUEL SHUTDOWN SOLENOID TEST continued FIGURE F 4 FUEL SOLENOID CONNECTIONS Return to Section TOC Return to Master TOC P73 J73 O D 4 2 TO D 4 231 9 SOLENOID 2 5 2 FUEL SOLENOID FUEL SOLENOID ala CONNECTOR WIRING HARNESS amp 2 LEAD ENTRY VIEW
219. a under the bottom curve The more darkened area under the curve the more power is present RANGER 305D LINCOLN Section 1 Section 1 TABLE OF CONTENTS 9 TROUBLESHOOTING 8 REPAIR SECTION 5 8 Troubleshooting amp Repair Section Section F How to Use Troubleshooting F 2 PC Board Troubleshooting Procedures imiinien F 3 E Troubleshooting F 4 F 20 e 21 Case Cover Removal Replacement Procedure F 21 Chopper Module Capacitor Discharge Procedure F 23 Fuel Shutdown Solenoid Test eene nnne nnns F 25 Engine Throttle Adjustment F 29 Solendid F 33 Engine Alternator ARONEN GRENAA EARRA 35 Brush Slip Ring Service F 37 E Rotor Resistance and Ground nens F 39 5 Rotor Resistance and Ground nennen nnns F 41 to Voltage de EE F 43 5 Flashing 47 Stator Voltage TeSt cen F 51 p Stator Short Circuit amp Ground F 55 a Output rectifier Bridge Test 57 2 Chopper Module Fu
220. active in the TIG mode The Ranger 305D can be used in a wide variety of DC TIG weld ing applications In general the Touch Start feature allows con tamination free starting without the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the Ranger 305D See Table B 2 for reference settings Ranger 305D settings when using the K930 2 TIG Module with an Amptrol or Arc Start Switch a Set the MODE Switch to the TOUCH START TIG setting b Set the IDLER Switch to the AUTO position Set the WELD TERMINALS switch to the REMOTELY CONTROLLED position This will keep the solid state con tactor open and provide a cold electrode until the Amptrol or Arc Start switch is pressed When using the TIG Module the OUTPUT control on the Ranger 305D is used to set the maximum range of the CURRENT WIRE WELDING CV Connect a wire feeder to the RANGER 305 D according to the instructions in INSTALLATION INSTRUCTIONS Section In the CV WIRE mode the Ranger 305D can be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc weld ing Welding can be finely tuned using the ARC CONTROL Turning the CONTROL clockwise for 10 soft to 10 crisp changes the arc from soft and washed in to crisp and nar row It acts as an inductance control The proper setting depends on the procedure and operator preference Start wit
221. afely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o He 0 5 20 Observe Safety Guidelines INSTALLATION detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will not go into high idle when attempting to strike an arc or when a load is applied to any of the auxiliary power receptacles Welding and auxiliary outputs are normal when the idle switch is in the HIGH IDLE position The engine goes to low idle but will not stay at low idle POSSIBLE AREAS OF MISADJUSTMENT S ENGINE AND IDLE PROBLEMS Check that the welding cables and the auxiliary power lead connections are tight Make sure there are no external loads on either the weld termi nals or the auxiliary receptacles Check that the welding cables and the auxiliary power lead connections are tight and that the insulation is undamaged F 20 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The weld control PC board may be defective The idler solenoid linkage may be damaged or out of adjust ment Make sure the solenoid plunger is able to
222. ailed components or connections Continue with the following test Check the field bridge rectifier D3 and capacitor C3 also check the wiring and terminals connecting them See the wiring diagram Perform the Rotor Resistance Test Perform the Stator Short Circuit and Ground Test When the Stator short circuit and ground test has been completed reconnect leads 7 and 79 to the field bridge rectifier D3 All other stator leads should remain discon nected and isolated at this time 16 17 18 19 Be sure that there no leads of any kind across any of the stator windings except the 77 49 winding Examine stator wiring for damage pinched leads chafed insula tion etc If necessary disconnect and iso late the stator output leads as close to the starter as possible See wiring diagram of these disconnected leads should be insulated and or positioned so they cannot come in contact with any other wiring or chassis ground and cannot be damaged by moving parts when the engine is running Re start the machine and measure the rotor voltage If rotor voltage continues to read signifi cantly lower than 50 VDC the Stator is probably defective and should be replaced Note The field bridge rectifier and field capac itor may appear to function normally when test ed independently but may malfunction when placed under the stress or normal operation For this reason It is recommended
223. als NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the input cable from the K584 XX Control Cable to the 14 pin amphenol on the Ranger 305D and the input cable plug on the LN 7 4 Set the VOLTMETER switch to or depend ing on the polarity chosen 5 Set the MODE switch to the CV WIRE position 6 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control cir cuit may be damaged The engine governor setting is preset at the factory do not adjust above RPM speci fications listed in this manual 7 Place the WELD TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust the wire feed speed at the LN 7 and adjust the welding voltage with the optional remote con trol is used 9 Set the ARC control to O initially and adjust to suit FIGURE C 5 Ranger 305D LN 7 WITH 584 CONTROL CABLE CONNECTION DIAGRAM 14 PIN AMPHENOL 6 PIN AMPHENOL TO WORK TO LN 7 INPUT CABLE PLUG OPTIONAL K857 REMOTE CONTROL K584 XX CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 5
224. also increase spatter It is recommend ed that the ARC CONTROL be set to the minimum num ber without electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CON TROL dial sets the short circuit current arc force during Stick welding to adjust for a soft or a more forceful digging arc crisp Increasing the number from 10 soft to 10 crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is pre ferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the CONTROL be set initially at 0 14 15 16 this reason there can only be one device plugged into the Ranger 305D at any time WELD TERMINALS CONTROL SWITCH the WELD TERMINALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED posi tion the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch is closed WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode DIGITAL OUTPUT METERS The digital meters allow the output voltage WIRE mode or current CC STICK DOWNHILL PIPE and TOUCH START TIG modes to be preset prior to welding using the output control dial
225. ande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de Soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger 6 i SAFETY i zones ou pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d
226. ary to remove the fuel cap in order to take the case cover off the machine Screw the cap back on when working on the Ranger 305D REPLACEMENT PROCEDURE 1 Install the right and left case sides and screw them in place Remove the fuel cap then carefully set the case cover in place Replace the fuel cap and the lift bail cover seal Install the exhaust pipe extension Install the screws that hold the case cover in place Install each door by positioning it as described in step 3 of the removal proce dure then slide it fully on the hinge Close and latch the doors RANGER 305D LINCOLN F 22 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE continued 23 23 TROUBLESHOOTING amp REPAIR CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE WARNING 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIP
227. aster TOC F 54 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS continued To test the 42 VAC wire feeder winding 1 Connect the voltmeter probes to pins I lead 41A and K lead 442A of the 14 pin Amphenol See Figure F 12 Start the engine and run it at high idle 3625 to 3675 RPM The AC voltage reading should be between 40 and 50 VAC If these voltage readings are not within the specified limits check for a tripped or defec tive circuit breakers loose connections or broken wires between the test points and the stator windings there are no wiring prob lems and the circuit breakers are not tripped or defective the stator is defective and should be replaced To test the three phase weld winding 1 Locate weld winding leads W1 W2 and W3 where they connect to the three phase output bridge rectifier See Figure 13 See wiring diagram Start the engine and run it at high idle 3625 to 3675 RPM Check for about 60 to 65 VAC from leads W1 to W2 W2 to W3 and W1 to W3 If these voltage readings are not within the specified limits check for loose connections or broken wires between the test points and the stator windings there are no wiring problems the stator is defective and should be replaced These values ar maximum for a cold machine RANGER 305D LINCOLN F 54 Return to Section TOC Return to Master TOC Return to Section TOC olo 515
228. ately 46 to 54 VDC is present across the rotor slip rings NOTE The slip ring voltage will most likely be correct if at least one of the AC output volt ages is correct MATERIALS NEEDED Miscellaneous hand tools Voltmeter Test pins RANGER 305D LINCOLN F 51 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 0 5 52 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS continued FIGURE F 12 RECEPTACLE LEAD LOCATIONS TYPICAL AMPHENOL 1 GROUND CONTACTOR CONTROL REMOTE CONTROL 120 FOR WIRE FEEDER 40 FOR WIRE FEEDER 2 TIMES THRU FERRITE LEADS 75A 76A amp 77A TEST PROCEDURE 1 Perform the Case Cover dure NOTE Voltage tests of the 120 and 120 240 VAC receptacles can be performed by placing the meter probes directly into the appropriate con nection slots in the front of the receptacles rather than testing at the lead connections described below If the meter probes are not long enough to make contact with the conductors inside the receptacles test pins may be used To test the 120 VAC auxiliary winding 1 Connect the volt ohmmeter probes to either 120 VAC receptacle as follows 2 For the upper receptacle
229. atic Weld Control PC Bd All Codes G4108 1 Page 4 of 5 G 32 Schematic Weld Control PC Bd All Codes G4108 1 Page 5 5 G 33 PC Board Assembly Weld Control Bd All Codes 4107 1 G 34 Schematic Pull Coil PC Bd Codes 4117 1 sse G 35 PC Board Assembly Pull Coil PC Bd All Codes L11768 1 G 36 Schematic Chopper Bd All Codes 19792 G 37 PC Board Assembly Chopper PC Bd All Codes 11845 1 G 38 NOTE Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice able The Assembly drawings are provided for reference only o 2 0 8 5 3050 LINCOLN G 2 ELECTRICAL DIAGRAMS me WIRING DIAGRAM ENTIRE MACHINE CODE 10926 G4250
230. ation A CAUTION An incorrect spark arrestor may lead to damage to the engine or adversely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K930 2 TIG Module is suitable for use with the Ranger 305D The Ranger 305D and any high fre quency generating equipment must be properly grounded See the K930 2 operating manual for com plete instructions on installation operation and main tenance RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle 5 5 9 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC A 7 INSTALLATION REMOTE CONTROL The RANGER 3050 is equipped with both a 6 pin and a 14 pin Amphenol connector The 6 pin connector is primarily used to connect a remote control device such as a K857 or a TIG Amptrol such as the K870 or K812 The 14 pin Amphenol connector is primarily used to directly connect a wire feeder TIG module or Spool Gun module control cable See Accessories section for more information NOTE Both the 6 pin and 14 pin Amphenols share the same output control auto sensing and contactor circuit ry for this reason there can only be one device plugged into the Ranger 305D at any time Switch operation is covered in Operation section ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the 120 and 240 volt receptacles weld o
231. ay be faulty or the rotor may be shorted RANGER 305D LINCOLN 7 Perform the Rotor Resistance Ground Test and the Rotor Flashing Voltage Test If voltage is higher than 54 VDC the engine RPM may be too high or there may be voltage intrusion from one of the higher voltage stator windings to the stator exciter winding Perform the and the If the voltage is lower than 46 but high er than 14 the engine RPM may be too low or there may be problems in the wind ings or other exciter circuit components or connections Perform the Engine Throttle Adjustment Test and then perform the testing described below under the heading If the voltage measures about 3 to 5 VDC Return to Section TOC Return to Master TOC Return to Section TOC 515 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC F 45 10 11 13 14 15 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST continued If the meter reading indicates battery voltage about 12 to 14 VDC the rotor may be open or the brushes may be faulty or not making proper contact with the slip rings Perform the Rotor Resistance Test and If the voltage measures about 3 to 5 VDC the generator is not building up to normal output even though the flashing cir cuit appears to be functioning normally This condition could be caused by one of several f
232. bleshooting assistance before you proceed 1 888 935 3877 RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 5 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No auxiliary power at one or more receptacles or at the 14 pin Amphenol receptacle Weld output is normal and the engine operates normally Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S Check for loose or faulty con nections at any cords attached to the auxiliary output recepta cles or to the 14 pin Amphenol receptacle POWER OUTPUT PROBLEMS RECOMMENDED COURSE OF ACTION Check for tripped circuit break ers and or tripped recep tacles 2 Perform the Stator Voltage The machine has low welding out put and low auxiliary output The engine RPM may be too low The brushes may be worn sticking or poorly seated 1 The high idle speed may be low Perform the Throttle Adjustment Test NOTE If the engine high idle RPM is normal but the engine slows down excessively when the machine is placed under a normal welding or auxiliary load The engine may have lost horsep
233. case front RANGER 305D LINCOLN 10 10 INSTALLATION FIGURE A 2 CONNECTION OF RANGER 305D TO PREMISES WIRING O o 213 240 VOLT PEN GROUNDED CONDUCTOR m POWER olo 240 Volt 120 VOLT 60 Hz 3 Wire COMPANY d 218 E 6 Service METER 1 NEUTRAL BUS LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT 9 PROTECTION J FE 09129 5 9S PREMISES 2 DISCONNECT AND 0 9 SERVICE cle GROUND OVERCURRENT 515 240 VOLT PROTECTION o o 1 DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 50 120 240 VOLT T NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS O o Fle 5 5 9 gt 815 4353 oO 1 WARNING Only a licensed certified trained electrician should install the machine to a premises or residential elec trical system Be certain that installation complies with the National Electrical Code and all other applicable electrical codes premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises
234. ce IN LOOKBACK TO FLASH 355 DECIMAL POINT gt FRAME t 22 458 VOLTMETER ta DISPLAY 58 42 COM S gt 159 METER INPUT 0 2V 1V 1000 ON METER CV MODE gt 4540 METER INPUT 22 CURRENT BATTERY SELECT CONTROL POINT LIMITS CHARGE 427 lt ROCV ENABLE BATTERY POSITIVE UMP 74 TOR AUSTRALIAN VANTAGE 575 CURRENT FEEDBACK AVERAGE 9 ABSOLUTE Ss v CURRENT FEEDBACK J DISPLAY WELD AMPS amp FOLDBACK BATTERY NEGATIVE 923 lt 15V when the battery charge light is OFF 5700 Machine running alternator charging battery 1 5V when battery charge lightis ON Battery Low Not charging and for a few DISPLAY PRESET PRESET seconds when machine is tumed off 2085 x MAr VALUE VOLTAGE ONLY 4 t 50mV 400 AMPS a A 475 ohm 8 1 DISPLAY WELD VOLTS PWM SIGNAL 412V ON MULTIMETER CHOPPER 47411 ANN AAN ANN AAN AAN AAAC ANN 9 ANN Wo ANN 1 FEEDBACK BOARD STUD FOR WELDCONTROL PWM 47 5 ohm gt SIGNAL 3124 ALL MACHINES E bx REGULATING CHOPPER STUD VOLTAGE FEEDBACK gt t AAA AMPLIFIER 47 5 ohm CONTROL POINT CONTROL gt 33 10 PWM COMMON 7 CIRCUIT aum
235. cking Start with the dial set at 0 DOWNHILL PIPE Welding This slope controlled setting is intended for out of posi tion and down hill pipe welding where the operator would like to control the current level by changing the arc length The output CONTROL dial adjusts the full output range for pipe welding The ARC CONTROL dial sets the Short circuit current arc force during stick welding to adjust for a soft or more forceful digging arc crisp Increasing the number from 10 soft to 10 increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pre ferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and depo sition stacking of iron are key to fast travel speeds TABLE 2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES Tungsten Electrode Diameter in mm 1 2 Thoriated Tungsten 2 15 5 20 15 80 70 150 10 20 150 250 15 30 250 400 25 40 400 500 40 55 500 750 55 80 750 1000 180 125 DCEN Approximate Argon Gas Flow Flow Rate 1 min 1 2 Thoriated Aluminum Stainless Steel Tungsten TIG TORCH Nozzle Size 5 6 6 7 8 8 10 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases Tungsten electrodes are classified as follows by the American Welding Societ
236. connect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 8 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Return to Master Return to Master TOC o Hr 9 lt 5 Return to Master SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locat
