Lincoln Electric RANGER 305 D CE Service Manual Download Page 142

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TROUBLESHOOTING & REPAIR

F-88

RANGER 305D

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CHOPPER MODULE REMOVAL AND REPLACEMENT

(continued)

FIGURE F.19 – EXCITER LEADS T1, T2, T3

SL302

SL301

SL14

SL13

HL W9

HL W4

HL W6

HL W8

HL W5

HL W11

PROCEDURE

Removal

1. Turn the engine off.

2. Perform the

Case Cover Removal

Procedure

3. Perform the

Power Module Capacitor

Discharge procedure

4. Disconnect leads 23 and 25 at their in-line

couplings.

5. Using the 7/16” socket wrench, remove the

following leads. Label the leads before

removal. Cut cable ties as needed. Note

placement of leads and fasteners: screw,

lock washer, flat washer, small lead, heavy

lead.

6. Using a 3/8” socket wrench, remove the three

screws holding the power module assembly

to its brackets on the vertical baffle. Remove

the plastic strip with the top two screws. Be

sure to support the Power Module as you

remove the last screw.

7. Remove the Power Module assembly from

the machine.

TERMINAL

LEADS

Heavy lead W11, small

lead 14

HL W5, SL 13

HL W8

HL W6

HL W4, SL 301

HL W9, SL 302

Summary of Contents for RANGER 305 D CE

Page 1: ... you act and be careful SERVICE MANUAL For use with machines having Code Numbers 10926 11121 11188 11275 Domestic 11027 11122 11189 11314 UK 11039 11123 11190 11315 EUROPE Ranger 305D TM Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info Sales and Service through Subsidiaries and Distributors World...

Page 2: ...NJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of...

Page 3: ...and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves t...

Page 4: ...ot 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 extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situatio...

Page 5: ...ge à lʼaide dʼécrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où ...

Page 6: ...on A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manuals Code 10926 P 417 Code 11027 11039 P 479 Code 11121 11188 11275 P 492 Code 11122 11123 11189 11190 11314 11315 P 494 ...

Page 7: ...ion A 5 Towing A 5 Pre Operation Engine Service A 6 Oil A 6 Fuel A 6 Engine Cooling System A 6 Battery Connections A 6 Muffler Outlet Pipe A 6 Spark Arrester A 6 High Frequency Generators for TIG Applications A 6 Remote Control A 7 Electrical Output Connections A 7 Machine Grounding A 7 Welding Output Cables A 8 Cable Installation A 8 Auxiliary Power Receptacles A 8 Standby Power Connections A 8 A...

Page 8: ... Model Description Speed RPM Displacement Starting Capacities cu in cu cm System 3 cylinder 43 88 789 12VDC Battery 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 3 6L naturally aspirated Low Idle 2450 Battery Charger...

Page 9: ...ctric Fuel Pump Code 11027 11039 11122 11123 or Mechanical Mechanical with Full Flow Filter Certified to EPA Tier I Fuel Pump Code 11189 11190 11314 11315 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 engine Mad...

Page 10: ...inuous 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...

Page 11: ...ncoln 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 Accessories section of this manual LIFTING The RANGER 305D weighs approximately 775lbs 352kg with a full tank of fuel 698 lbs less fuel A lift bail is mounted to the machine and should always be used when lifting the machine Lift only with equipment of a...

Page 12: ...ion and be careful when working near a battery Follow the instructions printed on the bat tery 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...

Page 13: ...ng 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 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 f...

Page 14: ... 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 codes The following information can be used as a guide by the electrician for most applications Refer to the connection diagram in Figure A 2 CAUTION ...

Page 15: ...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 ...

Page 16: ... the premises to be isolated before the generator is linked to the premises 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 240 Volt 60 Hz 3 Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GR...

Page 17: ...ine Controls B 4 Welding Controls B 5 Engine Operation B 6 Before Starting the Engine B 6 Starting the Engine B 6 Stopping the Engine B 6 Stick Welding B 7 Constant Current CC Stick Welding B 7 Pipe Welding B 7 TIG Welding B 8 Wire Welding CV B 8 Arc Gouging B 8 Auxiliary Power B 8 Simultaneous Welding and Auxiliary Power Loads B 9 Return to Master TOC Return to Master TOC Return to Master TOC Ret...

Page 18: ... 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 ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside Do 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 s...

Page 19: ...next to fuel cap on case top Some models have gauge located on front panel Voltmeter and ammeter display actual volts and amps at output terminals when welding Longer engine life reduced noise emissions and great fuel economy with the automatic engine idler Conveniently located engine maintenance label under top engine door Engine hour meter for scheduled maintenance Electric start Oil drain valve...

Page 20: ...le speed d The engine will automatically return to high idle speed when the welding load or AC power load is reapplied 4 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 holdi...

Page 21: ...tage 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 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 or the AC power load is turned off a fixed time dela...

Page 22: ... 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 2 Set IDLER switch to AUTO 3 Set the RUN STOP switch to RUN 4 Press Glow Plug Button and hold 5 to 10 seconds 5 Press and hol...

Page 23: ...l and oil filter 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 use...