237. contactor and is accomplished by closing the circuit between the 2 and 4 leads The welding terminal switch closes this circuit when it is placed in the WELD TERMINALS ON position When the switch is placed in the REMOTELY CONTROLLED position the circuit is closed by a TIG foot pedal a control cable type wire feeder or other remote control devices that can be plugged into either the 6 pin or the 14 pin Amphenol Digital Meters Two identical digital displays are connected to the control PC board and are used to indicate weld out puts Amps and Volts When no current is flowing the machine is in preset mode and only one of the dis plays will be active If mode switch is set for CV WIRE only the volts display will be active in all other modes only the amps display will be active When weld current is flowing both displays will indi cate actual weld volts and amps RANGER 305D LINCOLN 5 E 6 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 0 5 THEORY OF OPERATION CHOPPER TECHNOLOGY FUNDAMENTALS The new era of welding machines such as the Ranger 305D employ a technology whereby a DC source is turned on and off chopped up at high speed then smoothed through an inductor to control an arc Henc
238. d b When the electrode touches the work or power is drawn from the auxiliary power receptacles approximately 100 watts minimum the engine accelerates and operates at high speed c When welding ceases or the AC power load is turned off fixed time delay of approximately 12 seconds starts If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine RPM to low idle speed d The engine will automatically return to high idle speed when the welding load or AC power load is reapplied ENGINE ALTERNATOR TROUBLE LIGHT The yellow engine alternator light is off when the battery charging system is functioning normally If the light turns on the alternator or the voltage reg ulator may not be operating correctly The light may also come on if the battery is not holding a charge It is normal for the light to come on while starting the engine Code 10926 and over ELECTRIC FUEL GAUGE Codes 11121 and higher gives accurate and reliable indication as to how much fuel is in the fuel tank ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance ENGINE PROTECTION LIGHT A warning indicator light for low oil pressure and or coolant over temperature The light is off when the systems are functioning properly The light turns on then the RUN STOP switch is in the position before starti
239. d Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the shutdown solenoid resistance values are normal and also determine if it will function normally when energized with 12 VDC Return to Section TOC Return to Master TOC MATERIALS NEEDED Wiring Diagram Volt Ohmmeter Miscellaneous hand tools 12 volt D C power source an automotive battery works well O o FE Ex 9158 9 2 2 fe Sia oO 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 3 Q HF B 0 8 5 26 TROUBLESHOOTING amp REPAIR FUEL SHUTDOWN SOLENOID TEST continued FIGURE F 3 FUEL SHUTDOWN SOLENOID LOCATION TEST PROCEDURE 1 2 Turn the engine off Open the right side engine service access door Locate the fuel solenoid located on top of the engine Locate and unplug harness connection P J 73 Cut any necessary cable ties Figure F 4 See Wiring Diagram Using the Ohmmeter check the pull in coil resistance black wire to white wire The normal resistance is less than 0 5 ohms Check the hold in coil resistance black wire to red wire The normal resistance is approximately 11 ohms Check the Resistance between the black wire and
240. d inside one of the enclosure panels of your machine RANGER 305D WIRING DIAGRAM D o 12 8 Cyc 5 gt pit 9 ojo 7 7 Twisted Pair 13 TWISTED PAIR FAR goc 2008 P6J6 2045 19 ij Shunt wo Haim I ensem STATOR V 2 HEATSINK 3017 Ws OLTS 10 260 302 co 5 ese p B2 1 56 MODE SELECTOR SWITCH 222222 17 A 6 utut 214 901 2065 2045 1 6 P4 J4 7 WRAP TWO TURNS PIPE SHUNT 4111 9 BHS LEADS IN 300 AMP QS 4 218 cos o LOCATED BELOW THROUGH TOROID CES 220 TERMINAL 2 AMPS 2068 13 5 Wil 6 we 9 222 206 3 B 85 5 g i mE 208B 4 mE 5 5 o L1 CHOKE 2 Meter 38 FIELD WINDING R2 ARC CONTROL Fi piut cont Fon L 206B O 206C4 ccw is olg 208 208 1 p 4 277 77 p c zoea 3s 76 75 STATOR AUX WINDING WIRE FEED POWER POLARITY 3 wa WINDING o 7 17 SWITCH Output amp 0 2 208A BOTTOM INSIDE LEFTCASEFRONT ME ac 2 21 Y sue GND N GND E S SHOWN IN 5 POSITIVE Gu POSITION 5 D a 3 3 56 2244 21 2 12 GND R K ER 2208 OUR METER Zug ha Engine amp 5K Battery 7 9 Function 206 TOP GND SCREW ON 2008 200N TAM J INSIDE LEFT CASE FRONT FILTER 5N 5N 5 FUEL GAUGE
241. defective Check the Amphenol recepta cles Look for damaged or cor roded contact pins in the recep tacle and in the plug of the remote control unit RECOMMENDED COURSE OF ACTION 1 Check plug 1 on the control PC board Plug should be properly seated and pins in both the plug and the PC board jack must be clean and fit tight ly together There may be a poor connection between the weld control PC board and the Amphenol recep tacles Check for continuity between the following terminals See Wring diagram and control connection diagram P1 10 to 6 pin Amphenol pin C and to 14 pin Amphenol P1 11 to 6 pin Amphenol pin A and to 14 pin Amphenol pin E P1 14 to 6 pin Amphenol B and to 14 pin Amphenol pin F 3 The weld control Pc board may be defective The machine seems to be locked into the CC STICK mode of oper ation Check the position of the WELD MODE selector switch The switch should cleanly snap into each mode position and should not feel gritty or get hung up between positions CAUTION 1 Check that plug P 7 is fully seat ed into the weld control PC board socket See Control Inner Connection diagram Check for corroded dirty or damaged Molex terminals in plug P 7 also check for similar problems in socket J 7 on the weld control PC board Check the wiring between the control PC board and the mode switch look for poor crimp
242. djust until the external meters read about 305 amps and about 29 VDC If the machine will not produce this output apply as much load as possible CAUTION 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 RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 9 2 amp x 3 Return to Section TOC Return to Master TOC o 2 0 5 7 7 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine will weld but the welding arc is cold The engine runs normally and the auxiliary power is normal continued POSSIBLE AREAS OF MISADJUSTMENT S WELD OUTPUT PROBLEMS 7 The weld cables may be coiled or wrapped around metal reels or racks This can cause exces sive electrical inductance in the weld circuit Try welding after uncoiling the cables or discon nect the existing cables and weld with a set of adequately sized short test cables TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 6 With the above load applied the engine should maintain at least 3350 RPM If the
243. e chassis Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 50 5 3050 LINCOLN amp F 50 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC F 51 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TESTS WARNING 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 or 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 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the stator is able to produce correct voltage from of its windings It will only yield meaning data if the engine high idle speed is correct 3625 to 3675 RPM and approxim
244. e and valve back into unit re con nect negative battery cable and close doors and engine top cover before restarting unit Wash your hands with soap and water after handling used motor oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation DO NOT throw it in the trash pour it on the ground or down a drain Engine Oil Refill capacities Without oil filter replacement 3 3 U S Quart 2 7 Imp Quart 3 2 liter With oil filter replacement 3 4 U S Quart 3 0 Imp Quart 3 2 liter Use motor oil designed for diesel engines that meets requirements for API service classification Kubota manual CD CE CF CF 4 CG 4 or CH 4 Oils levels that meet ACEA Performance levels E1 E2 can also be used Always check the service label on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classi fications SAE 10W30 is recommended for general tempera ture use 5F to 104F 15C to 40C See engine owner s manual for more specific informa tion on oil viscosity recommendations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We su
245. e checking for volt age between a good clean chassis ground connection and lead 211 at the starter solenoid See the wiring dia gram If no voltage is present check the start button the run stop switch and the CB7 circuit breaker See the wiring dia gram If battery voltage is present the starter motor or solenoid may be defective or the engine may be prevented from turning due to a mechanical failure Perform the ENGINE ALTER NATOR TEST There may be a defective com ponent or fault wiring causing a current draw when the run stop switch is in stop position Check the Run stop switch the glow plug button the alternator and the starter solenoid Also check for damaged wiring and insulation If the engine charging system is operating properly but the bat tery is not staying charged the battery is defective and should be replaced 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 RANGER 305D dili TROUBLESHOOTING amp REPAIR ds Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section
246. e it CAUTION 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 RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section TOC Return to Master TOC o p 0 5 18 18 TROUBLESHOOTING amp REPAIR 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 If the solenoid does not hold in the low idle position remove plug P6 from control PC board and wait for about 30 seconds If the engine drops to low idle check for damage or a buildup of conductive materials on or around the bypass filter assem bly and the output terminals See wiring diagram Note The bypass filter assem bly is connected between the output terminals See wiring diagram 10 If the engine still does not drop to low idle the control PC board is probably defective Replace it CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely
247. e on right side of machire 7 15 220 7 16 222 ROL 10K 1217 7 8 TOROID 261A 33 2 9 2248 IDLER 2 7 2108 IDLE SOLENOID ENERGIZED FOR LOWIDLE 1723 P723 IDLE SOLENOID ELLOW PULL PROTECTION ENGINE 0 2 OHM RELAY HOLD 15A BATTERY Si 1 110HMS CIRCUIT BREAKER P724 P722 12 to 14V 8 NORMAL OIL PRES INPUT 12 to 14V RUN INPUT e 210 GLOWPLUG GLOWPLUG SWITCH ENERGIZES IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITC ND ae SWITCH 57 ELECTRIC FUEL PUMP AND FUEL Located on wiring behind J 1 7 305 GLOWPLUGS SOLENOID HOLD COIL THRU CLOSE CR1ENERGIZES OPENING CONTACTS A SHUTTING OFF FUEL S LENOID TO STOP ENGINE receptacles 1 12 305 ALSO FUNCTIONS AS AN ENGINE s Control board circuits associated with 2 ae part 023 4 1 to 10 05140 0 PROTECTION BYPASS UNTIL OIL ENGINE of engine electrical system and are common to frame ground negative battery terminal ul PRESSURE BUILDS UP Allleads 305 1 0 JUMPER Part 223 1 time thu of amphenol plug and ferrite lead assembly Allleads 1 time thu ferrite PTL J RUN STOP SWITCH o EE s HIE lt gle ES ply 9 ojo WELD AMMETER Meters display setpoint vol Meters display actual volts
248. e the name Chopper The biggest advantage of chopper technology is the high speed control of the arc similar to the inverter machines A block diagram for this is as follows 3 PHASE DC RECTIFIER SOLID STATE INDUCTOR ARC ALTERNATOR AND FILTER SWITCH AND DIODE ARC CONTROL In this system the engine drives a three phase alter nator which generates power that is rectified and fil tered to produce about 90 VDC The current is applied through a solid state switch to an inductor By turning SWITCH DIODE the switch on and off current in the inductor and the arc can be controlled The following diagram depicts the current flow in the system when the switch is open and closed INDUCTOR 1 1 1 1 1 1 1 CURRENT WITH SWITCH CLOSED When the switch is closed current is applied through the inductor to the arc When the switch opens current stored in the inductor sustains flow in the arc and through the diode The repetition rate of switch closure is 20Khz which allows ultra fast control of the arc By varying the ratio of on time versus off time of the switch Duty Cycle the current applied to the arc is con trolled This is the basis for Chopper Technology Controlling the switch in such a way as to produce superior welding RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Retu
249. eas or 23 vent exhaust to the outside AA not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place These provide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Ranger 305D is a diesel engine powered DC multi process welding power source and 120 240 VAC power generator The engine drives a generator that supplies three phase power for the DC welding cir cuit and single phase power for the AC auxiliary out lets The DC welding control system uses state of the art Chopper Technology for superior welding perrormance RANGER 305D OPERATION DESIGN FEATURES Longer engine life reduced noise emissions and Single full range output control dial great fuel economy with the automatic engine idler 4 welding modes CC stick downhill stick welding Conveniently located engine maintenance label under pipe CV wire welding and Touch Start TIG elimi top engine door nates high frequency and tungsten contamination Return to Section TOC Return to Master TOC
250. ectifier gt x at Cit 818 ah Be 10000 10000 100 100V JE 88 85 ANIANI D e o E Rectifier 5 a a 4451BN GNO2 E rie 56 3 20V Qufput 5 To Choke is glaa 15 071 ij 217 E 2 514 415 V Blt GNO su From Rectifier 815 output BS olo 43 1 4 E 121K dg LED3 05 0 54 Rectifier 40V To Choke GENERAL INFORMATION LAST NO USED o aE lt 2 2 AE ply 0 9 ojo 3 LEO 2 ELECTRICAL SYMBOLS PER E1537 05 L1 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS Wem e DIODES 1A 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT 5 COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USEO FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC DRAWN BY ABILITY OF COMPLETE BOARD THIS SUBJECT SCHEMATIC 300 A CHOPPER PCB DIAGRAM NOT SHOW THE EXACT J ENGINEER LC UO NOT SCALE THIS DRAWING COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NU
251. ects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 2 o 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC 23 ELECTRIC AND DI MAGNETIC FIELDS may dangerous 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF
252. ed personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine e Remove guards only when necessary to perform maintenance and replace them when the mainte nance requiring their removal is complete guards are missing from the machine obtain replacements from a Lincoln Distributor See Operating Machine Parts List Read the Safety Precautions in the front of this manual and in the diesel Operator s Manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from the fans and all other moving parts when starting operating or repairing the equipment MAINTENANCE ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE A CAUTION To prevent the engine from accidentally starting disconnect the negative battery cable before servicing the engine See Table D 2 for a summary of maintenance intervals for the items listed Table D 1 Follow either the hourly or the calendar intervals whichever come first More frequent servicing may be required depending on your specific application and operating conditions See Figure 0 1 major component locations At the end of each day s use refill the tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add o
253. equal to the current capacity of the associated receptacle For extension cord lengths see Table B 5 NOTE The 240 VAC receptacle has two circuits each of which measure 120 VAC to neutral However they are of opposite polarities and cannot be paralleled SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS The above auxiliary power ratings are with no welding load Simultaneous welding and power loads are spec ified in Table B 4 The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time RANGER 305D Simultaneous Welding and Power Loads Welding Output Amps at NEMA Arc Volts Permissible Auxiliary Power Watts Unity Power Factor Permissible Auxiliary Current in Amps 120 VAC 240 VAC Each 120 VAC leg of the 120 240 VAC Full KVA receptacle can deliver a maximum 40 amps up to a total of 80 amps at 9500 Watts 60 amps at 7100 Watts or 46 amps at 5600 Watts These outputs cannot be paralleled so the greatest single 120 VAC load is 40 amps Each 120 VAC Duplex receptacle is limited to 20 amps maximum TABLE B 5 RANGER 305D Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Load Watts 14 AWG 12 AWG Maximum Allowable Cord Length in ft m for Conductor Size 10 AWG 8 AWG 6 AWG 4 ANG 1800 75 23 125 38 300 91 2400 50 5 88 27 13
254. er the meter manufacturer instructions and plug it into one of the 120VAC auxiliary receptacles Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is no load on the machine The frequency should read between 60 5 and 61 5 Hz 3 Move the idle switch to the AUTO IDLE position and wait for the idle solenoid to energize and the engine RPM to drop and stabilize at the low idle RPM The frequency should read between 40 and 42 Hz If either of the readings is incorrect pro ceed to the THROTTLE ADJUSTMENT PROCEDURE later in this section NOTE For the Ranger 305D and any other Lincoln Electric 3600 RPM 2 Pole machine engine RPM can be determined by multiplying the frequency in Hz By 60 Example 60 Hz 60 3600RPM RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 0 5 32 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued Vibratach Method A Vibratach is used to measure the vibrations caused by the running engine It can be posi tioned anywhere where the engine vibration is reasonably strong The best results will likely be obtained by opening the top engine cover and placing the Vibratach directly aga
255. ered by this manual LINCOLN RANGER 305D ELECTRICAL DIAGRAMS ci SCHEMATIC ENTIRE MACHINE CODE 11121 L12212 PAGE 2 OF 2 ENGINEERING CONTROLLED CHANGE DETAL FE 216011 MANUFACTURER No AUXLLARY CURRENT Return to Section TOC Return to Master TOC WELDING TERVINAL CONTROL SWITCH SHOWN INLAYS ON POSTION XV ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT 12V Battery Supply to VBATERY ee ey 15 IDLER DICDEONLYON E VERSIONNND rer side ofthe Hold OV when energized LOWIDLE 12 when not energized HIGH IDLE Be FRAME FRAME IS COMMON FOR ENGINE CONTROL CIRCUITS 4 Ae Tepus HGH PULLTOLOWIDLE MACHINE IDENTITY TABLE S t 22 K 24 PINS JUVPERED TO SELECT HOLD 5V HOLD FORALXUSE ONET 1 L 1151117 113 2 ia TOFRAVE FORHGH IDLE RANGER 250 G amp D 5 o FRAME RANGER 305 G amp D 44 4 VANTAGE 500 gt 1 RANGER OIL PRESSURE VANTAGE 575 4 5 220124 AIR VANTAGE 500 VBATERY 0 PULL OIL d 9 DISPLAY F m 49 METER 4 INPUT 0 2V 1 1000 i gt J40 METER INPUT Latya 128 gt 5700 METERS OPTIONAL ONVANTAGE
256. ery MATERIALS NEEDED Return to Section TOC Return to Master TOC Miscellaneous hand tools Volt meter Wiring Diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 5 5 9 gt 815 4353 oO 1 Return to Section TOC Return to Master TOC Return to Master TOC F 36 TROUBLESHOOTING amp REPAIR ENGINE ALTERNATOR TEST continued FIGURE 8 LEAD LOCAIONS BATTERY IGNITION TEST PROCEDURE Turn the engine off Open the engine access door and check the voltage at the battery terminals It should be approximately 12 volts DC Attach the meter leads to the battery termi nals being careful to position them so they stay clear of moving parts while the engine is running Place the idle switch in the HIGH IDLE posi tion start the engine and allow it to run at high idle speed for about 15 to 30 seconds The meter should read about 13 7 to 14 2 VDC If the meter reads correctly the engine alter nator is producing adequate power to charge the battery and this test is complete If the voltage is significantly higher than the above values the alternator is not properly regulating the battery charging voltage and should be replaced If the voltage reads the same or less than the measureme
257. et metal cover and engine access doors Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Rubber mallet olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 TROUBLESHOOTING amp REPAIR FIGURE F 1 DOOR REMOVAL REMOVAL PROCEDURE Turn the engine off Unlatch and open the engine service access doors To remove each door partially close the door until the locking tabs at the hinges dis engage from the slots in the base Hold the door at this angle while sliding it off the hinge It may be necessary to lightly tap the door with a rubber mallet to free it from the hinge See Figure F 1 Remove the exhaust pipe extension Remove the cover seal from around the lift bail Remove the sheet metal and machine screws holding the case cover in place Remove the sheet metal screws from the right and left case sides lift the case cover slightly then tilt each side back and lift up to free the bottom tabs from their slots 8 ENGINE SERVICE ACCESS DOOR LOCKING TAB Lift the case cover off the machine NOTE It is necess
258. eturn to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 gt 815 43 Return to Section Return to Master TOC Return to Master TOC F 48 F 48 TROUBLESHOOTING amp REPAIR FLASHING VOLTAGE TEST continued TEST PROCEDURE 1 Perform the Case Cover Removal 2 Make sure that the battery is fully charged and in good condition and the battery con nections are clean and tight 3 Remove lead 2229 from the oil pressure switch see wiring diagram and Figure 71 Insulate or position the lead so it cannot come in contact with chassis ground or any other wiring See Figure F 11 NOTE Disconnecting lead 7229 bypass the oil pressure switch and simulates a running engine NOTE The oil pressure switch is located on the left side of engine just above the oil filter See Figure 1 4 Place the RUN STOP switch in the RUN position The engine protection light should remain off 5 Connect the voltmeter probes to brush terminals See wiring diagram and figure 2 6 Measure the voltage it should read about 3 to 5 VDC 7 Set the RUN STOP switch to the STOP position 8 If the meter reads normal voltage of 3 to 5 VDC this test is complete 9 If the meter reading indicates battery volt age about 12 to 14 VDC The rotor may be open or the brus
259. etween the machine and the arc RECOMMENDED COURSE OF ACTION 1 The engine may not be main taining correct RPM Perform the Engine Throttle Adjustment Test Make sure the engine has an adequate supply of clean fresh fuel Check the fuel and air filters replace if necessary If the engine still fails to main tain correct RPM the engine will need to be serviced Check the internal cables and leads that connect the weld winding of the stator chopper module shunt choke and the output terminals See the wiring diagram Look for any damaged conductors or faulty connections There may be poor connections in the control wiring at the weld control PC board or the chopper board Pull each plug from the weld control PC board and thor oughly insect the terminals in both the plugs and the PC board receptacles Make sure the connections are clean and that the pins are properly seat ed in the plastic plug housing Check for loose or damaged pins and faulty crimp connec tions Check for damaged wiring and poor connections in leads 13 14 23 and 25 between the chopper module and the weld control PC board CAUTION 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 RANGER 305D LINCOLN 9 Return to Section
260. f application 2 220 8 Adjust wire feed speed at the LN 25 and adjust the Set the VOLTMETER switch to or depend welding voltage with the output CONTROL at the ing on the polarity chosen LN 25 if optional remote control kit is used 4 Set the MODE switch to the CV WIRE position 9 Set the ARC control to 0 initially and adjust to Suit Return to Section TOC Return to Master TOC FIGURE C 2 Ranger 305D LN 25 ACROSS THE ARC CONNECTION DIAGRAM 14 PIN AMPHENOL 6 PIN OPTIONAL K444 1 AMPHENOL REMOTE CONTROL LN 25 WIRE FEEDER TO WORK A ELECTRODE CABLE WORK CLIP LEAD TO WORK olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 ACCESSORIES CONNECTION OF THE LN 25 TO THE RANGER 305D WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE SEE FIGURE C 3 1 Shut the welder off 2 Connect the electrode cable from the K626 XX Input Cable Assembly to the terminal of the welder and to the LN 25 Wire Feeder Connect the work cable to the terminal of the welder NOTE Figure C 3 shows the electrode con
261. f generator on support Power Supply d 15 volt 20 kHz Open CircuitVolts m S D C3 and D3 locatal on rear of fan baffle s mere TWISTED TED dad 12 volts located front of fan ba TO AUX AC 4O0VAC 3PH on left side of machine T PAIR until generator builds up on left side neg bottom of lt 85 SLIP RINGS i 230 VAC 1 PH then 350 volts 0 amps machine es ERE 50 V DC 13038 1403 16 253 9 23 3 10 E TISNAC 200A 2045 161 24 ROTOR FLASHING y ANNA OUTLETS pe CENTER TAP 1206 162 2 41 e 2 5 215 LOW DLE SOLENOID HOLD COIL 0V 8 LOW IDLE AND 2088 315 Control board common is 42 VOLT AC at welder positive output 15V LOW IDLE TO PULL COILBOARD WIRE FEEDER 177 andshunt 24040 AMPHENOLS POWER 0 10V T 76 7 4 Swich closed fcr high idle 42 WELD CONTROL 3 14 252 IDLER SWITCH oY 5075 pc BOARD 3 7 251 4 2 42 VOLT AC REVOLVING FIELD OY maga PAN G40 AMPHENOL BOWER TOR FIELDRESISTANCE TO AMPHENOL REMO 25 WO 114 013 4 5 ROTOR FELD CIRCUIT 9 Located on front of fan TO AMPHENOL Y e 75A 1 1 10 7 9 214 110 ET top of ban 218 Relay CR1 and 04 on fron 279 7 6 baffle onright side of machire ROL 10K 2 278 7 7 7 15 220 7 16 222
262. f the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRIC RANGER S030 MATERIAL TOLERANCE AGREE ENGINEER SCALE WITH PUBLISHED STA DO NOT SCALE THIS DRAWING G4107 1 SOLID EDGE EN 170 o lt 818 ES 43 9 c NOTE 6 35 ELECTRICAL DIAGRAMS iiid SCHEMATIC PULL COIL PC BD ALL CODES G4117 1 Return to Section TOC Return to Master TOC TO PERIPHERAL 80 TOR COMMANDERS East SIGNAL FROM CPLD IS FONTROLLEN BY ENGINE GIL p a SWITCH LOW OIL PRESSURE 410V CRANK CIRCUIT OFF SU THE BATTERY IS DRAINED WHEN THE ENGINE HES ENGINE RUNNING FLASH WILL AUTONATIORLLY STOP DUE TO BLOCKING DIODES BEING REVERSED BIASED Rie 10V CRANK E 12V RUN m BATT R48 100 1 CR CON 12V_BATT COMMANDERS FLASH FROM PERIPHERAL RC MO ERN 909 lao uF TO ENG ALT 1 204 SUPPLY DOUBLER L 400V CIR EOM CIR COM CIR C
263. f the resistance readings are not as specified in the table replace the potentiometer and mode switch plug and lead assembly or replace the defective component See the wiring diagram If testing is complete plug P7 back into the control PC board and perform the Case Cover Replacement procedure RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle 5 5 9 8 43 oO Return to Section Return to Master TOC F 77 F 77 TROUBLESHOOTING amp REPAIR CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST continued TABLE F 3 POT MODE SWITCH RESISTANCE TEST MODE SWITCH OHMMETER OHMMETER SETTING CONNECTION READING STICK P7 9 214 27 9 214 TO 7 14 218 7 14 218 500 soKorHighe CC STICK P7 9 214 TO P7 15 220 500K or Higher CC STICK P7 9 214 TO P7 16 222 500K or Higher CC STICK P7 14 4218 TO P7 15 4220 500K or Higher CC STICK P7 14 218 TO P7 16 222 500K or Higher CC STICK P7 15 220 TO P7 16 222 500K or Higher TOUCH START TIG P7 15 220 TO P7 16 222 DOWNHILL PIPE P7 14 218 TO P7 16 222 CV WIRE P7 9 214 TO P7 16 222 P7 5 75 TO P7 1 77 about 10K Ohms values should sweep smoothly from 10K to 0 when ARC CONTROLis P7 1 77 TO P7 4 76 turned from Min to Max P7 6 279 TO P7 8 277 about
264. fan 206A FEED BACK SIGNAL baffle near top of Requies added 206 FLYBACK baffle for cooling af flow BY PASS DIODES 6 WIREFEEDER Located on back of PC BOARD ro DC BUS VOLTAGE w1 VOLTMETER FILTER output panel 208C 2 POLARITY CAPACITORS 4 904 10 0 Q HI IDLE 60TO 65 VAC PHASE TO PHASE Return to Section TOC Return to Master TOC between terminals SWITCH BETWEEN W1 W2 AND W3 208A IGBT 8 AT HIGH IDLE NEGATIVE _ AR TWO POLE 3600 RPM ALTERNATOR OUTPUT L1 CHOKE 2 TURNS i i PWM Signal to Chopper Choke is beneath be d THRU TERMINAL of generator on support gt FERRTE Power Supply 15 volt 20 kHz Open CircuitVolts 4 1 Mi 2TURNS 7 C3 and D3 locatal on rear of fan baffle cc 58 58 Rotor Flashing 12 volts lt CV 58 58 1 2 TURNS FERRITE PR WISTED 0 0 5 amps AUX m on left side of machine Pipe 58 26 TARY FERRITE PAIR until generator builds up R3 located front of fan baffle i lt 200 Tg 12 gt aie then 50 volts 0 amps on left side nea bottom of OUTLETS 200 50 V DC Control Board senses Weld Output 1303 8 14 346 25 3 9 2303 10 8325 OHM machine n from Current Feedback Shunt 2045 61 24 200N ROTOR FLASHING AW C3 to activate idler 12065 62 AND 800uf i 201
265. fle near top of machine 75A 110 279 7 6 I 28 7 1 7 9 214 17 14 218 Relay CR1 and 04 on fron baffle on right side of machire 07 15 220 7 16 222 ROL 10K 1217 7 8 TOROID 261A 33 2 9 2248 IDLER 2 7 2108 IDLE SOLENOID ENERGIZED FOR LOWIDLE 1723 12 to 14V 8 NORMAL OIL PRES INPUT 12 to 14V RUN INPUT e 210 GLOWPLUG GLOWPLUG SWITCH ENERGIZES IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITC ND am SWITCH 57 ELECTRIC FUELPUMP AND FUEL 723 Located on wiring behind 1 7 305 A 61091065 SOLENOID HOLD COIL THRU D4 IT IDLE 7 receptacles 11 12 305 ALSO FUNCTIONS AS AN ENGINE 4 SOLENOID Control board circuits associated with 2 ae part 023 J 4 1 to 10 05140 0 PROTECTION BYPASS UNTIL OIL ENGINE ELLOW PULL PROTECTION ENGINE 0 2 OHM RELAY HOLD 15A BATTERY S1 11 OHMS CIRCUIT BREAKER _ P724 722 PRESSURE BUILDS UP of engine electrical system and are common to frame ground negative battery terminal ul Allleads 305 1 0 JUMPER Part 223 1 time thu of amphenol plug and ferrite lead assembly All leads 1 time thu ferrite PTL J RUN STOP SWITCH o EE s HIE lt gle ES ply 9 ojo WELD AMMETER
266. for long cable lengths to reduce voltage drops Long lengths of cable should not be left coiled when welding CABLE INSTALLATION TABLE A 1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 305 Amps 100 Duty Cycle Cable Length 0 100Ft 0 30 meters 1 0 AWG 100 150 Ft 30 46 meters 2 0 AWG 150 200 Ft 46 61 meters 3 0 AWG Install the welding cables to your RANGER 305D as follows The engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode and work cables to the weld output terminals The terminals are identified on the case front 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is properly connected to the work clamp and cable 6 Check and tighten the connections periodically NOTE Long lengths of welding cable should not remain coiled or wrapped while welding CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and sepa rate from one another AUXILIARY POWER RECEPTACLES The auxiliary power of the RANGER 305D consists of two 20 Amp 120 VAC 5 20R duplex receptacles with GFCI protection and one 50 Amp 120 240 VAC 14 50 receptacle The 240 VAC receptacle can be split for single phase 120 V
267. framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode ew if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders
268. fully seat against the internal stop of the solenoid coil assembly 2 The low idle RPM may be too low Perform the Throttle Adjustment Test 3 The solenoid hold coil power circuit may be faulty Check wiring and connections on lead 210A and lead 215 The weld control PC board may be defective CAUTION 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 RANGER 305D LINCOLN 9 21 21 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING 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 or 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 Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case she
269. ggest you take it in a sealed container to your local service sta tion or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain Filter Change Drain the oil Remove the oil filter with an oil filter wrench and drain the oil into a suitable container Discard the used fil ter Note Care should be taken during filter removal to not disrupt or damage in any way the fuel lines Clean the filter mounting base and coat the gasket of the new filter with clean engine oil Screw the new filter on by hand until the gasket con tacts the mounting base Using an oil filter wrench tighten the filter an additional 1 2 to 7 8 of a turn Refill the crankcase with the specified amount of the recommended engine oil Reinstall the oil filler cap and tighten securely Start the engine and check for oil filter leaks Stop the engine and check the oil level If necessary add oil to the upper limit mark on the dipstick RANGER 305D LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle 5 5 9 gt 815 43 Return to Section Return to Master TOC MAINTENANCE Service Instructions amp Installation Tips For Engine Air Filter Check the Old Filter for Leak Clues Visually inspect the old filter for any signs of leaks A streak of dust on the clean side of the filter
270. ghten the connection securely F 84 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 o 0 5 85 85 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACE MENT continued Replacing the Output Rectifier 1 Place the Output Rectifier into the machine so that its mounting studs fit into the holes in the bracket Place a lock washer and a nut on each stud and tight en Apply a thin film of electrical joint com pound Dow Corning 340 Lincoln T12837 between the surfaces of the W leads the Output Rectifier Reconnect the Output Rectifier position ing the leads bolts washers and nuts exactly as hey had been originally con nected Tighten all of the connections securely See Wiring Diagram Swing the case front back into position Mount the D4 diode bridge and the 1 engine protection relay to the center baf fle assembly See Wiring Diagram Attach the case front to the machine base with four screws 7 Reconnect all of the leads and plugs that were disconnected during the removal procedure and replace any cable ties that were removed Perform the Case Cover Removal Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 86 5 3050
271. gt E TO THE LAMINATION 1 2 82 0 1 758 2A ROTOR 2 c CONTAGIO D 5F 2C 2B lob Cie 4 ST oi 212A ee BLO S1RUN STOP 82 Di ala Pn j om s SAn 4 4 GROUND UN POS 9 B GND A 5 i bs loo 223A PCB2WELD CONTROL PC BOARD AMPHENOL 1 E ELSE 2098 5 n 77 210 J 210 GND R REMOTE 18 768 2100 210A 2108 2108 CONTROL B 2 768 i 11 2108 C2 225 2 101 Bl B2 B3 B4 7 59 223A m 232 i 5 231 210A 2 GROUND 5E 223 sic t 404 A GND SCREW ON Y AMPHENOL 2 j T SU o o 7438 209A GND L ae a Tea 214 LEAD COLOR CODE CONTROL 4 th 28 209 MBA po 12 2 24 1 5 1 1 4 1 5 N S3 BATTERY GND M 5 0000 55555 GND aL blk red SE LUNG one pesi ENGINE 2 5 g 6 0 G GREEN WYELLOW STRIPE POMON pA SW D GROUND FUEL 1 1 PUMP ET GND H an 00000000 L2 L3 RF CHOKES GON PCB3 PLUGS ENGINE COMPONENTS 1x2 d STARTER FUEL SOLENOID IDLE SOLENOID PULL COIL BD FRAME c ELECTRICAL SYMBOLS PER E1537 GND GROUND J OJS CONNECTORS VIEWED FROM INSERTION END 2
272. guisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building
273. h the dial set at 0 Some recommended Innershield electrodes are NR 311 NS NR 203 Ni 195 NR 204H Recommended Outershield elec trodes are 05 70 OS 71M Some recommended solid wires for MIG welding are 035 0 9mm and 045 1 1mm L 50 and L 56 035 0 9 mm and 045 1 1mm Blue Max MIG 308 LS For any electrodes including those above the procedure should be kept within the rating of the machine ARC GOUGING The RANGER 305D can be used for limited arc goug ing For optimal performance set the MODE switch to CC STICK and the ARC CONTROL to 10 Set the OUTPUT CONTROL knob to adjust output cur rent to the desired level for the gouging electrode being used according to the ratings in the following Table B 3 TABLE B 3 CURRENT RANGE PER ELECTRODE DIAMETER Carbon Diameter Current Range DC electrode positive 1 8 75 140 Amps 5 32 90 150 Amps 3 16 200 250 Amps AUXILIARY POWER A WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand 10 voltage and a 3 frequency variation Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings as long as no welding current is being drawn The auxiliary power of the Ranger 305D consists of two 20 amp 120 VAC 5 20R duplex receptacles and one 50 amps 120 240 VAC 14 50R receptacle The 240