Page 24: ...in to crisp and nar row It acts as an inductance control The proper setting depends on the procedure and operator preference Start with the dial set at 0 Some recommended Innershield electrodes are NR 311 NS 3M NR 203 Ni 1 NR 204H Recommended Outershield elec trodes are 0S 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...

Page 25: ...he 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 Welding Output Amps at NEMA Arc Volts 0 100 150 200 250 300 Permissible Auxiliary Power Watts Unity Power Factor 9500 7100 5600 4500 2800 0 Eac...

Page 26: ...NOTES B 10 B 10 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 27: ... K867 Universal Adapter C 3 Connection of the LN 25 Across the Arc C 4 Connection of the LN 25 with 42V Remote Output Control Module C 5 Connection of the LN 25 with K857 Remote Control C 6 Connection of the LN 7 Using the K584 Control Cable C 7 Connection of the LN 8 Using the K595 Control Cable C 8 Connection of the LN 742 C 9 Section C 1 Section C 1 RANGER 305D Return to Master TOC Return to Ma...

Page 28: ...uired 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 ...

Page 29: ...eads 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 Any increase of the high idle ...

Page 30: ...his is only a control lead it carries no welding current 6 Place the IDLER switch in the AUTO or HIGH position as desired If you are using an LN 25 without an internal contac tor the electrode will be HOT when the Ranger 305D is started 7 Place the WELD TERMINALS switch in the WELD TERMINALS ON position 8 Adjust wire feed speed at the LN 25 and adjust the welding voltage with the output CONTROL at...

Page 31: ...IDLER switch in the AUTO or HIGH position as desired 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...

Page 32: ...e the IDLER switch in the AUTO or HIGH position as desired If you are using an 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 Set the WELD TERMINALS switch in the WELD TERMINALS ON position 8 Set the VOLTMETER switch to or depend ing on the polarity chosen 9 Adjust the wire feed speed at the LN 25 and adjust the weld...

Page 33: ... MODE switch to the CV WIRE position 6 Place the IDLER switch in the HIGH position 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 ...

Page 34: ...IGH position 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 VOLTMETER switch to or...

Page 35: ... desired 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 ...

Page 36: ...NOTES C 10 C 10 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 37: ...enance D 2 Engine Maintenance D 3 Engine Oil Change D 4 Oil Filter Change D 4 Service Instruction Installation Tips D 5 Cooling System D 6 Tighten the Fan Belt D 6 Fuel System Service D 7 Battery Maintenance D 7 Welder Generator Maintenance D 8 Storage D 8 Cleaning D 8 Receptacles D 8 Cable Connections D 8 Brush Removal and Replacement D 8 GFCI Receptacle Testing and Resetting Procedure D 9 Major ...

Page 38: ...arts when starting operating or repairing the equipment WARNING ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE 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 in Table D 1 Follow either the hourly or the calendar intervals whichever come first More frequ...

Page 39: ...75 Hours Check engine oil 100 Hours Clean air cleaner element 1 Clean fuel filter Check battery electrolyte level 150 Hours Change oil filter 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 3000 Hours Check f...

Page 40: ...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 or E3 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...

Page 41: ... force the filter into the air cleaner It is tempting to assume the cover will do the job of seating the filter ñ but it will not Using the latches to push the filter in could cause damage to the housing and will void the warranty 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 ...

Page 42: ...n 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 th...

Page 43: ...heck 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 ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an a...

Page 44: ...connect 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 M...

Page 45: ...t 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 Push the Test button lo...

Page 46: ...turn to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D 10 D 10 RANGER 305D FIGURE D 1 MAJOR COMPONENT LOCATIONS 7 7 6 6 3 3 4 4 2 2 1 1 5 5 1 CASE FRONT ASSEMBLY 2 CONTROL PANEL ASSEMBLY 3 STATOR ROTOR ASSEMBLY 4 BLOWER BAFFLE ASSEMBLY 5 BASE FUEL TANK ASSEMBLY 6 ENGINE ASSEMBLY 7 CASE COVERS ...

Page 47: ...ENTS THEORY OF OPERATION SECTION FIGURE E 1 RANGER 305D BLOCK LOGIC DIAGRAM ROTOR ENGINE PROTECTION CIRCUIT ENGINE PROTECTION LIGHT RUN STOP SWITCH GLOW PLUG BUTTON 12V BATTERY STARTER ENGINE ENGINE SENSORS GLOW PLUGS ENGINE ALTERNATOR START BUTTON IDLE SOLENOID PULL COIL HOLD COIL FUEL PUMP FUEL SOLENIOD PULL COIL PULL COIL PC BOARD CHARGING SYSTEM LIGHT CODE 10926 ONLY WELD WINDING STATOR EXCITE...

Page 48: ... 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 n...

Page 49: ...noid 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...

Page 50: ...achine 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 ...

Page 51: ...eewheeling 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 IGBTʼs off times See Chopper Technology Fundamentals Weld Control and Feedback The operator provides input to the weld control circuitry by means of the output control and arc control poten tiometers and th...

Page 52: ...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 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 C...

Page 53: ...w in the system when the switch is open and 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 curre...

Page 54: ... 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 ou...