274. h in the REMOTELY CONTROLLED position Start the engine and allow it to stabilize at high idle RPM Check for 80 to 100 VDC at terminals B1 to B2 and B4 to B5 of the chopper module See wiring diagram and figure 1 If the correct DC voltage is not present at ter minals B1 to B2 and B4 to B5 check for damaged conductors or faulty connections between the chopper module the output rec tifier and the stator weld winding See Figure F 17 See the wiring diagram Perform the and the 9 SL13 If the correct voltage is present at terminals B1 to B2 and B4 to B5 of the chopper module check for DC voltage at the chopper module terminals 2 to B3 and B5 to B6 If significant voltage is present disconnect leads 23 and 25 from the chopper module PC board If voltage is still present the cop per module is shorted and should be replaced If the voltage drops to 0 VDC after the 23 and 25 leads have been disconnected the control PC board is driving the chopper mod ule when it should not be doing so Reconnect the 23 and 25 leads and per form the Weld Control Board Gate Drive Reconnect leads 23 and 25 and place the Welding Terminal switch in the WELD TER MINALS ON position Check for about 58 VDC between Chopper Module Terminals 2 to B3 and B5 to B6 and between the welder output terminals See Figure 17 See the wiring diagram RANGER 305D
275. he engine speed is controlled by a two stage solenoid connected to the engine speed control lever When the solenoid is inactive the engine operates at high RPM and is controlled by the governor When the solenoid is activated the speed control lever is pulled to a pre set low RPM setting The solenoid is powered by battery voltage directly from the run stop switch The control PC board and pull coil PC board activate the pull and hold coils by providing a path to ground When the machine goes to low idle speed the control PC board grounds the hold coil of the idle solenoid and at the same time it sends a signal of about 14VDC to the pull coil PC board This DC signal remains at 14VDC for the entire time that the hold coil is active When the signal is applied to the Pull coil PC board the board will energize the pull coil of the idle solenoid for a brief moment normally less than one second This momentary activation of the pull coil supplies the need ed power to reliably move the speed control lever to the low idle position NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o Fle 22 Se 9 5 81 8 43 o o 1 Return to Section Return to Master TOC E 4 E 4 THEORY OF OPERATION FIGURE E 4 GENERATING POWER amp OUTPUT ENGINE
276. he engine will continue to operate at high RPM If the engine is started with the idle switch in the auto if the idle switch is moved to the auto position while the engine is running a 12 second on the control PC board is started If there is no signif icant current flow detected from the weld or auxiliary outputs during that 12 second time the idle solenoid will be activated dropping the engine RPM to preset low idle speed If a load is applied during the 12 sec ond delay the engine speed will remain high While operating at low RPM if the idle switch is moved to high or there is a load detected from either the weld of auxiliary outputs the idle solenoid will be deactivat ed allowing the engine governor to increase the RPM to high speed When the idle switch is in the auto position and the machine is under load and running at high RPM If the load is removed the machine will continue to run at high RPM for 12 seconds then drop to low RPM unless a load is re applied during that 12 second delay CHARGING SYSTEM LIGHT a 10926 ONLY FLASHING SHUNT POWER elt MODULE STATOR 120 240 42 VAC WELD CONTROL NDING AUX WINDING WINDING 07770 3 BOARD AMPHENALS 90 O 1 SWITCH OUTPUT MODE WELDING CONTROL SWITCH TERMINAL Idle Solenoid Operation T
277. he polarity chosen 9 Adjust the wire feed speed at the LN 25 and adjust the welding voltage with the K857 if optional remote control is used 9 Adjust the control to initially and adjust to Suit FIGURE C 4 Ranger 305D LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL 14 PIN AMPHENOL 6 PIN AMPHENOL TO WORK ELECTRODE CABLE OPTIONAL K857 REMOTE CONTROL WIRE FEEDER EE WORK CLIP LEAD TO WORK RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 2 0 5 ACCESSORIES CONNECTION OF THE LN 7 TO THE RANGER 305D USING K584 CONTROL CABLE SEE FIGURE C 5 NOTE If your LN 7 comes equipped with a K291 or K404 input cable refer to CONNECTIONS OF THE LN 7 Using K867 UNIVERSAL ADAPTER rather than this discussion to connect your Ranger 305D for wire feed welding 1 Shut the welder off 2 Connect the electrode cable from the K584 XX Control Cable to the terminal of the welder and to the LN 7 wire feeder Connect the work cable to the terminal of the welder NOTE Figure C 5 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the output termin
278. hes may be faulty or not making proper contact with the slip rings 10 Perform the Rotor Resistance Test Perform the Brush and Slip Ring Service 11 If the voltage measures zero or very near zero this condition could be caused by a poor connection or a defective component in the flashing circuit or a shorted rotor wind ing 12 Perform the Rotor Resistance Test 11 Refer to the wiring diagram pull plug P 2 from the control PC board and inspect each terminal Make sure that all terminals both on the board and in the plug are clean and in good condition and that the pins are securely crimped to the flex leads Perform the following additional test 13 Switch the RUN STOP switch to the RUN position 14 Use a voltmeter to check for the presents of about 12VDC battery voltage at the follow ing locations on the control PC board Lead 45K P2 3 to Lead 210 P2 7 Lead 45K P2 3 to Lead 224 P2 9 Lead 45K P2 3 to Lead 4200N P2 1 NOTE Lead 210 supplies 12VDC battery voltage to the control PC board whenever the run stop switch is in the run position Lead 200 supplies DC flashing voltage from the control PC board to the positive slip ring through the R3 resistor 15 If battery voltage is preset at all of the above points check the top grounding stud on inside left case from and lead also check leads 200 200N and the 25 Ohms flashing resistor Make
279. hine Codes 11188 11275 64571 1 G 4 5 Wiring Diagram Entire Machine Code 11027 64226 G 5 Wiring Diagram Entire Machine Code 11122 6457 G 6 Wiring Diagram Entire Machine Codes 11189 11314 64572 1 G 7 Wiring Diagram Entire Machine Code 11039 G4409 G 8 Wiring Diagram Entire Machine Code 11123 4573 sse G 9 Wiring Diagram Entire Machine Codes 11190 11315 64573 1 G 10 Schematic Entire Machine Code 10926 111946 Page 1 of 2 G 11 5 Schematic Entire Machine Code 10926 111946 Page 20012 6 12 Schematic Entire Machine Code 11121 112212 Page 1 of 2 G 13 2 Schematic Entire Machine Code 11121 112212 Page 2 of 2 G 14 gt Schematic Entire Machine Codes 11188 11275 L12212 1 Page 1 2 G 15 js Schematic Entire Machine Codes 11188 11275 L12212 1 Page 2 of 2 G 16 a Schematic Entire Machine Code 11027 112039 Page 10812 G 17 2 Schematic Entire Machine Code 110
280. his test will only yield usable information if the machine is producing some weld output Return to Section TOC MATERIALS NEEDED Digital Multi meter suitable for accurate readings in both the millivolt and normal weld voltage ranges Resistive load bank Ammeter suitable for accurate readings of normal welding current Often built into the load bank Wiring diagram Control Inner Connection diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 815 4353 Return to Section Return to Master TOC Return to Master TOC F 72 TROUBLESHOOTING amp REPAIR WELD CONTROL FEEDBACK TEST continued TEST PROCEDURE 1 Place the idle switch in the HIGH IDLE position 2 Place the mode switch in the CC STICK position 3 Place the weld terminals switch in the WELD TERMINALS ON position 4 Make sure that nothing is plugged into either Amphenol receptacle 5 Connect the resistive load bank and the ammeter to the weld output terminals per the equipment manufacturer s instructions also connect the voltmeter probes across the weld output terminals 6 Start the machine and apply a load of about 200 Amps as shown on the external amme ter If the machine will not
281. ht PLI r 2106 233 gt WORK H e 2 2 FRAME GND GND A 228 B Sense 2 0 778 GND G GND C i 20A POSITIVE BRUSH CONNECTED 210D 2298 a l PWM 1 CONTROL F 0 1 768 GND D TO SLIP RING NEAREST 2294 23 4 4 758 2A TO THE LAMINATION cic CONTACTOR ROTOR elc 70 48 Lo 212A S1RUN STOP 2 S m 02 0 28 SWITCH START 223A 5 0 GROUND SHOWNIN 51 BUTTON o o GND A 10 PCB2WELD CONTROL PC BOARD 1 Slow m sls 297 B Du BUTTON 087 20 118 15 2108 2108 76A CONTROL 768 2 2 992 u sis TES 210 102 225 CONTACTOR 2A 81 W2 83 B 2 8 2 E 223A 232 O ES of B 50 2258 8 GROUND F GND 8 5E 23 ac 231 aA 404 SCREW ON T AMPHENOL 2 o o 9818 4 FANBARELE J73 Jm GND L 1234 1 T GONTROL 229 209 UBLT P74 P73 prol g 1 5 GND M SHOWNIN i om HO mer bik 2 29 901 eegee WELDING ON 2 L PRES BAT red ku wnt 5 8 6 1 POSITION 2A SW 228 l gt 6 b _ ud m IGN ENGINE GND H T E 699099 L2 L3RFCHokES LEAD COLOR CODE dow L GROUND amp 2 900000 0
282. il if indicated TABLE D 1 ENGINE MAINTENANCE COMPONENTS KUBOTA D722 DIESEL ENGINE ITEM OIL FILTER AIR FILTER MAIN FUEL FILTER FUEL FILTER IN LINE BATTERY GROUP 58 550 CCA BELT GLOW PLUGS MAKE AND PART NUMBER KUBOTA 70000 15241 DONALDOSON P822686 KUBOTA 15393 43017 KUBOTA 12581 43012 LINCOLN M9399 14 KUBOTA 15881 97011 KUBOTA 16851 65512 RANGER 305D LINCOLN 9 MAINTENANCE TABLE D 2 KUBOTA D722 ENGINE MAINTENANCE SCHEDULE INTERVAL REQUIRED MAINTENANCE Fill fuel tank Check oil level Check coolant level Check air cleaner for dirt or damage Check air intake for cracks looseness 200 hrs per Kubota Check fan belt tension Kubota Manual every 100 hrs Return to Section TOC Return to Master TOC First 50 Hours Check engine oil and oil filter 75 Hours Check engine oil 100 Hours Clean air cleaner element 1 Clean fuel filter Check battery electrolyte level 150 Hours Change oil filter Return to Section TOC Return to Master TOC 200 Hours Check radiator hoses and clamps 400 Hours Replace fuel filter 500 Hours Replace fan belt Flush radiator Remove sediment from fuel tank 800 Hours Check and adjust valve clearances 2 1500 Hours Check fuel injector nozzle pressure 2 2 3000 Hours Check fuel injection pump and timer Every Year Replace air cleaner element 1 olo O o Fle 5 5 9 815 4353 Every Two Years Rep
283. inals 1 Check the brushes for wear and proper contact to the rotor slip rings 2 Perform the Brush Slip 3 Perform the Rotor Voltage Test 4 Perform the Stator Voltage No welding output in any mode The auxiliary output is normal The engine operates normally Place the Welding Terminals switch in the WELD TERMI NALS ON position If the prob lem is solved the fault may be in the external control cable or the attached wire feeder amptrol arc start switch etc if used With the engine at high idle 3650RPM the machine in the CC STICK mode the output control at maximum and the welding terminals switch in the WELD TERMINALS ON posi tion check for the presence of approximately 58VDC OCV open circuit voltage at the weld output terminals If the correct OCV is present at the welding output terminals check the welding cables connectors work clamps electrode holder etc for loose or faulty connections 1 Check for damaged conductors or faulty connections on the heavy current carrying leads that connect the output studs to the Chopper module and to the output Rectifier Also Check the shunt and choke assem blies for damage and faulty connections 2 Perform the Chopper Module CAUTION 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 trou
284. ing lever on the pump to assist starting and after extended periods of non use or out of fuel conditions WARNING To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust manifold creating a danger of fire Bleed the fuel system as follows 1 Fill the fuel tank with fuel 2 Open the fuel shut off valve vertical position of han dle on the Fuel Filter 3 Press and hold the glow plug button for 10 to 20 seconds For Code 10926 11121 3a Crank the engine by pressing the start button for 45 seconds For Code 11188 11275 4 Check to see that fuel is flowing through both fuel filters 5 Follow the normal STARTING procedures FUEL FILTER 1 Check the fuel filter and fuel pre filter for water accu mulation or sediment 2 Replace the fuel filter if it is found with excessive water accumulation or sediment Empty fuel pre fil ter OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3650 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop BATTERY MAINTENANCE To access the battery Disconnect the Negative and then Positive battery cables
285. inst the top of the engine Read and understand the manufacturer s instructions for the Vibratach 1 Startthe engine and place the idle switch in the HIGH IDLE position Make sure that there is no load on the machine 2 Position and adjust the Vibratach it should read between 3525 and 3675 RPM 3 Move the idle switch to the AUTO IDLE position and wait for the idle solenoid to energize and the engine RPM to drop and stabilize at the low idle RPM 4 Position and adjust the Vibratach it should read between 2400 and 2500 RPM If either of the readings is incorrect pro ceed to the THROTTLE ADJUSTMENT PROCEDURE later in this section THROTTLE ADJUSTMENT PROCEDURE IMPORTANT Both the high and low idle set tings are adjusted at the solenoid DO NOT ATTEMPT TO ADJUST THE STOP SCREWS ON KUBOTA ENGINE The high speed stop screw on the engine is for over speed protection only It is set to 3800 RPM at the Kubota factory and is wire locked in place to prevent tampering 1 Check that the linkage attaching the sole noid to the engine speed control lever is properly aligned and in good condition It is more important that the solenoid linkage be more precisely aligned when in the high speed de energized position 2 Check to be sure the spring located inside the rubber boot is not broken or missing In the default de energized position the spring should be holding the solenoid in the high speed position
286. ion TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D 6 27 ELECTRICAL DIAGRAMS EET SCHEMATIC ENTIRE MACHINE CODES 11190 11315 L12214 1 PAGE 1 OF 2 ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURER PC BOARD Rectifier mounted to generator support IGBTS FLYBACK DIODES AND Shunt on back of positive R4 located on font of FILTER CAPACITORS ARE INTEGRALI above output chole POSITIVE SHUNT output terminal hi TO CHOPPER MODULE AND NOT 50MV 400 AMPS INDIVIDUALLY REPLACEABLE D1 THREE PHASE BRIDGE RECTIFIER 206B 2065 2045 WELD CURRENT 85 10 000uF x4 Chopper is mountet on the back side of fan Q 206A FEED BACK SIGNAL baffle near top of machine Requires added 206C FLYBACK baffle for cooling flow W1 60 TO 65 VAC PHASE TO PHASE BY PASS WIREFEEDER DIODES 6 2 0 DC BUS VOLTAGE BETWEEN W1 W2 AND W3 Located on back of BOARD VOLTMETER FILTER 90410VDC Q HI IDLE AT HIGH IDLE output panel 208C 1 POLARITY CAPACITORS 4 between terminals 77 SWITCH Return to Section TOC Return to Master TOC 2 IGBT 8 NEGATIVE __ Bl TWO POLE 3600 RPM ALTERNATOR Tl CHOKE OUTPUT 2 PWM Signal to i THRU TERMINAL 3l end FERRITE Power Supply 15 volt 20 kHz IGN
287. ions or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from spar
288. ks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and ap
289. lace battery Replace radiator hoses and clamps Replace fuel hoses and clamps KUBOTA D722 DIESEL ENGINE Note 1 Service more frequently when used in dusty and or high ambient temperatures Note 2 Consult your Kubota engine dealer for this service Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o Fle S 9 gt 815 43 o o 1 Return to Section TOC Return to Master TOC D 4 MAINTENANCE Engine Oil Change Drain the engine oil while the engine is warm to assure rapid and complete draining It is rec ommended that each time the oil is changed the oil fil ter be changed as well See Table D 2 Be sure the unit is off Disconnect the negative bat tery cable to ensure safety Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder Remove the cap from the drain valve Push valve in and twist counterclockwise Pull to open and drain the oil into a suitable container for disposal Close the drain valve by pushing in and twisting clockwise Replace the cap Re fill the crankcase to the upper limit mark on the dipstick with the recommended oil see engine oper ation manual OR engine service items decal OR below Replace and tighten the oil filler cap secure ly Push oil drain hos
290. lder positive output 15V LOW IDLE TO PULL COILBOARD WIRE FEEDER Qv 177 7 1 and shunt 2 4 404 POWER 0110 V Swich dosed for high BREAKERS 76 7 4 5 0 WELD CONTROL 0324 252 SWITCH 75 7 5 BOARD 3 7 251 _ 22 21 THRU FERRI 2A TO AMPHENOL 1 11 1 1 POWER FOR To AMPHENOL REMO IV 14 10 TERM SW ROTOR FELD CIRCUIT CON Located on front of fan TO AMPHENOL 21111 75A 140 baffie near top of 7 9 214 Relay CR1 and 04 locatel on fron 279 76 Machine 1744 218 baffle onright side of machire ROL 10K R2 28 7 7 07 15 220 716 222 ARC VOLTAGE FEEDBACK SIGNAL 0v REVOLVING FIELD 4 VOLT AC FIELD RESISTANCE APPROX 5 OHMS 75F Return to Section TOC Return to Master TOC 1217 7 8 TOROID SENSES AC 260A 34 POWER 12 to 14V NORMAL OIL PRES INPUT ENERGIZEDFOR ACTIVATE 261A 33 2 9 2248 IDLER 2 7 2108 312 to 14V RUN 4 210 picos GLOWPLUG GLOWPLUG SWITCH ENERGIZES IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITC SWITCH 57 ND P723 2 ELECTRIC FUELPUMP AND FUEL Located on wiring behind 1 7 305 cui GLOWPLUGS SOLENOID HOLDCOIL THRU D4 IT 11 5K 23 PROTECTI
291. le to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rotor winding is operating at normal charge Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Voltmeter Wiring Diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q HE 2 5 2 5 Return to Section TOC Return to Master TOC Q 0 5 44 44 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST continued FIGURE F 10 LEAD LOCATIONS SLIP RINGS BRUSHES TEST PROCEDURE 1 Perform the Case Cover Removal proce dure Connect the voltmeter probes to the brush terminals See Figure F 10 See the wiring diagram Set the RUN STOP switch to RUN and the IDLE switch to HIGH Start the engine and allow the RPM to stabilize for about 15 to 30 seconds The meter should read 46 to 54 VDC Set the RUN STOP switch to STOP If the meter reading is normal this test is complete If the voltage measures zero or very near zero the rotor flashing circuit m
292. letely disable the front panel control in all modes except touch start TIG mode sure nothing is plugged into either of the Amphenol recepta cles Check for dirt or moisture cont amination in either 6 pin or the 14 pin amphenol receptacle Perform the Receptacle Resistance Test The output control potentiome ter may be defective 3 Perform the Contro Potentiometer and Mode Switch Resistance Test CAUTION 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 RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 10 10 TROUBLESHOOTING 8 REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine front panel output control is still active when the remote control unit is connected to one of the Amphenol Receptacles Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELD OUTPUT PROBLEMS 1 The condition is normal in Touch Start TIG mode See the operators manual The remote control unit may be
293. low 23 F 5 C it is recommended that No 1D diesel fuel is used in place of No 2D Allow engine to warm up before applying a load or switching to high idle Lincoln Electric supplies a Cold Weather Kit if the unit is to be used in Cold Weather Extremes for long periods See Field Installed options in the of this manual WARNING DO NOT USE ETHER OR STARTING FLUID FOR STARTING SEVERE DAMAGE TO THE ENGINE WILL RESULT TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle is Lincoln s K957 1 See Accessories Section of this manual for trailer and trailer options If the user adapts a non Lincoln trailer he must assume respon sibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the weld ing equipment so there will be no undue stress to the frame Work 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed roughness of sur face on which the trailer will be operated environmental con ditions like maintenance 1 5
294. low voltage and frequency of the idling machine If this happens the current draw will likely be insuf ficient to activate the automatic idle system Devices of this type may require that the idler switch be in the HIGH IDLE position Check that the welding cables are in good condition and the connections are tight sure that work clamp 1 attached to clean bare metal TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check that leads 3 and 6 are properly routed through the torodal current sensor Each lead must have two turns and must pass through the sensor in opposite directions the wiring diagram leads should be wrapped tightly and tie wrapped in place Check the toriodal current sen sor for an signs of damage Check leads 260 and 261 for poor connections and damage to the conductors and insulation between the toroidal current sensor and the P3 connector on the control Pc board Unplug plug P3 from the control PC board and check for dam aged dirty or corroded pins Measure the resistance of the toridal current sensor Measure between P3 3 and P3 4 the meter should read about 10 to 14 ohms If the current sensor is shorted or open replace it The control PC board may be defective The weld control PC board may be defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs s
295. ly Attach the hoist to the lift bale to support the engine and stator assembly Remove the support blocks remove the screws from the engine support brackets and carefully rotate the engine and generator back to its original position Make sure all of the wiring is routed correct ly and replace the fasteners securing the engine and generator Reverse the above procedures to reassem ble the machine Reconnect all wiring and replace any cable ties that had been removed Refill the engine cooling system with the coolant that was drained earlier or with a 50 50 mix of permanent type antifreeze coolant See the engine operator s manual for more detailed information RANGER 305D 96 97 97 TROUBLESHOOTING amp REPAIR O 9 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 120 SUPPLY S 9 d HIGH IDLE NO LOAD 0 12 2 z 5 16 4 ms 1 10 F O I F 0 volts 9158 313 50V 5ms This is the typical auxiliary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time NOTE Scope probes are connected at machine 120 VAC receptacle o Fle 5 5 9 gt 813 43 o o 1 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms
296. mas ELECTRICAL DIAGRAMS inii SCHEMATIC ENTIRE MACHINE CODE 11123 112214 PAGE 2 OF 2 vlLecl ENGINEERING CONTROLLED CHANCE DETAIL RELEASED A02 FROM X MANUFACTURER No AUXLLARY CURRENT SENSE Return to Section TOC Return to Master TOC WELDING TERMINAL CONTROL ISOLATEDCIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT 12V Battery Supply to IDLE SWITCH SENSE VBATTERY tha ide Hold Solenoid 9 22 gt 15 FRANE IS COMMONFOR adc side ofthe Idle Hold Solencid ENGINE CONTROL 5 40V when energized LOWIDLE 12V when not energized HGH IDLE 15VCOM 5700 x TonEPUuLCaLgOwD HGH PULL TOLOWIDLE MACHINE IDENTITY TABLE J212 lt 124 PINS JUVPERED TOSH ECT MACHNE 1 jrs n z ns MACHINE TOME FORHGHIDLE L4 lt RANGER 250 G amp D 4 x FRAME RANGER 305 G amp D VANTAGE 500 RANGER PRESSURE VBATTERY VANTAGE 575 129 PULL OIL AIR VANTAGE 500 T 0 2 4 BOARD STARTER BUTTON 49 METER INPUT 0 24 1V 1000 ONIMETER d 12V when stating the machine RUN swich CN and 140 INPUT L pns PH Start Button Pressed and hald OV when the machine METER
297. n nections If the wiring is good the shunt and lead assembly is faulty and should be replaced Perform the Case Cover Replacement RANGER 305D LINCOLN 5 F 73 74 5 3050 LINCOLN amp F 74 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes 75 75 TROUBLESHOOTING amp REPAIR CONTROL POTENTIOMETER AND MODE SWITCH RESIS TANCE TEST 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will check the Output Control potentiometer Arc Control potentiometer Mode Switch and associated wiring for damage proper operation tracking and grounds MATERIALS NEEDED Digital Ohmmeter Wiring Diagram Control Inner Connection Diagram Retur
298. n Z2 red wire While the voltage is applied manually move the solenoid to the low idle position The sole noid plunger should hold this position until the voltage is removed See Figure 7 If either coil does not operate as described check for mechanical restrictions or other problems with the linkage If the linkage is intact and the solenoid does not operate correctly when the 12VDC is applied the solenoid may be faulty Replace Re connect idle solenoid and replace any previously removed cable ties If finished testing close the engine service access door RANGER 305D LINCOLN F 34 35 35 TROUBLESHOOTING amp REPAIR ENGINE ALTERNATOR TEST 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will determine if the engine alternator is properly charging the batt
299. n is ROTOR FLASHING to activate idler 24 200N VIA CIRCUIT t welder positive output WIRE FEEDER sh 5 02044 BREAKERS POWER 040 76 47 4 Svich closed for high WELD CONTROL 3 14 252 SWITCH 2 TURNS THRU 75 75 PC BOARD 3 7 251 FERRITE wv 2 TO AMPHENOL 2 VOLT AC Es 77 1 11 PNGAl POWER FOR TO AMPHENOL REMO 1 25V POT 114 LD TERM SW ROTOR FELD CIRCUIT CON TO AMPHENOL 1 Choke is beneath bearing end THRU TERMINAL Lg Of generator on support Open CircuitVolts Mi 2TURNS 7 CC 58 THRU TWISTED D3 locatal on rear of fan baffle on left side of machine A B C 400 VAC HE SLIP RINGS BS 200 230 VAC 1 PH E 115 VAC 1 PH 200A 50 V DC CENTER TAP AN AND lt 41 o AMPHENOLS LOW IDLE SOLENOID HOLD COIL 0V LOW IDLE ARC VOLTAGE FEEDBACK SIGNAL 2 5 215 42 VOLT AC 15V LOW IDLE TO PULL COILBOARD 42 0v REVOLVING FIELD FIELD RESISTANCE APPROX 5 OHMS 75 Return to Section TOC Return to Master TOC Located on front of fan baffle near top of machine 75A 110 279 7 6 I 28 7 1 7 9 214 17 14 218 Relay CR1 and 04 on fron baffl
300. n the P1 plug so it can not make elec trical contact with any other conductor or chassis ground Perform the following resistance tests shown in the following table Be very careful not to damage or spread any of the connection pins in the Amphenol receptacle See Table F 4 If the measured resistance does not meet values specified check for damage dirt or moisture contamination in the Amphenol receptacles and the P1 Molex plug Check for damaged or grounded wiring 7 9 10 If the resistance values are found to be too low due to contaminated electrical compo nents in the Amphenol harness assembly Try removing the contamination and drying the components completely If the resistance values are still too low replace the Amphenol harness assembly If the values are incorrect for the last two tests in the table Pin C to Pin D check the welding terminal switch and the wiring con nected to that switch See the wiring dia gram Repair any faulty connections or replace the switch if necessary Plug P1 back into the Control Pc board Perform the Case Cover Replacement Procedure RANGER 305D 80 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 olg 512 212 515 43 o o a Return to Section TOC Return to Master TOC F 81 F 81 TROUBLESHOOTING amp REPAIR REMOTE RECEPTACLE RESISTANCE TEST contin
301. n to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC o 0 5 MAINTENANCE FUEL SYSTEM SERVICE At the end of each day refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for expansion Use only fresh No 2 grade DIESEL fuel Do not use kerosene the Engine Operators Manual for instructions on replacing the fuel filter BLEEDING THE FUEL SYSTEM You may need to bleed air from the fuel system if the fuel filter or fuel lines have been detached the fuel tank has been run empty or after periods of long storage It is recommended that the fuel shutoff valve be closed during periods of non use For Code 10926 11121 The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that functions when the electric fuel pump is actuated It is generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system For Code 11888 11275 The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that helps purge the air from the mechanical fuel pump sys tem Itis generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system Operate the prim
302. n to Section TOC Return to Master TOC olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 76 TROUBLESHOOTING amp REPAIR Procedure Unplug P7 from control board see control Inner connection diagram and visually check the plug and attached wiring for damage cor rosion improperly seated or damaged con tact pins P7 will remain unplugged for fol lowing test Set the mode switch in the CC Stick posi tion Test the resistance between each of the leads in P7 and a good clean chassis ground connection Be very careful that the connec tion pins in P7 are not damaged or spread out The resistance should be very high A read ing of 500 000 500 ohms or higher is acceptable 10 CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST continued TEST PROCEDURE Turn the engine off Perform the Case cover Removal 7 If the resistance is lower than 500k Ohms replace the potentiometer and mode switch plug and lead assembly or replace the defec tive component within the assembly See wiring diagram Perform the resistance tests per Table I
303. nction Test eene enne nnne nnn nnn nnns F 61 Chopper Module Resistance F 65 Weld Control Board PWM Gate Signal Test sss F 69 Weld Control Feedback 002020 0 enne nnne nennen nennen nen F 71 Control Potentiometer and Mode Switch Resistance F 75 Remote Receptacle Test 79 Replacement Procedures 83 Output Rectifier Bridge and Choke Removal and F 83 Chopper Module Removal F 87 e Engine Stator Rotor Removal and F 91 5 o i Oscilloscope Wayvelortms reete F 97 Normal Open Circuit Voltage Waveform 120 VAC F 97 Normal Open Circuit Voltage Waveform Stick seen F 98 a Normal Weld Voltage Waveform Stick F 99 2 Normal Open Circuit Voltage Waveform Wire CV F 100 Normal Weld Voltage Waveform Wire CV F 101 Retest
304. nected for negative polarity To change polarity shut the welder off and reverse the electrode and work cables at the Ranger 305D output terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the input cable from the K626 XX Input Cable Assembly to the 14 pin amphenol on the Ranger 305D and the input cable plug on the LN 25 4 Set the VOLTMETER switch to or depend ing on the polarity chosen 5 Set the MODE switch to the CV WIRE position 6 Place the IDLER switch in the AUTO or HIGH position as desired A CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control cir cuit may be damaged The engine governor setting is preset at the factory do not adjust above RPM speci fications listed in this manual 7 Place the WELD TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire feed speed and voltage at the LN 25 9 Set the ARC control to 0 initially and adjust to suit FIGURE C 3 Ranger 305D LN 25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM 14 PIN AMPHENOL TO WORK TO LN 25 INPUT CABLE PLUG K626 XX INPUT CABLE ASSEMBLY ELECTRODE CABLE TO WIRE FEED UNIT RANGER 305D LINCOLN 5 Return to Sec
305. ng assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the chopper module is functioning properly and receiving the correct input from the output rectifier and control PC board This test can only provide meaningful results if the machine is producing normal AC auxiliary output Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Digital Multi meter Frequency counter or digital multi meter with frequency counter function Wiring diagram Control Inner Connection diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 5 Return to Section TOC Return to Master TOC Q p 0 5 62 TROUBLESHOOTING amp REPAIR CHOPPER MODULE FUNCTION TEST continued FIGURE F 17 POWER MODULE CONNECTIONS B8 B7 HL W4 HL W11 51302 51301 TEST PROCEDURE 1 Perform the Case Cover Removal Procedure Make sure that there is nothing plugged into either of the Amphenol receptacles Place idle switch the HIGH position Place the mode switch in the CC STICK position Place the Welding Terminal switc
306. ng at the correct speed RPM during both HIGH and LOW idle conditions You can check RPM using a strobe tach a frequency counter or a vibratach Directions for adjusting the throttle to the correct RPM are given MATERIALS NEEDED Miscellaneous hand tools and metric wrench set High visibility marker Strobe tach frequency counter or vibratach RANGER 305D LINCOLN F 29 30 30 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 5 STROBE MARK LOCATION ENGINE SPEED CONTROL LEVER Return to Section TOC Return to Master TOC FAN HUB STROBE TACH MARK Return to Section TOC Return to Master TOC TEST PROCEDURE 6 Direct the strobe tach light on the fan hub that had been marked earlier and synchro nize the light with the rotating mark See the strobe tach manufacturer instructions The tach should read between 3625 and o 0 5 Strobe Tach Method 1 Turn the engine off o 2 5 2 5 2 open the top and right side engine service 3675 RPM 7 Move the idle switch to the AUTO IDLE 3 Place a highly visible mark on the engine position and wait for the idle solenoid to cooling fan hub See Figure F 5 energize and the engine RPM to drop and 4 Connect the strobe tach according to the manufacturer s instructions 8 Synchronize the strobe tach
307. ng the engine If the Engine Protection or Battery Charging lights do NOT turn off shortly after start ing the engine stop the engine immediately and determine the cause IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the high idle speed controlled by the engine governor 2 In the AUTO position the idler operates as follows When switched from HIGH to AUTO or after starting the engine the engine will operate at full speed for approximately 12 seconds and then go to low idle speed RANGER 305D LINCOLN 5 5 OPERATION When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed When welding ceases the AC power load is CV WIRE mode In this mode turning the ARC CONTROL clock wise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with a setting of 0 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 5 2 5 Return to Section TOC Return to Master TOC 0 5 turned off a fixed time delay of approximately 12 seconds starts If the welding or AC power load is
308. nses Weld Output 13 3 8 14 J316 25 J 3 9 23 3 10 8325 OHM lt E from Current Feedback Shunt 2045 61 L 206S J62 12088 J315 Control board common is ROTOR FLASHING to activate idler 2 1 200N VIA CIRCUIT t welder positive output WIRE FEEDER sh 5 02044 BREAKERS POWER 040 76 47 4 Svich closed for high WELD CONTROL 3 14 252 SWITCH 2 TURNS THRU 75 75 PC BOARD 3 7 251 FERRITE wv 2 TO AMPHENOL 2 VOLT AC Es 77 1 11 PNGAl POWER FOR TO AMPHENOL REMO 1 25V POT 114 LD TERM SW ROTOR FELD CIRCUIT CON TO AMPHENOL 1 Choke is beneath bearing end THRU TERMINAL Lg Of generator on support Open CircuitVolts Mi 2TURNS 7 CC 58 THRU TWISTED D3 locatal on rear of fan baffle on left side of machine A B C 400 VAC HE SLIP RINGS BS 200 230 VAC 1 PH E 115 VAC 1 PH 200A 50 V DC CENTER TAP AN AND lt 41 o AMPHENOLS LOW IDLE SOLENOID HOLD COIL 0V LOW IDLE ARC VOLTAGE FEEDBACK SIGNAL 2 5 215 42 VOLT AC 15V LOW IDLE TO PULL COILBOARD 42 0v REVOLVING FIELD FIELD RESISTANCE APPROX 5 OHMS 75 Return to Section TOC Return to Master TOC Located on front of fan baf