Page 55: ... Test F 47 Stator Voltage Test F 51 Stator Short Circuit Ground Test F 55 Output rectifier Bridge Test F 57 Chopper Module Function Test F 61 Chopper Module Resistance Test F 65 Weld Control Board PWM Gate Signal Test F 69 Weld Control Feedback Test F 71 Control Potentiometer and Mode Switch Resistance Test F 75 Remote Receptacle Test F 79 Replacement Procedures F 83 Output Rectifier Bridge and Ch...

Page 56: ...BLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute 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 speci...

Page 57: ...tic or static dissi pative Remove the PC Board from the static shielding bag and place it directly into the equipment Donʼt set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board canʼt be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers donʼt remove them until installation is complete If you ...

Page 58: ...erform the Brush and Slip Ring Service procedure 3 Perform the Rotor Voltage Test 4 Perform the Stator Voltage Test CAUTION Observe Safety Guidelines detailed in the beginning of this manual TROUBLESHOOTING GUIDE No welding output in any mode The auxiliary output is normal The engine operates normally 1 Place the Welding Terminals switch in the WELD TERMI NALS ON position If the prob lem is solved...

Page 59: ...d the engine operates normally 1 Check for loose or faulty con nections at any cords attached to the auxiliary output recepta cles or to the 14 pin Amphenol receptacle 1 Check for tripped circuit break ers and or tripped GFCI recep tacles 2 Perform the Stator Voltage Tests The machine has low welding out put and low auxiliary output 1 The engine RPM may be too low 2 The brushes may be worn stickin...

Page 60: ...nals and welding cable con nections 5 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 6 The weld cables may be too long and or too small causing excessive voltage drop between the machine and the arc 1 The engine R...

Page 61: ...lays 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 9 If all of the these connections are good perform the Rotor Voltage Test the Stator Voltage Test the Output Rectifier Test and the Power Modu...

Page 62: ...y 2 If the engine still fails to main tain correct RPM the engine will need to be serviced 3 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 4 There may be poor connections in the control wiring at the weld control PC board or the chopper ...

Page 63: ...s plugged into either of the Amphenol recepta cles 2 Check for dirt or moisture cont amination in either 6 pin or the 14 pin amphenol receptacle 1 Perform the Remote Receptacle Resistance Test 2 The output control potentiome ter may be defective 3 Perform the Control Potentiometer and Mode Switch Resistance Test The machine welds but it will not maintain a steady output The arc may suddenly get ho...

Page 64: ...ntact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION WELD OUTPUT PROBLEMS The machine front panel output control is still active when the remote control unit is connected to one of the Amphenol Receptacles 1 The condition is normal in Touch Star...

Page 65: ...y and free of contamination Try using some new Lincoln Electrode and set ting the machine per the Lincolnʼs recommendations for that product 4 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 5 The weld cables may be coiled or wrapped around metal reels or racks This can cause exces si...

Page 66: ...ame 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 2 If 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 3 If the known go...

Page 67: ...output 1 Check that the welding terminal switch is in the WELD TERMI NALS ON position 2 Check that the WELD MODE switch in the correct position for the process being used typical ly CV WIRE mode 3 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 4 Check that the wire feederʼs work sensing lead is proper...

Page 68: ...ROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION ENGINE AND IDLE PROBLEMS The engine will not crank when start button is pushed 1 Check circuit breaker CB7 Reset if tripped 2 Make sure the run stop switch is in the RUN position 3 Check for loose or faulty battery cable connections See wiring diagram 4 The battery may be low or faulty If the battery is low recharge it...

Page 69: ...to Master TOC Return to Master 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 proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION ENGINE AND IDLE PROBLEMS ...

Page 70: ...e D4 diode bridge and the fuel solenoid See wiring diagram 5 The fuel solenoid may be faulty Perform the Fuel SolenoidTest The engine shuts down shortly after starting and trips the battery circuit breaker CB7 1 Try resetting circuit breaker If it trips again do not attempt to use the machine 2 Contact a Lincoln Authorized Field Service Facility Note Repeated tripping and reset ting of the circuit...

Page 71: ... to low RPM The machine has normal weld output and auxiliary power 1 Make sure the idle switch is in the AUTO IDLE position 2 Make sure there is no external load on the weld terminals or the auxiliary power receptacles 3 Check for mechanical restric tions in the idler solenoid link age 1 Perform the Idle Solenoid Test 2 Check for damaged wiring or faulty connections at idle sole noid the pull coil...

Page 72: ...SIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION ENGINE AND IDLE PROBLEMS 7 If the solenoid does not hold in the low idle position remove plug P6 from control PC board and wait for about 30 seconds 8 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 9 Note The bypass ...

Page 73: ...w 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 1 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 See the wiring diagram The leads should be wrapped tightly and tie wrapped in p...

Page 74: ...e switch is in the HIGH IDLE position 1 Check that the welding cables and the auxiliary power lead connections are tight 1 The weld control PC board may be defective The engine goes to low idle but will not stay at low idle 1 Make sure there are no external loads on either the weld termi nals or the auxiliary receptacles 2 Check that the welding cables and the auxiliary power lead connections are ...