309. nt taken when the engine was not running proceed with the following tests Turn off the engine disconnect the meter from the battery and open the engine access door on the left side of the machine 10 11 12 13 14 15 OIL PRESSURE SWITCH Make sure the idle switch is still in the high position start the engine and allow it to run at high idle speed for about 15 to 30 seconds Place the negative meter probe on a good chassis ground or the negative battery termi nal Place the positive meter probe on the battery terminal on the back of the alternator Lead 209 See Figure 8 See Wiring Diagram The meter should read about 13 7 to 14 2 VDC Move the positive probe to the IGN terminal on the back of the alternator Lead 9210C See Figure F8 The meter should read about 13 7 to 14 2 VDC If the meter reads correctly check the con nections between the alternator and the bat tery See wiring diagram If the voltage at both of the above test points reads the same or less than the battery volt age measurement taken when the engine was not running the alternator is defective Repair or replace it If battery voltage is present at the battery ter minal of the alternator but not at the IGN terminal check the run stop switch and the wiring connecting the IGN terminal to the Switch See Figure F8 RANGER 305D LINCOLN 9 F 36 37 37 TROUBLESHOOTING amp REPAIR B
310. nual Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if th rotor winding is open shorted or grounded Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Ohmmeter Analog type meter required for dynamic resistance test Wiring Diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 0 5 40 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE AND GROUND TEST STATIC continued FIGURE F 9 ROTOR BRUSH LEADS SLIP RINGS BRUSHES TEST PROCEDURE Turn the engine off Perform the Case Cover Removal dure Locate and label the four leads from the rotor brush holder assembly See Figure F 8 Using the needle nose pliers remove the leads This will electrically isolate the rotor windings Using the ohmmeter check the rotor winding
311. o 2 0 5 34 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST continued FIGURE F 7 PLUG S PIN LOCATION IDLE SOLENOID CONNECTOR LEAD ENTRY VIEW TEST PROCEDURE 1 2 3 Turn the engine off Open the right side engine service access door Locate the idler solenoid mounted on the fuel injection pump illustration in Fuel Solenoid Test Locate and unplug harness connection P J 72 Cut any necessary cable ties See Wiring Diagram Using the volt ohmmeter check the pull in coil resistance pins 3 and 4 black wire to white wire The normal resistance is less than 0 5 ohms Check the hold in coil resistance pins 3 and 2 black wire to red wire The normal resistance is approxi mately 12 to 15 ohms Check the resis tance between pin 3 black wire and a clean unpainted chassis ground The resistance should be very high 500 000 Ohms or more If any of the above resis tance values are incorrect the solenoid may be faulty Replace See Figure 7 215 TO CONTROL P C BOARD PULL COIL P C BOARD IDLE SOLENOID WIRING HARNESS CONNECTOR LEAD ENTRY VIEW Using the external 12VDC supply apply 12VDC to the pull in coil leads at pins 3 and 4 black wire to white wire The sole noid should activate REMOVE THE VOLTAGE IMMEDIATELY to avoid dam age to the unit Apply 12VDC to the hold in coil at pin 3 black wire and pi
312. o Master TOC B 7 BREAK IN PERIOD Any engine will use a small amount of oil during its break in period For the diesel engine on the Ranger 305D break in is about 50 running hours Check the oil every four hours during break in and change both oil and oil filler at 50 hours of operation Change the oil every 75 hours thereafter and the oil filter every 150 hours For more details see the Maintenance section of this manual During break in subject the Ranger 305D to moderate loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes STICK WELDING The Ranger 305D can be used with a broad range of DC Stick electrodes The MODE switch provides two stick welding settings as follows OPERATION B 7 Constant Current CC STICK Welding The CC STICK position of the MODE switch is designed for horizontal and vertical up welding with all types of electrodes especially low hydrogen The OUTPUT con trol dial adjusts the full output range for stick welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the number from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CON TROL be set to the minimum number without electrode sti
313. o Section TOC Return to Master TOC ojo 5 5 5 5 FORWARD BIAS 8 2 813 JE DC A FORWARD BIAS 212 Low Resistance DC A FORWARD BIAS Low Resistance DC A FORWARD BIAS Low Resistance C AC2 DC REVERSE BIAS High Resistance DC REVERSE BIAS High Resistance Return to Section TOC Return to Master TOC SUOI 29UUO JeUlUlJ9 DC A REVERSE BIAS High Resistance DC A REVERSE BIAS High Resistance A REVERSE BIAS High Resistance 11 Reconnect all leads 12 Perform the Case Cover replacement Procedure RANGER 305D LINCOLN C1 C2 C3 High Resistance C1 C2 C3 Return to Section TOC Return to Master TOC F 60 61 61 TROUBLESHOOTING amp REPAIR CHOPPER MODULE FUNCTION TEST WARNING 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot i
314. odes The following information can be used as a guide by the electrician for most applications Refer to the connection diagram in Figure A 2 RANGER 305D LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 9 16 8153 43 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC A 9 1 A 9 INSTALLATION Install the double pole double throw switch between the power company meter and the premis es disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary steps to assure load is limited to the capacity of the Ranger 305D by installing a 50 amp 240 VAC double pole circuit breaker Maximum continuous rated load for each leg of the 240 VAC auxiliary is 40 amperes Loading above the rated output will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equip ment and may result in overheating of the Ranger 305D engine and or alternator windings 3 Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the double pole circuit breaker using No 6 4 conductor cable of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit or as part number T12153 9 Plug this cable into th 50 amp 120 240 VAC recep tacle on the Ranger 305D
315. oids pull coil PC board engine pro tection relay fuel gauge and sender alternator and all the wiring connecting these compo nents Look for any damaged or out of place wiring that may be in contact with other conductors or chassis ground See the wiring diagram Perform the Idle Solenoid Test Perform the Solenoid Test The Pull coil PC board may be defective Disconnect lead 232 from terminal B1 of the pull coil PC board and insulate it or posi tion it so it does not come into contact with chassis ground or any other conductor Start the engine if the engine continues to run and the CB7 circuit breaker does not trip the pull coil PC board is probably defective and should be replaced CAUTION If for any reason you do not understand the test procedures 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 RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o He 0 5 17 17 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will not develop full power
316. on left side of machine TO AUX 120 SLIP RINGS 240 vac lt OUTLETS novac Rotor Flashing 12 volts 0 5 amps until generator builds up then 450 volts 0 amps 1303 8 1403 16 253 9 23 J 3 10 2045 61 121 2004 ROTOR FLASHING R3 located m front of fan baffle on left side nea bottom of machine 50 V DC C3 L 800uf 5 25 OHM NDE 2004 ANVVV 6 Return to Section TOC Qjo o EE s HIE lt gle ES ply 9 ojo Return to Master TOC 2065 6 2 ARC VOLTAGE FEEDBACK SIGNAL 10V 0 10 V 7 71 76 7 4 OV 5 10 na Es AMPHENOL RENO LL 25 14 75A 1 10 279 7 6 3 28 7 7 271 7 8 TOROID SENSES AC POWER TO ACTIVATE IDLER 260A 34 261A 33 Located on wiring behind receptacles Control board circuits associated with 2 ae part 5K 23 12088 3 15 Control board common is at welder positive output and shunt WELD CONTROL PC BOARD PIN 64107 1 Located on front of fan baffle near top of machine 41010 05 10 10 LOW IDLE SOLENO D HOLD COIL 0V 9 LOW IDLE 2 5 215 15V LOW IDLE 2 4 404 O PULL COILBOARD 3 14 252 2V 3 251 IDLE Swich closed far high idle R SWITCH dm AMP
317. on when connected to the 14 pin amphenol receptacle Machine operates normally in CC STICK mode and has normal AC auxiliary output Check circuit breaker CB1 if using a 115 120 VAC wire feed er Check CB8 if using a 42 VAC wire feeder Reset circuit breaker if tripped Check the Amphenol receptacle for damaged corroded or dirty contact pins The wire feeder control cable may be defective The wire feeder may be defec tive Use a volt meter to check for the presents of supply voltage at the 14 pin Amphenol receptacle 115 120 VAC power is supplied through pins A and J 42 VAC power is supplied through pins 1 and K NOTE Be careful that meter probes do not deform or dam age the contact pins in the Amphenol receptacle Perform the STATOR VOLT AGE TEST CAUTION 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 RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC o 2 0 5 13 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of thi
318. ontribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION 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 RANGER 305D LINCOLN B F 2 Return to Section TOC Return to Master TOC Return to Section TOC O o Fle 5 5
319. or that product If shielding gas is used check that the correct gas is being used and that the gas flow is set correctly Check the gas system for damaged pinched or leaking hoses The weld cables may be coiled or wrapped around metal reels racks This can cause exces sive electrical inductance in the weld circuit Try welding after uncoiling the cables or discon nect the existing weld cables and attach a set of adequately sized short test cables TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check that the weld circuit is not grounded With the engine off check the resistance between chassis ground and the weld output terminals resis tance should be very high a reading of 500 000 500 ohms or higher is acceptable The weld control system may be grounded or malfunctioning Perform the and the 3 The Chopper module may be defective Perform the Chopper Module Resistance CAUTION 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 RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0
320. or align ment of the stator frame assembly NOTE If the stator had been removed due to a bearing or tolerance ring failure the bearing seat in the stator frame assembly must be checked for a possible oversize condition before reassembly 2 Apply a thin film of grease to the tolerance ring and insert it into the bearing seat cavity of the stator frame assembly Use the hoist along with lifting straps or chains to lift the stator frame assembly Carefully align the stator to the rotor and slide the stator frame over the rotor Be very care ful not to damage either the stator or rotor Align the rotor shaft bearing to the tolerance ring also align the screw holes in the mount ing flange Insert the 8 screws with lock washers through he stator flange and into the engine mounting flange It may be necessary to tap the stator with a mallet to partially seat the bearing in order to get the screws started Begin tightening the screws evenly to draw the stator onto the engine mounting flange Bolts stator frame to engine 20 to 22 ft lbs Be very careful that the flange and bearing are seated properly and do not bind Tighten the stator flange screws to 20 to 22 Ft Lbs 6 10 11 12 Check the air gap between the stator and the rotor A 017 thick 1 2 wide feeler gauge should pass between the stator and rotor Install the flat washer and then the blower fan on the rotor shaft The fan should be hand tightened on
321. ould be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rectifier is grounded or if there are any failed diode groups NOTE This test will not be able to detect individual open diodes within a group Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Analog Ohmmeter or diode tester For testing diodes Ohm meter any type for ground test olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 2 0 5 58 1 TROUBLESHOOTING amp
322. output rectifier bridge and the choke in the Ranger 305D MATERIALS NEEDED Miscellaneous hand tools Electrical joint compound Dow Corning 340 Lincoln T12837 Return to Section TOC Return to Master TOC olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 815 4353 Return to Section Return to Master TOC Return to Master TOC F 84 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACE MENT continued REMOVAL PROCEDURE Turn the engine off Remove negative battery cable 3 Perform the Case Cover Removal pro 4 Perform the Chopper Module Capacitor Discharge procedure Remove the four screws holding the case front to the base of the machine Remove all plugs and leads from the weld control and pull coil PC boards Be sure to mark the leads and plugs so they can be properly re connected See wiring dia gram Remove the screws holding the D4 diode bridge and the CR1 engine protection relay to the center baffle assembly and allow these components to remain attached to the case front wiring Remove any additional wring and cable ties as needed Carefully mark leads for accurate re connection Swing the case
323. over and push by hand the filter further into the air cleaner and try again The cover should go on with no extra force Never use the latches on the cover to force the filter into the air cleaner It is tempting to assume the cover will do the job of seating the filter but it will not Using the latches to push the filter in could cause damage to the housing and will void the warranty RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo o a gt 23 cic 515 ply o ajo Return to Section TOC Return to Master TOC Return to Master TOC D 6 A WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result A CAUTION Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn from the engine AIR CLEANER The diesel engine is equipped with a dry type air filter Never apply oil to it Service the air cleaner as follows MAINTENANCE D 6 COOLING SYSTEM A WARNING 2 COOLANT can burn skin Do not remove cap if radiator is hot Check the coolant level by observing the level in the radiator and recovery bottle Add 50 50 antifreeze water solution if the level is close to or below the LOW mark Do not fill above the FULL mark Remove radiator cap and add coolan
324. ower and may be in need of service NOTE Normal Full load engine speed should be about 3500 RPM 2 Inspect and if necessary ser vice the brushes and slip rings per the Brush and Slip Ring Service brocedure 3 Perform the Rotor Voltage 4 Perform the Stator Voltage A CAUTION 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 RANGER 305D LINCOLN B 6 6 TROUBLESHOOTING amp REPAIR 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 Make sure the machine is prop 1 The engine RPM may be too welding arc is cold The engine erly set for the electrode and low Perform the runs normally and the auxiliary process being used Check Throttle Adjustment test Return to Section TOC Return to Master TOC Return to Section TOC o 22 9 1 0 iz g 8 cic 5 5 4353 o o Return to Section TOC Return to Master TOC Return to Master TOC power is normal electrode size mode switch set ting amps or voltage setting If gas is used make sure the cor rect type of gas is
325. pair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This following procedure will aid the technician in removing and replacing the stator and rotor for repair or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Gear puller Hoist chains straps 017 by 5 wide feeler gauge for air gap Rubber plastic or wooden mallet Wooden blocks or equivalent to support engine Right handed thread CT to tighten CCW to loosen olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O o Fle 5 5 PEN 813 4353 oO 1 Return to Section TOC Return to Master TOC Return to Master TOC F 9
326. pecific to your code is pasted inside one of the enclosure panels of your machine LINCOLN RANGER 3050 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC o HE lt gle 5 43 oO 9 ojo Return to Section TOC Return to Master TOC Return to Master TOC G 7 ELECTRICAL DIAGRAMS G 7 WIRING DIAGRAM ENTIRE MACHINE CODES 11189 11314 G4572 1
327. per module mounting screws may need to loosened or removed so the chopper mod ule can be positioned to provide additional clearance If the chopper module screws are removed the chopper module will need to be supported 26 27 28 29 30 31 32 Rotate the engine and generator assembly 180 degrees and line up the engine mounting bracket to the rubber engine mounts Be careful that the wiring still attached to the engine does not get damaged Disconnect additional engine wiring and or remove addi tional cable ties if necessary Replace the screws which had been removed from those mounts and tighten Use wooden blocks or other means to securely support the flywheel end of the engine and remove the hoist from the lift bale The generator is now in position for easy removal Remove the plastic blower and flat washer from the rotor shaft by turning the blower counter clockwise It may be necessary to prevent the rotor shaft from turning a small pipe wrench can be used for this purpose DO NOT HOLD THE ROTOR BY THE SLIP RINGS Use the hoist along with lifting straps or chains to support the generator stator assembly and then remove the screws attaching it to the engine Separate the stator assembly from the engine in most cases two screwdrivers can be used to pry the stator away from the engine Be careful not to damage the mating surfaces of the engine or stator frame assem bly If the bearing i
328. plication involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b AUG 06 Return to Master Return to Master TOC o 9 lt 5 Return to Master TOC SAFETY WELDING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extin