Page 75: ...e 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...

Page 76: ...exhaust pipe extension 5 Remove the cover seal from around the lift bail 6 Remove the sheet metal and machine screws holding the case cover in place 7 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 Lift the case cover off the machine NOTE It is necessary to remove the fuel...

Page 77: ... avoid elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will insure that the lar...

Page 78: ... module capacitors 3 Locate the chopper module and capacitor assembly on the inner machine baffle See Figure F 2 and the Wiring Diagram NEVER USE A SHORTING STRAP TO DIS CHARGE CAPACITORS If 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 term...

Page 79: ...ctory 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 Thi...

Page 80: ...lack 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 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 l...

Page 81: ...OC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FUEL SHUTDOWN SOLENOID TEST continued FIGURE F 4 FUEL SOLENOID CONNECTIONS RED BLACK WHITE GND L TO FRAME 225B TO D 4 231 TO STARTER SOLENOID P73 J73 FUEL SOLENOID CONNECTOR LEAD ENTRY VIEW FUEL SOLENOID WIRING HARNESS CONNECTOR LEAD ENTRY VIEW ...

Page 82: ...NOTES F 28 F 28 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 83: ...rve 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 e...

Page 84: ...e F 5 4 Connect the strobe tach according to the manufacturerʼs instructions 5 Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is no load on the machine 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 ...

Page 85: ... 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 ...

Page 86: ...o 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 See Figure F 6 ...

Page 87: ...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...

Page 88: ...000 Ohms or more If any of the above resis tance values are incorrect the solenoid may be faulty Replace See Figure F 7 6 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 pin 2 red wire While ...

Page 89: ... 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 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 assist...

Page 90: ...s the same or less than the measurement taken when the engine was not running proceed with the following tests 7 Turn off the engine disconnect the meter from the battery and open the engine access door on the left side of the machine 8 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 9 Place the negative met...

Page 91: ...n 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 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 yo...

Page 92: ... the rotor resistance test 6 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 7 If there is any evidence that the brushes may h...

Page 93: ...ian 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 y...

Page 94: ... 8 Using the needle nose pliers remove the leads This will electrically isolate the rotor windings 4 Using the ohmmeter check the rotor winding resistance across the slip rings See Figure F 9 Normal resistance is approximately 4 7 ohms at 77 degrees Fahrenheit 25degreesC 5 Measure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpaint e...

Page 95: ...al 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test checks for faults in the rotor winding while these...

Page 96: ...leads to the brush terminals Use clips or terminals to attach 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 s...

Page 97: ... 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 assi...

Page 98: ... switch to STOP 5 If the meter reading is normal this test is complete 6 If the voltage measures zero or very near zero the rotor flashing circuit may be faulty or the rotor may be shorted 7 Perform the Rotor Resistance and Ground Test and the Rotor Flashing Voltage Test 8 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 volta...

Page 99: ...the Stator short circuit and ground test has been completed reconnect leads 7 and 9 to the field bridge rectifier D3 All other stator leads should remain discon nected and isolated at this time 16 Be sure that there are no leads of any kind across any of the stator windings except the 7 9 winding Examine stator wiring for damage pinched leads chafed insula tion etc If necessary disconnect and iso ...

Page 100: ...NOTES F 46 F 46 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 101: ...ger 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 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 a...

Page 102: ...n or the brushes 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 Procedure 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 w...

Page 103: ...is present at lead 210H but not present at leads 224B or 200N check the engine protection wiring and CR1 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 18 If battery voltage is not present at lead 210H check wiring per wiring diagram and ch...

Page 104: ...NOTES F 50 F 50 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 105: ... 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...

Page 106: ...volt ohmmeter probes to either 120 VAC receptacle as follows 2 For the upper receptacle place the probes directly into receptacle or connect to leads 3D and 5A See Figure F 12 See wiring diagram For the lower receptacle place the probes directly into the receptacle or connect to leads 6E and 5B See Figure F 12 See wiring diagram 3 Start the engine and run it at high idle 3650 RPM 4 Check the AC vo...

Page 107: ...g 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 1 Connect the voltmeter probes to pins A lead 32 and J lead 31 of the 14 p...

Page 108: ...it breakers loose connections or broken wires between the test points and the stator windings If 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 F 13 See wiring diagr...

Page 109: ...ughout 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 be...

Page 110: ... 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 winding and the weld winding 4 Lead 5 and lead 7 or 9 This checks for a connection between the auxiliary winding and the weld winding See Wir...

Page 111: ...ranty 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 wi...

Page 112: ...e rectifier as follows 4 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 5 Mark the leads connected to the positive and negative terminals of the output bridge rect...

Page 113: ...nal should be very high 500 000 500K ohms minimum If the resistance reading is less than specified the rectifier is grounded and should be replaced 8 If using diode checker or 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 ...

Page 114: ...S Low Resistance AC3 DC FORWARD BIAS Low Resistance DC AC1 FORWARD BIAS Low Resistance DC AC2 FORWARD BIAS Low Resistance DC AC3 FORWARD BIAS Low Resistance AC1 DC REVERSE BIAS High Resistance AC2 DC REVERSE BIAS High Resistance AC3 DC REVERSE BIAS High Resistance DC AC1 REVERSE BIAS High Resistance DC AC2 REVERSE BIAS High Resistance DC AC3 REVERSE BIAS High Resistance 11 Reconnect all leads 12 P...