329. ply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal Again do NOT use the service cover to push the filter into place When the filter in is place put the service cover back on making sure the Vacuator Valve points down Inspect the Vacuator Valve for cracks or dust hang ups to insure that it is functioning properly Re fasten the latches Check Connections for Tight Fit Make sure that all clamps bolts and connections in the entire air intake system are tight Check for holes in piping and repair if needed Clean Sealing Surface of the Outlet Tube Use a clean cloth to wipe the sealing surface Dust on the outside diameter of the outlet tube could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Clean the Inside of the Outlet Tube Carefully wipe the inside of the outlet tube with a clean cloth Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers says that it takes only a few grams of dirt to dust an engine Be careful not to damage the sealing area on the tube making certain it is completely into the air cleaner housing before latching the cover in place If the cover hits the filter before it is fully in place remove the c
330. r 6 Pin Connector ojo 2109 6 9 trip current trip current 8 8 1 Phase 15 Amp x 5 1 Phase 15 Amp x 4 1 Output rating in watts is equivalent to volt amperes at unity power factor Output 2 To top of enclosure add 152mm 6 to top of exhaust elbow 5 2 voltage is within 10 at all loads up to rated capacity When welding avail 8 Engine warranty may vary outside of the USA See Engine warranty for details D 9 able auxiliary power will be reduced 4 Center Tapped to ground 3050 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 gt 815 43 o 1 Return to Section Return to Master TOC Return to Master TOC 4 4 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated area
331. ranks the engine and powers the fuel solenoid pull cord The engine starts builds oil pressure and spins the engine alternator which begins charging the battery The charging system indicator light code 10926 and the engine protection indicator will turn off When the engine protection light turns off the fuel pump codes 10926 and 11121 and fuel solenoid are receiving power from the engine protection circuit The operator can now release the glow plug button The engine protection system now monitors the oil pressure and coolant temperature sensors If either sensor detects a fault condition the engine protection indicator will light and power will be interrupted to the fuel solenoid immediately shutting the engine off NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 ENGINE IDLE SYSTEM IDLE SWITCH amp IDLE SOLENOID IDLE SOLENOID PULL HOLD COIL COIL PULL COIL PC BOARD GLOW PLUG 12V BUTTON BATTERY un ah STOP SWITCH Engine Idle System Idle Switch Operation When the engine is started it operates at high RPM If the idle switch is in the high position 6 23 the automat ic idle system is inactive and t
332. ransistor on the chopper module This test will also verify that the control PC board can turn the PWM gate signal on and off properly Return to Section TOC Return to Master TOC MATERIALS NEEDED Digital Multi meter Frequency counter or digital Multi meter with frequency counter function Wiring Diagram Control Inner Connection diagram olo 515 9 16 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 0 5 70 70 TROUBLESHOOTING amp REPAIR WELD CONTROL BOARD PWM GATE SIGNAL TEST continued TEST PROCEDURE 1 Perform the Case Cover Removal 2 Unplug any device that may be attached to either the 6 pin or the 14 pin Amphenol receptacles 3 Place the idle switch in the HIGH IDLE position 4 Place the mode switch in the CC STICK position 5 Place the Weld terminals switch in the WELD TERMINALS ON position 6 Start the engine and let it run and stabilize at high idle RPM 7 Locate plug P3 on the control PC board See Control Inner Connection diagram 8 Use the frequency counter to test for 20kHz PWM gate signal between leads 723 4 10 and 25
333. receptacle Return to Section TOC Return to Master TOC If the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equip ment is providing at least 80 volts to the recep tacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI receptacle This will assure normal GFCI oper ation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Return to Section TOC Return to Master TOC Push the Test button located on the GFCI receptacle The night light or other product should go OFF Push the Reset button again The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not work ing properly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if neces sary or replace the device olo O o Fle 5 5 9 815 4353 oO 1 Return to Section Return to Master TOC RANGER 305D LINCOLN 5 0 10 2
334. resistance across the slip rings See Figure F 9 Normal resistance is approximately 4 7 ohms 77 degrees Fahrenheit 25degreesC Measure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpaint ed chasms ground The resistance should be very high at least 500 000 500k ohms If the test does not meet the resistance spec ifications then the rotor may be faulty and should be replaced If this test meets the resistance specifica tions continue testing using the dynamic rotor resistance and ground test RANGER 305D LINCOLN 41 41 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE AND GROUND TEST DYNAMIC Also referred to as flying resistance test 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test checks for faults in the ro
335. rn to Master TOC o 2 5 2 G 5 Return to Section Return to Master TOC o 5 8 THEORY OF OPERATION E 8 FIGURE E 6 IGBT OPERATION MINIMUM OUTPUT 2 48 sec 50 sec Dwell Time MAXIMUM OUTPUT Dwell or Off Time 50 usec PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle Changing the pulse width is known as MODU LATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing shows the minimum output sig nal possible over a 50 microsecond time period The positive portion of the signal represents one IGBT group conducting for 2 microseconds The dwell time off time is 48 microseconds Since only 2 microsec onds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 48 microseconds and allowing only 2 microseconds of dwell time off time during the 50 microsecond cycle the output is maxi mized The darkened area under the top curve can be compared to the are
336. rts See the Maintenance section for details on changing oil 4 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place 5 f the engine is not used for a long period of time every two or three months fill the radiator and run the engine for about five minutes to keep it free from rust Also see your engine Operator s manual Fuel should also be drained when stored for long peri ods or a fuel additive should be used STACKING Ranger 305D machines CANNOT be stacked ANGLE OF OPERATION Engines are designed to run in the level of condition which is where the optimum performance is achieved The maximum angle of continuous operation is 20 degrees in all directions 30 degrees Intermittent less than 10 minutes continuous in all directions If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 12 gallons 45 ltrs RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC O10 Fle 515 gt 5 8 43 21 cc a Return to Section TOC Return to Master TOC Return to Master TOC A 5 INSTALLATION LIFTING The RANGER 3050 weighs approximately 775108 352kg with a full tank of f
337. s Section G Parts ETE ER Code 10926 P 417 EM Code 11027 11039 P 479 M Code 11121 11188 11275 P 492 Code 11122 11123 11189 11190 11314 11315 P 494 RANGER 305D LINCOLN 9 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION o E 5 Installation Section A E Technical Specifications ee eene n enar dde ern ad edens A 2 A 3 9 sies A 4 Location ANd 4 Ej 4 SACKING A 4 EAT 4 5 High Altitude Operation ares de 5 High Temperature Operation 5 8 Cold Weather Starting and oiia 5 p tms 5 Pre Operation Engine Service cci a b ua n A 6 9 6 5 IC A ANEA E E A 6 c Engine Cooling System te Drei v d A 6 Battery Connections 6 Outlet Pipe 6 Spark Arrestat 1 6 High Frequency Generators for TIG Applications A 6 5544 5 425552 RE A 7 8 Electrical Output Connections eite
338. s Return to Section TOC Return to Master TOC ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 2400 2500 High Idle 3625 3675 3350 3750 WELDER DC STICK OUTPUT ARC control 10 Mode Selector Output Control Open Circuit Load Volts Load Amps Switch Volts Stick CC 55 60 27 32 295 325 Return to Section TOC Return to Master TOC WELDER CV WIRE OUTPUT Control 10 Selector d V TOUCH START TIG Control 10 Voltage 10 15 20 24 240 255 TIG Minimum 10 15 18 28 o 22 olg iz 8 8 5 5 43 o o AUXILIARY POWER OUTPUT 240 Volt Receptacle 120 Volt Receptacles Load Volts Load Amps Load Volts Load Amps Voltage Voltage 240 270 216 240 40 45 120 135 115 130 18 22 Upper limit reflects cold machine voltage will be below 132 264 for machine at normal operating temperature 42 VOLT WIRE FEEDER POWER 42 46 40 44 7 0 9 0 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Section 6 1 Section 6 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION o E ZZ Electrical Diagrams ariin Section G 2 Wiring Diagram Entire Machine Code 10926 04250 G 2 Wiring Diagram Entire Machine Code 11121 4571 G 3 Wiring Diagram Entire Mac
339. s binding in the tolerance ring it may be necessary to use a gear puller to Separate the stator frame from the engine 33 Carefully side the stator assembly off the rotor RANGER 305D 94 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section TOC Return to Master TOC o 0 5 95 95 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 23 DISC RING LOCATION COUPLING DISC Removing the Rotor 1 Use the hoist and lifting straps to support the rotor assembly 2 Remove the screws and disc clamping bars from the rotor coupling disc and remove the rotor NOTE earlier machines used three 0 31 thick clamping bars and later models use six 0 14 thick camping bars arranged in three sets of two bars each 3 If the rotor is to be replaced remove the screws rotor clamping ring and coupling disc from the rotor hub Replacing the Rotor 1 Whenever the rotor and stator are separat ed it is highly recommended that a new bearing and tolerance ring be installed when the rotor and stator are reassembled 2 Examine the rotor coupling disc clamping ring clamping bars screws lock washers and the engine flywheel Make sure that all of the parts are clean and in good condition CLA
340. s manual PROBLEMS SYMPTOMS An Across the arc type wire feeder does function when connected to the weld output of the machine The machine operates normally in CC STICK mode and has normal AC auxiliary output POSSIBLE AREAS OF MISADJUSTMENT S MISC WELD ISSUES Check that the welding terminal switch is in the WELD TERMI NALS position Check that the WELD MODE switch in the correct position for the process being used typical ly CV WIRE mode Check for poor weld cable con nections between the feeder and the welder output terminal and between the work and the other weld output terminal Check that the wire feeder s work sensing lead is properly connected to the work piece and is in good condition The wire feeder may be defec tive TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Use a volt meter to check for the presents about 58 VDC open circuit voltage OCV across the output studs of the machine If the OCV is low there may be a problem with the mode switch Perform the If there is no see the trou bleshooting section for No welding output in any mode CAUTION If for any reason you do not understand the test procedures 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 RANGER 305D LINCOLN
341. s or vent exhaust outside Do not set anything near the engine 3 X MOVING PARTS can injure Do not operate with doors open or x guards off m Stop engine before servicing Keep away from moving parts See additional safety information in the front of this manual Only qualified personnel should install use or ser vice this equipment LOCATION AND VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Allow a mini mum clearance of 2 feet 0 6m from the case back and 16in 406mm from either side of the base to a vertical surface Also locate the welder so that the engine exhaust fumes are properly vented to an out side area STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 If you will be storing the machine for over 30 days you should drain the coolant from the radiator Open the cock at the bottom of the radiator and remove the pressure cap so that the coolant drains completely Attach a note that says WATER on the radiator 3 While the engine is still warm drain the oil and refill with fresh 10W30 oil Change the oil filter Run the engine for about five minutes to circulate oil to all the pa
342. t non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page 11 15 11 007 Section Section ACCOSSONIOS Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagram
343. t the control PC board If the voltage reads 0 or very near 0 Check for damaged insulation at leads 2 and 4 also check for a shorted welding terminal switch or damaged or contaminated Amphenol receptacle See the wiring dia gram If the above wiring and components are undamaged and functioning properly the control PC board is defective and should be replaced If the voltage reads about 5 VDC and the PWM signal remains the control PC board is defective and should be replaced Perform the Case Cover Replacement RANGER 305D LINCOLN 9 71 71 TROUBLESHOOTING amp REPAIR WELD CONTROL FEEDBACK TEST 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the weld control PC board is receiving accurate current and voltage feedback from the weld circuit Return to Master TOC T
344. t to radiator Fill up to the top of the tube in the radiator filler neck which includes a connecting hose coming from the thermo stat housing To drain the coolant open the petcock at the bottom of the radiator Open the radiator cap to allow complete drainage Tighten the petcock and refill with a 50 50 antifreeze water solution Use an automotive grade low silicate ethylene glycol antifreeze The cooling system capacity is 3 85 quarts 3 6L Squeeze upper and lower radiator hoses while filling to bleed air from system coolant Replace and tighten the radiator cap A CAUTION Always premix the antifreeze and clean tap water before adding to the radiator It is very important that a precise 50 50 solution be used with this engine year round This gives proper cooling during hot weather and freezing protection to 34 F 37 C Cooling solution exceeding 50 antifreeze can result in engine overheating and damage to the engine Coolant solution must be premixed before adding to radiator Periodically remove the dirt from the radiator fins Periodically check the fan belt and radiator hoses Replace if signs of deterioration are found TIGHTENING THE FAN BELT If the fan belt is loose the engine can overheat and the battery lose its charge Check tightness by pressing on the belt midway between the pulleys It should deflect about 0 28 to 0 35 in under a load of 22 Ibs 7 to 9 mm 10Kg RANGER 305D LINCOLN 9 Retur
345. tach the leads BEFORE starting the engine 4 Start the engine and run it at high idle speed 3650 RPM The resistance should read approximately 5 ohms at 77 degrees Fahrenheit 25 deg C 4 Shut off engine and move one of the ohm meter leads to a good clean chassis ground 5 Restart the engine and run it at high idle speed 3650 RPM The resistance should be very high at least 500 000 500k ohms 6 If the resistance readings differ significantly from the values indicated re check the brushes and the brush spring tension If the brushes and slip rings are good replace the rotor 7 If all testing is finished perform Case Cover Replacement procedure NOTE The resistance of the windings will change with temperature Higher temperatures will produce higher resistance and lower tem peratures will produce lower resistance RANGER 305D LINCOLN 5 43 43 TROUBLESHOOTING amp REPAIR ROTOR VOLTAGE TEST WARNING 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 or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unab
346. tage generated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 1 millisecond in time The machine was loaded with a resis tance grid bank to 300 amps at 27 volts o Fle 5 5 9 gt 813 43 o 1 NOTE Scope probes connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 100 100 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV TAP MAX CONTROL POT HIGH IDLE NO LOAD Return to Section TOC Return to Master TOC UN H HHHCHHTHHHHHHH HH 0 volts Return to Master TOC Return to Section TOC 50V 5ms This is the typical DC open circuit out put voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time NOTE Scope probes are connected at weld output terminals Fle 5 5 gt 8 43 21 a SCOPE SETTINGS Volts Div 50V
347. tank Remove the fuel cap slowly to release pressure OIL The RANGER 305D is shipped with the engine crankcase filled with high quality SAE 10W 30 Oil that meets classification CG 4 or CF 4 for diesel engines CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 50 running hours Refer to the engine Operator s Manual for specific oil recom mendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the Engine Operator s Manual for more details on the proper service and maintenance intervals FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh fuel The capacity of the fuel tank is 12 gallons 45 4 liters When the fuel gauge reads empty the tank contains approximately 2 gallons 7 6 liters of reserve fuel NOTE Close the fuel shutoff valve located on the pre filter if not running the welder for extended peri ods ENGINE COOLING SYSTEM A WARNING HOT COOLANT can burn skin not remove cap if radiator is hot engine and radiator or this machine are filled with a 5096 mixture of ethylene glycol based permanent type antifreeze See the Maintenance and the engine Operation s Manual for more information BATTERY CONNECTION WARNING BATTERY ACID CAN BURN