Page 115: ...e 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the chopper module is functioning properly and re...

Page 116: ...en the chopper module the output rec tifier and the stator weld winding See Figure F 17 See the wiring diagram Perform the Stator Voltage Tests and the Output Rectifier Test 9 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 B2 to B3 and B5 to B6 If significant voltage is present disconnect leads 23 and ...

Page 117: ...o 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 15 If the voltage at terminals B2 to B3 and B5 to B6 of the chopper module is very low or not present use the frequency counter to check for the presents of a 20 k...

Page 118: ...Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 64 F 64 RANGER 305D ...

Page 119: ...your factory warranty For your safety and to avoid elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION ...

Page 120: ...EST continued TEST PROCEDURE 1 Perform the Case Cover Removal Procedure 2 Perform the Capacitor Discharge Procedure 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 4 Use a digi...

Page 121: ...nd Expected Test Result B5 B6 6K to 9K B6 B5 6K to 9K B4 B5 200k or higher B5 B4 400k or higher B4 B6 200k or higher B6 B4 400k or higher B2 B3 6K to 9K B3 B2 6K to 9K B4 B2 200k or higher B2 B4 400k or higher B4 B3 200k or higher B3 B4 400k or higher TABLE F 2 DIODE TEST TABLE OHMMETER OHMMETER READING Chopper Terminal Connections 5 Reconnect all leads 6 The chopper module screw connection should...

Page 122: ...NOTES F 68 F 68 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 123: ... 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 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 ...

Page 124: ... 13 and 14 for faulty or damaged wiring or connections between the control PC board and the chopper module 13 Test for 80 to 100 VDC at the terminals where the 13 and 14 leads connect to the chopper module See the wiring diagram If there is no voltage at the chopper module perform the chopper module function test 14 If the 80 to 100 VDC supply voltage is pre sent at the weld control PC board but t...

Page 125: ...s 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 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 w...

Page 126: ...n 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 9 If the readings differ significantly continue with this procedure 10 Turn off the engine and release the load from the weld terminals The load bank and ammeter should remain connected b...

Page 127: ...illivolt signal will need to be calculated by dividing the read ing displayed on the external ammeter by 8 See the following explanation 19 The shunt used in this machine will produce 50 millivolts at a load of 400 amps or 8 amps per millivolt 20 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 7...

Page 128: ...NOTES F 74 F 74 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 129: ...perator 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 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...

Page 130: ... CC Stick posi tion 5 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 6 The resistance should be very high A read ing of 500 000 500k ohms or higher is acceptable 7 If the resistance is lower than 500k Ohms replace the potentiometer and mode switch plug and lead assembly or ...

Page 131: ... CV WIRE P7 9 214 TO P7 16 222 N A P7 5 75 TO P7 1 77 about 10K N A P7 1 77 TO P7 4 76 Ohms values should sweep smoothly from 10K to 0 when ARC CONTROLis turned from Min to Max N A P7 6 279 TO P7 8 277 about 10K N A P7 8 277 TO P7 7 278 Ohms values should sweep smoothly from 10K to 0 when ARC CONTROLis turned from Min to Max Resistance should be very low The Ohmmeter should read about the same val...

Page 132: ...NOTES F 78 F 78 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 133: ...For your safety and to avoid elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help de...

Page 134: ...nductor or chassis ground 5 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 6 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...

Page 135: ...00K or Higher N A PIN F 76B to PIN C 2B 500K or Higher N A PIN F 76B to PIN D 4B 500K or Higher N A PIN F 76B to PIN E 77B 500K or Higher N A PIN F 76B to PIN H 21 500K or Higher N A PIN F 76B to PIN I 41A 500K or Higher N A PIN F 76B to PIN J 31 500K or Higher N A PIN F 76B to PIN K 42A 500K or Higher N A PIN E 77B to PIN A 32 500K or Higher N A PIN E 77B to PIN B GND 2 500K or Higher N A PIN E 7...

Page 136: ...NOTES F 82 F 82 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 137: ...chine 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 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 proce...

Page 138: ...put Rectifier 10 Remove the heavy leads from the output rectifier Carefully mark the leads for accurate re connection and also note the order and position of multiple lead connections 11 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...

Page 139: ... of electrical joint com pound Dow Corning 340 Lincoln T12837 between the surfaces of the W leads and 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 3 Swing the case front back into position 4 Mount the D4 diode bridge and the CR1 engine protec...

Page 140: ...NOTES F 86 F 86 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 141: ... warranty For your safety and to avoid elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedu...

Page 142: ...e Capacitor Discharge procedure 4 Disconnect leads 23 and 25 at their in line couplings 5 Using the 7 16 socket wrench remove the following leads Label the leads before removal Cut cable ties as needed Note placement of leads and fasteners screw lock washer flat washer small lead heavy lead 6 Using a 3 8 socket wrench remove the three screws holding the power module assembly to its brackets on the...

Page 143: ...nect leads 23 and 25 at their in line cou plers 3 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 lbs 4 Replace a...

Page 144: ...NOTES F 90 F 90 RANGER 305D Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 145: ...nd to avoid elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This following procedure will aid the t...

Page 146: ...crews holding the radiator frame to the base Remove the radiator and frame assembly 11 Remove the coolant recovery tank by pulling it straight up and off of its mounting bracket 12 Remove the air filter assembly from its brack et it may remain connected to the engine air intake hose 13 Remove the filter bracket by removing the two nuts and bolts holding it to the engine mounting bracket 14 Clearly...

Page 147: ... TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 21 WIRE GUIDE HOLE HOLE FIGURE F 22 ALTERNATOR LEADS OIL PRESSURE SWITCH BATTERY IGNITION 209 210 ...

Page 148: ...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 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 additiona...

Page 149: ...isc 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 5 Insert the screws with lock washers and evenly tighten to a torque of 17 to 19 Ft Lbs 6 Lift the rotor assembly with the hoist and lift ing straps and recheck the engine flyw...

Page 150: ...n 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 5 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 fla...

Page 151: ...al 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 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 120VAC SUPPLY HIGH ...

Page 152: ...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 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX CONTROL PO...

Page 153: ...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 NOTE Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div Coupling DC Trigger Internal NORMAL WELD VOLTAGE WAVEFORM ST...

Page 154: ...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 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV TAP MAX CONT...

Page 155: ...om 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 NOTE Scope probes are connected at weld output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 1 ms Div Coupling DC Trigger Internal NORMAL WELD VOLTAGE WAVEFO...

Page 156: ...8 30 300 CV Minimum 55 60 13 15 120 TOUCH START TIG ARC Control 10 Mode Selector Output Control Open Circuit Load Volts Load Amps Switch Voltage TIG Maximum 10 15 20 24 240 255 TIG Minimum 10 15 Short Circuit 18 28 AUXILIARY POWER OUTPUT 240 Volt Receptacle 120 Volt Receptacles Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 240 270 216 240 40 45 120 135 115 130...

Page 157: ...ematic Entire Machine Code 11122 L12213 Page 1 of 2 G 19 Schematic Entire Machine Code 11122 L12213 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 L12038 Page 1 of 2 G 23 Schematic Entire Machine Code 11039 L12038 Page 2 of 2 G 24 Schematic Entire Machine ...

Page 158: ...3 M1 M2 M3 M4 M9 M5 M10 M10 M9 M6 M5 M4 M6 VOLTS M1 M2 M3 M10 M9 M6 M5 M4 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M5 M10 1 1 M1 M2 M3 M4 M5 M10 1 1 M1 M2 M3 M4 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 G425...

Page 159: ...OUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N 4B 2B 2B 4B 208C 206C 206B 4A 77A 76A 75A 2A 4A Engine Protection Light PL1 212A PULL COIL BD B4 PCB3 S7 GLOW PLUG BUTTON H2O TEMP SW GLOW PLUGS 9 1 16 8 7 1 12 6 P7 J7 Output Arc Cont Mode Select P2 J2 Engine Battery Function P1 J1 Amphenol Model Select Hot Start C8 C9 25 23 Twiste...

Page 160: ...E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N 4B 2B 2B 4B 208C 206C 206B 4A 77A 76A 75A 2A 4A Engine Protection Light PL1 212A PULL COIL BD B4 PCB3 S7 GLOW PLUG BUTTON H2O TEMP SW GLOW PLUGS 9 1 16 8 7 1 12 6 P7 J7 Output Arc Cont Mode Select P2 J2 Engine Battery Function P1 J1 Amphenol Model Select Hot Start C8 C9 25 23 Twisted Pair B4 B5 B6 B1 B2 B3 W5 B1 B2 B3 8 5 1 4 1 2 3 4 P72 J72 210A P43 J43...

Page 161: ... 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 G4226 31 32 GND B A B C D E F 77B 21 75B GND A 41A 42A 76B 115VAC CONTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N GND B 4B 2B 2B 4B...

Page 162: ...9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 G4572 31 32 GND B A B C D E F 77B 21 75B GND A 41A 42A 76B 115VAC CONTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N GND B 4B 2B 2B 4B 208C 206C 206B 4A...

Page 163: ...TACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N 4B 2B 2B 4B 208C 206C 206B 4A 77A 76A 75A 2A 4A Engine Protection Light PL1 212A PULL COIL BD B4 PCB3 S7 GLOW PLUG BUTTON H2O TEMP SW GLOW PLUGS 9 1 16 8 7 1 12 6 P7 J7 Output Arc Cont Mode Select P2 J2 Engine Battery Function P1 J1 Amp...

Page 164: ...5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 G4409 31 32 GND B A B C D E F 77B 21 75B GND A 41A 42A 76B 115VAC CONTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N GND B 4B 2B 2B 4...

Page 165: ...6B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N 4B 2B 2B 4B 208C 206C 206B 4A 77A 76A 75A 2A 4A Engine Protection Light PL1 212A PULL COIL BD B4 PCB3 S7 GLOW PLUG BUTTON H2O TEMP SW GLOW PLUGS 9 1 16 8 7 1 12 6 P7 J7 Output Arc Cont Mode Select P2 J2 Engine Battery Function P1 J1 Amphenol Model ...