348. the VOLTMETER switch to or depend ing on the polarity chosen 5 Set the MODE switch to CV WIRE position 6 Place the IDLER switch in the AUTO or HIGH position as desired CAUTION An increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control cir cuit may be damaged The engine governor setting is preset at the factory do not adjust above RPM speci fications listed in this manual 7 Place the WELD TERMINALS switch in the REMOTELY CONTROLLED position 8 Adjust wire feed speed and voltage at the LN 742 9 Set the ARC control to 0 initially and adjust to suit FIGURE C 7 Ranger 305D LN 742 CONNECTION DIAGRAM 14 PIN AMPHENOL K619 CONTROL CABLE TO WORK TO LN 742 INPUT CABLE PLUG ELECTRODE CABLE TO WIRE FEED UNIT RANGER 305D LINCOLN 5 C 10 NOTES RANGER 305D LINCOLN amp C 10 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes Section 0 1 Section 0 1 TABLE CONTENTS o e MAINTENANCE 5 Section D Safety
349. the weld control circuitry by means of the output control and arc control poten tiometers and the mode switch These operator inputs are used by the microprocessor together with pre pro grammed internal parameters current feedback from the shunt and voltage feedback from the output studs to control the IGBT s via the PWM signal discussed ear lier RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O10 Fle 55 9 16 gt 813 4353 o o 1 Return to Section TOC Return to Master TOC Return to Master TOC E 6 THEORY OF OPERATION Remote output control The Weld control PC board automatically detects when a remote control potentiometer is connected to either of the Amphenols In CC STICK DOWN HILL PIPE or CV WIRE modes the front panel out put control is disabled when a remote control device is connected In TOUCH START TIG mode the front panel output control potentiometer is used to set the maximum output value The remote potentiome ter varies the output from minimum to maximum value 56 by the front panel control Electronic Output Contactor The operator also has the ability to control when power is delivered to the output studs This is accom plished by signaling the control PC board when to send the PWM signal to the chopper module Turning the PWM signal on or off has the same effect as acti vating or deactivating an output
350. tion TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 ACCESSORIES CONNECTION OF THE LN 25 TO THE RANGER 305D ACROSS THE ARC WITH K857 REMOTE CONTROL SEE FIGURE CA 1 Shut the welder off 2 Connect the electrode cable from the LN 25 to the gt terminal of the welder Connect the work cable amp m to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 4 shows the electrode connected for negative polarity To change polarity shut the welder off and reverse the electrode and work cables at the Ranger 305D output terminals 3 Connect the K857 Remote Control to the 6 pin amphenol on the Ranger 305D 4 Attach the single lead from the LN 25 to the work using the spring clip on the end of the lead This is only a sense lead it carries no welding current 5 Place the IDLER switch in the AUTO or HIGH position as desired CAUTION If you are using LN 25 without an internal contactor the electrode will be HOT when the Ranger 305D is started 6 Set the MODE switch to CV WIRE 7 Setthe WELD TERMINALS switch in the WELD TERMINALS position 8 Set the VOLTMETER switch to or depend ing on t
351. tor winding while these windings are being stressed by the mechanical forces encountered during normal operation Return to Section TOC Return to Master TOC MATERIALS NEEDED Miscellaneous hand tools Ohmmeter Analog type meter required for dynamic resistance test Wiring Diagram Note This test is best performed with a good quality analog type ohmmeter Many digital meters will not provide stable or accurate Resistance readings while the rotor is spinning olo O o Fle 5 5 9 gt 8153 43 oO 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 G 5 Return to Section TOC Return to Master TOC o 0 5 42 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE AND GROUND TEST DYNAMIC continued TEST PROCEDURE This test requires that the brushes and slip rings are clean in good condition and are properly seated 1 Perform the brush and slip ring service procedure if necessary 2 Insulate the lead wires that had been dis connected from the brushes during the static rotor resistance test Position and secure them so the y cannot become damaged by the spinning rotor 3 Securely attach the ohmmeter leads to the brush terminals Use clips or terminals to at
352. trol wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims RANGER 305D LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o E ci 9 1 0 512 212 e 515 4353 oO ajo Return to Section TOC Return to Master TOC F 4 F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major mechanical or electrical damage is evident POSSIBLE AREAS OF MISADJUSTMENT S POWER OUTPUT PROBLEMS Contact your Authorized Facility Lincoln Service local Field TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department at 1 888 935 3877 No welding output or auxiliary power The engine operates nor mally Check for loose or faulty con nections at any leads cables or cords attached to either the aux iliary output receptacles and or the weld output term
353. ucing 300 amps at 29VDC at a 100 duty cycle The engine is coupled to a brush type alternating current generator This AC output is rectified then controlled by Technology to produce DC current for multi purpose welding applications The Ranger 305D is also capa ble of producing 9 500 watts 10 000 watts peak of AC auxiliary power at 100 duty cycle Battery Engine Engine Protection and Charging System BATTERY The 12VDC battery powers the engine starter motor glow plug circuit engine protection circuit fuel pump codes 10926 and 11121 and fuel solenoid Power is also supplied to other components CHARGING SYSTEM LIGHT CODE 10926 ONLY FLASHING PULL COIL PC BOARD SHUNT Ee POWER Go VO DISPLAY p gt gt WINDING STATOR 120 240 42 VAC WELD CONTROL RUNE AUX WINDING WINDING pasan P C BOARD AMPHENALS IDLE SWITCH OUTPUT MODE WELDING CONTROL TERMINAL WITCH L Starting the engine Starting the engine first requires that the Run Stop switch be in the run position The glow plug button is then pressed and held this preheats the engine to enhance starting and also temporarily provides power to the fuel pump codes 10926 and 11121 and fuel solenoid hold coil The start button is pressed while still holding the glow plug button The start button c
354. ued TABLE F 4 AMPHENOL RESISTANCE TEST OHMMETER OHMMETER READING SWITCH SETTING CONNECTION 2B 500K or Higher 76B to PIN J 31 Resistance should be very low The Ohmmeter should read about the same value as one would get by touching the two meter probes together 500K or Higher 3050 LINCOLN 5 82 5 3050 LINCOLN amp F 82 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes 83 83 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing and replacing the
355. uel 698 Ibs less fuel A lift bail is mounted to the machine and should always be used when lifting the machine WARNING Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For max imum rating derate the machine 2 5 to 3 5 for every 1000 ft 305m Due to new EPA and other local emissions regulations modifications to the engine for high altitude are restricted within the United States and some European Countries Use above 6000 ft 1828 m may be limited due to poor engine performance or excessive exhaust smoke An authorized Kubota engine field service shop should be contacted to determine if any adjust ments can be made for operation in higher elevations locally HIGH TEMPERATURE OPERATION At temperatures above 104 40 Welder output derating is necessary For maximum output ratings derate the welder out put 2 volts for every 50 F 10 C above 104 F 40 C Cold Weather Starting amp Operation The Kubota engine used in the Ranger 305D can be started in temperatures as low as 5 F 15 C At tem peratures be
356. uency counter to check for the presents of a 20 2 PWM sig nal between leads 23 and 25 where they connect to the chopper module PC board olo O o Fle 5 5 9 gt 8153 43 o o 1 Return to Section TOC Return to Master TOC RANGER 305D LINCOLN 5 64 5 3050 LINCOLN H F 64 DOL J91Se N uunjeH 901 J91Se N 01 uunjeH 901 J91Se N UuunjeH 901 J91Se N 01 UuunjeH DOL uonoes uumeg DOL uonoes DOL uonoes uumeg DOL uonoes 65 65 TROUBLESHOOTING amp REPAIR CHOPPER MODULE RESISTANCE TEST WARNING 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 or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the chopper module is shorted This test can only detect some problems in the Power section of the module Problems in
357. uonoes uumeg DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC olo 515 9 16 8 43 21 a Return to Section TOC Return to Master TOC Return to Master TOC F 94 20 21 22 23 24 25 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued The wires connected to the solenoid side of the engine can remain attached in most cases Compress the spring clamp and remove the fuel line from the fuel filter shut off valve Pull the line out of the hole in the engine baffle and then plug the line and the opening in the filter housing to prevent fuel leakage and contamination Remove the fuel return line from the fitting in the top of the fuel tank Plug this line and fit ting as well Remove the engine baffle Attach the hoist to the lift bale and raise the hoist until it just begins to support some of the weight of the generator and engine Remove the two nuts holding the generator to the support bracket and the two screws holding the engine support brackets to the rubber engine mounts Raise the hoist to lift the engine and genera tor assembly just high enough to clear the generator mounting studs The center baffle will need to be gently pushed forward to pro vide clearance between the fan and the Chopper module some cases the Chop
358. used and that the gas flow is set correctly Make sure that the process does not demand more power than the machines able to pro duce If the current seems about right but the electrode easily sticks in the puddle try increasing the ARC CONTROL setting Check for loose or faulty con nections at the weld output ter minals and welding cable con nections Check for adequate connection between the work cable and the work piece The work cable should be attached to clean metal as close to the weld area as practical The work clamp must be in good condition and have adequate spring tension The weld cables may be too long and or too small causing excessive voltage drop between the machine and the arc Connect the machine to a resis tive load bank Connect an accurate ammeter and volt meter to the output of the machine Meters are often built into modern load banks Connect a means of measuring the engine RPM See the recommended methods of measuring engine RPM Place the mode switch in the CC STICK position turn the output control fully clockwise place the idle switch in the HIGH IDLE position Set the weld terminals switch to WELD TERMINALS position Make sure that nothing is plugged into either of the Amphenol receptacles Start the machine and allow the engine to run for about a minute Apply a load with the resistance load bank and a
359. utput terminals and ground stud Output stud covers are provided on code 11275 and above MACHINE GROUNDING 2 Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must Be grounded to the frame of the welder using a grounded type plug or be double insulated WARNING Do not ground this machine to a pipe that carries explo sive or combustible material When this welder is mounted on a truck or trailer its frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle When this engine driven welder is con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local code Figure A 1 RANGER 305D OUTPUT CONNECTIONS
360. ver Removal Examine brushes and slip rings The slip rings brush holder and brushes should be clean and free from oil or grease The brushes should be making good continuous contact with the slip rings The brushes should be of sufficient length and have adequate spring tension Generally the brushes should be replaced if either brush has less than 1 4 remaining before it reaches the end of its travel Spring tension should be sufficient to hold the brushes firmly against the slip rings The brushes should be removed from the brush holder and examined The terminals should be clean The shunt braided lead connecting the carbon brush to the terminal should be in good condition and firmly con nected to the carbon brush and to the con nection terminal If the slip rings are discolored display evi dence of excessive sparking or the brushes have worn prematurely these may be signs of a grounded or shorted rotor Perform the rotor resistance test Check for evidence of sticking brushes Sticking brushes will normally result in th slip rings being pitted and discolored from excessive arcing Another sign of sticking brushes is instability or loss of both weld and auxiliary output but the machine may begin to work properly for a short time after being jarred or moved If there is any evidence that the brushes may have been sticking in the brush hold ers a new brush holder and brush assembly should be installed
361. voltage GROUND SOLENOD SWITCH TEMPERATURE i 12 6 volts at rest ANDFLEL CLOSES ON SWITCH Located next to AMPHENOL 14 volts engine 77RMP LOW OIL CLOSES ON HIGH control board running ENERGIZED PRESSURE TEMPERATURE FORRUN ABOVE 230F 12 VOLT 20 35 OHMS FULL ROPRIETARY 8 CONFIDENTIAL 71150 OCUME NTC ONTAINS PR RIETARY INFORMATION OWNED BY LINCOLNGLOBAL INC A NDMAY NOTBED UPLICATE D COMMU D TO HERPARTIESO USE DF ORANY PU RP OSEWIT HOUTT HEEX PRESS W_RITTE NPE RMISSION OF LIN COLN GLOBAL INC 7 ams DESIGN INFORMATION EQ UIPM ENT TYPE 3050 PAGE lor 2 DRAWN BY MAP 112212 DOCUMENT SUBJECT MACHINE SCHEMATIC NUMBER REVISION WITH PUB LISHED STANDARDS MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING NONE pseosmow pare 0752004 CRM35978 L12212 1 A EN 168 SOLID EDGE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN RANGER 305D Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC G 16 SCHEMATIC ENTIRE MACHINE CODES 11188 11275 L12212 1 PAGE 2 OF 2 2122
362. winding and the weld winding AMPHENOL 1 GROUND 1 120 VAC FOR WIRE FEEDER 40 VAC FOR WIRE FEEDER 21 WORK SENSE 4 Lead 5 and lead 7 9 This checks for a connection between the auxiliary winding and the weld winding See Wiring Diagram 5 Lead 5 and lead W1 W2 or W3 This checks for a connection the auxiliary wind ing and the weld winding See Wiring Diagram 6 Lead 7 or 9 and lead W1 W2 This checks for a connection between the exciter winding and the weld winding See Wiring Diagram If any of the above readings is less than 500 000 500k ohms check for damaged contaminated or shorted wiring or components between the test points and the stator winding necessary dis connect and isolate the stator leads as close to the stator winding as possible See wiring dia gram If the low resistance is determined to be between the windings within the stator the stator is defective and should be replaced NOTE The field bridge rectifier and field capac itor may appear to function normally when tested independently But may malfunctions when placed under the stress of normal operation For this reason It is recommended that the bridge rectifier and capacitor be replaced with known good components before replacing the stator RANGER 305D LINCOLN 9 F 56 57 57 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST WARNING Service and repair sh
363. y AWS Pure EWP 196 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 is not commonly used in these sizes TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 11 8 1 2 12 5 10 5 8 16 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles RANGER 305D LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 amp 5 Return to Section TOC Return to Master TOC o He 2 0 5 8 OPERATION TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUT PUT control is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the Work there is very little voltage or current and in general no tungsten contamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc The ARC CONTROL is not
364. y tank Add coolant if necessary See Maintenance section of this manual for details 5 See the Maintenance section for specific oil and antifreeze recommendations Check and fill the engine fuel tank WARNING Stop engine while fueling not smoke when fueling e Keep sparks and flame away from tank not leave unattended while fueling e Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expan sion may cause over flow DIESEL FUEL ONLY DIESEL FUEL can cause fire 1 Remove the fuel tank cap 2 Fill the tank approximately 4 inches 100mm from the top of the filler neck to allow for fuel expansion Observe the fuel gauge while filling DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel cap and tighten securely 4 See the Maintenance section and engine manual for specific fuel recommendations STARTING THE ENGINE 1 Remove all plugs connected to the AC power receptacles Set IDLER switch to AUTO lt gt Set the RUN STOP switch to RUN Press Glow Plug Button and hold 5 to 10 seconds Press hold both the Glow Plug Button and START button together until the engine starts or for up to 10 seconds 6 Release the engine START button immediately when the engine starts 7 Release the glow plug button after the Engine Protection Light turns off or after an additional 5 seconds maximum 8
365. z 0254 5 GND y Y 01W d 102V BUF 5 T 1 lt Ke 50 50 SW 3 me y mS 8 s 22 E 0213 i l 1 TOK 9 5 E 9 i 1 M REMOTE n 029 Zu 2 8 SV 50 i ABT i bla 4 3 Sec RET d 15 T i i 2 nm cli 1 C ug i STICK PIPE AF Ej PE i fs 2 NOT USED INCLUDED Uu 2x y ARE FORCE toc 1 ON ARTWORK ONLY olo Yeu 010 SP BUr 1181 1 Bic 1 125 57 e 1 T 5 5 Ux X538 ow n Biz 8172 18 ofi 4 5 2 75 T mu 0 i AR 5 5 07 pezorapy 16 i x 7 REO i 1 33075 0 7 ox 74 co 100 15 8 Y i 1 16 1 8 i ah i 50 509K gh REMOTE SENSE 1320 81 i pp i 5 2 89 2 645 RS RAS i 8423 13 KO 8s eh am Pen Wis i T 1 7 3 Veo i Vaw 15V m 1 USED INCLUDED ON ARTWORK ONLY 7 7 777775 1 RIS jH

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