Page 166: ...NTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENOL 2 CONTROL J A D C H B K E F G I 208C 206C BYPASS FILTER ASSEMBLY 5N 4B 2B 2B 4B 208C 206C 206B 4A 77A 76A 75A 2A 4A Engine Protection Light PL1 212A PULL COIL BD B4 PCB3 S7 GLOW PLUG BUTTON H2O TEMP SW GLOW PLUGS 9 1 16 8 7 1 12 6 P7 J7 Output Arc Cont Mode Select P2 J2 Engine Battery Function P1 J1 Am...

Page 167: ...LOWPLUGS YELLOW ENGINE PROTECTION LIGHT CR1 9 B A 3 COOLANT TEMPERATURE SWITCH CLOSES ON HIGH TEMPERATURE ABOVE 230F IDLE SOLENOID PULL HOLD BLACK WHITE RED 404 J43 8 PULL COIL PC BOARD B2 B1 B4 15V LOW IDLE TO PULL COILBOARD LOW IDLE SOLENOID HOLDCOIL 0V LO W IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 228 D4 TWISTED PAIR REVOLVIN...

Page 168: ...OT THERMOSTAT IF USED 15V J3 5 AUXILIARY SENSE TOROID MACHINE IDENTITY TABLE PINS JUMPERED TO SELECT MACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SWITCH AUSTRAILIAN VANTAGE 575 USES A 3 POSITION TOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONTROL REMOTE CONTROL ARC CONTROL STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD 206S 204S...

Page 169: ...RT BUTTON SWITCHS2 GLOWPLUGS YELLOW ENGINE PROTECTION LIGHT CR1 9 B A 3 COOLANT TEMPERATURE SWITCH CLOSES ON HIGH TEMPERATURE ABOVE 230F IDLE SOLENOID PULL HOLD BLACK WHITE RED 404 J43 8 PULL COIL PC BOARD B2 B1 B4 15V LOW IDLE TO PULL COILBOARD LOW IDLE SOLENOID HOLDCOIL 0V LO W IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 D4 TWIST...

Page 170: ...UTDOW N FR AME V BATTERY FR AME J2 7 J2 3 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT STUD ST UD AUXI LL ARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILIARY SENSE TOROID MACHINEIDENTITYTABLE PINSJUMPEREDTOSELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VAN TAGE575U SESA 3POSITIONTOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONTRO...

Page 171: ...RED 404 J43 8 PULL COIL PC BOARD B2 B1 B4 15V LOW IDLE TO PULL COILBOARD LOW IDLE SOLENOID HOLDCOIL 0V LO W IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F ENGINE PROTECTION RELAY GLOWPLUGSWITCHENERGIZES ELECTRICFUELPUMP AND FUEL SOLENOID HOLDCOIL THRU D4 IT ALSO FUNCTIO...

Page 172: ...DOW N FR AME V BATTERY FR AME J2 7 J2 3 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT STUD ST UD AUXI LL ARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILIARY SENSE TOROID MACHINEIDENTITYTABLE PINSJUMPEREDTOSELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VAN TAGE575U SESA 3POSITIONTOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONTROL ...

Page 173: ...S ON HIGH TEMPERATURE ABOVE 230F IDLE SOLENOID PULL HOLD BLACK WHITE RED 404 J43 8 PULL COIL PC BOARD B2 B1 B4 15V LOW IDLE TO PULL COILBOARD LOW IDLE SOLENOID HOLDCOIL 0V LO W IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 228 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F ENGINE PROTECTION RELAY GLOWPLUGSWITCHENER...

Page 174: ...K POT THERMOSTAT IF USED 15V J3 5 AUXILIARY SENSE TOROID MACHINE IDENTITY TABLE PINS JUMPERED TO SELECT MACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SWITCH AUSTRAILIAN VANTAGE 575 USES A 3 POSITION TOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONTROL REMOTE CONTROL ARC CONTROL STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD 206S 2...

Page 175: ...SE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 223 211 209 209 231 215 232 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F ENGINE PROTECTION RELAY GLOWPLUGSWITCHENERGIZES ELECTRICFUELPUMP AND FUEL SOLENOID HOLDCOIL THRU D4 IT ALSO FUNCTIONS AS AN ENGINE PROTECTIONBYPASS UNTIL OIL PRESSURE BUILDS UP IF COOLANT TEMPSWITCH OR OIL PRESSURE SWITCH CLOSE CR1 ENERGIZES OPENIN...

Page 176: ...SHUTDOW N FR AME V BATTERY FR AME J2 7 J2 3 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT STUD ST UD AUXI LL ARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILIARY SENSE TOROID MACHINEIDENTITYTABLE PINSJUMPEREDTOSELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VAN TAGE575U SESA 3POSITIONTOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONT...

Page 177: ...N W1 W2 AND W3 AT HIGH IDLE 210 210 229 223 211 209 209 231 215 232 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F GLOWPLUGSWITCHENERGIZES ELECTRICFUELPUMP AND FUEL SOLENOID HOLDCOIL THRU D4 IT ALSO FUNCTIONS AS AN ENGINE PROTECTIONBYPASS UNTIL OIL PRESSURE BUILDS UP IF COOLANT TEMPSWITCH OR OIL PRESSURE SWITCH CLOSE CR1 ENERGIZES OPENING CONTACTS AND SHUTTING OFF FUEL S OLENOID...

Page 178: ...UTDOW N FR AME V BATTERY FR AME J2 7 J2 3 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT STUD ST UD AUXI LL ARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILIARY SENSE TOROID MACHINEIDENTITYTABLE PINSJUMPEREDTOSELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VAN TAGE575U SESA 3POSITIONTOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONTRO...

Page 179: ...S ON HIGH TEMPERATURE ABOVE 230F IDLE SOLENOID PULL HOLD BLACK WHITE RED 404 J43 8 PULL COIL PC BOARD B2 B1 B4 15V LOW IDLE TO PULL COILBOARD LOW IDLE SOLENOID HOLDCOIL 0V LO W IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 228 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F ENGINE PROTECTION RELAY GLOWPLUGSWITCHENER...

Page 180: ...K POT THERMOSTAT IF USED 15V J3 5 AUXILIARY SENSE TOROID MACHINE IDENTITY TABLE PINS JUMPERED TO SELECT MACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SWITCH AUSTRAILIAN VANTAGE 575 USES A 3 POSITION TOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CONTROL REMOTE CONTROL ARC CONTROL STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD 206S 2...

Page 181: ...IDLE 60 TO 65 VAC PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F ENGINE PROTECTION RELAY GLOWPLUGSWITCHENERGIZES ELECTRICFUELPUMP AND FUEL SOLENOID HOLDCOIL THRU D4 IT ALSO FUNCTIONS AS AN ENGINE PROTECTIONBYPASS UNTIL OIL PRESSURE BUILDS UP IF COOLANT TEMPSWITCH OR OIL PRESSURE SWITCH C...

Page 182: ...ELSHUTDOW N FR AME V BATTERY FR AME J2 7 J2 3 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT STUD ST UD AUXI LL ARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILIARY SENSE TOROID MACHINEIDENTITYTABLE PINSJUMPEREDTOSELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VAN TAGE575U SESA 3POSITIONTOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CO...

Page 183: ...C PHASE TO PHASE BETWEEN W1 W2 AND W3 AT HIGH IDLE 210 210 229 225 223 211 209 209 231 215 232 D4 TWISTED PAIR REVOLVING FIELD FIELDRESISTANCE APPROX 5 OHMS 75F GLOWPLUGSWITCHENERGIZES ELECTRICFUELPUMP AND FUEL SOLENOID HOLDCOIL THRU D4 IT ALSO FUNCTIONS AS AN ENGINE PROTECTIONBYPASS UNTIL OIL PRESSURE BUILDS UP IF COOLANT TEMPSWITCH OR OIL PRESSURE SWITCH CLOSE CR1 ENERGIZES OPENING CONTACTS AND ...

Page 184: ...LSHUTDOW N FR AME V BATTERY FR AME J2 7 J2 3 12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS NOT ALL MACHINES USE EVERY CIRCUIT STUD ST UD AUXI LL ARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILIARY SENSE TOROID MACHINEIDENTITYTABLE PINSJUMPEREDTOSELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VAN TAGE575U SESA 3POSITIONTOGGLE SWITCH 77 76 75 77B 76B 75B 277 278 279 OUTPUT CON...

Page 185: ... 1 OF 5 G 29 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 186: ... 2 OF 5 G 30 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 187: ... 3 OF 5 G 31 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 188: ... 4 OF 5 G 32 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 189: ... 5 OF 5 G 33 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 190: ...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 machine ELECTRICAL DIAGRAMS RANGER 305D PC BOARD ASSEMBLY WELD CONTROL PC BD ALL CODES G4107 1 Return to Section TOC Return to Section TOC Return to Section TOC Return to ...

Page 191: ...1 G 35 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 192: ... 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 machine ELECTRICAL DIAGRAMS G 36 RANGER 305D PC BOARD ASSEMBLY PULL COIL PC BD ALL CODES L11768 1 G 36 Return to Section TOC Return to Section TOC Return to Section TOC R...

Page 193: ... G 37 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 194: ...COVER BLANK NUMBER ON BOARD AND ONE LABEL TO BE ON POTTING TRAY N J THIS ASSEMBLY IS NOT ESD AFTER POTTING CURRENT PRODUCTION USES LATEST DASH NUMBER ALL PREVIOUS DASH NUMBERS ARE SUPERSEDED UNLESS OTHERWISE SPECIFIED CAPACITANCE MFD VOLTS INDUCTANCE HENRIES RESISTANCE OHMS N B ITEM REQ D PART No DESCRIPTION 1 1 L11613 M P C BOARD BLANK 2 3 1 CL012867 W 18 3 10 167 B7 4 1 CL012868 W 18 3 133 167 B...

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Lincoln Electric RANGER 305 D CE, Service Manual

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