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TM
Ranger 305D
For use with machines having Code Numbers: 10926, 11121, 11188, 11275 (Domestic)
11027, 11122, 11189, 11314 (UK)
11039, 11123, 11190, 11315 (EUROPE)
SVM175-A
July, 2007
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . .
and thoughtful operation on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
DD
SERVICE MANUAL
Copyright© 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
i SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
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.
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 “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 powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling 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.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1.e. 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.
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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii 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 locations 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.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks 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 to the arc rays or to hot spatter or metal.
ii
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
FUMES AND GASES can be dangerous.
5.a. 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.
5. b. 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 application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.c. 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 products.
5.d. 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.
5.e. Read and understand the manufacturerʼs instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG ʻ06
iii
WELDING SPARKS can 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 extinguisher readily available.
6.b. 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.
6.c. 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.
6.d. 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).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. 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.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building 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.
SAFETY
CYLINDER may explode if damaged.
7.a. 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. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to physical damage.
• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
Mar ʻ95
iv SAFETY zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique: iv
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le refroidir.
e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.
8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au soudage 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, pantalons sans revers, et chaussures montantes.
1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ʻ93
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN MENU
Page
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 v
RANGER 305D
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation .............................................................................................................................Section A
Section A-1
RANGER 305D
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS -
Ranger 305D (K1727-2) Code 10926, 11121, 11188, 11275
A-2
Make/Model
Kubota**
D722
INPUT - DIESEL ENGINE
Description Speed (RPM) Displacement cu. in. (cu. cm.)
Starting
System
Capacities
18.8 HP
(14 KW)
43.88(789) 12VDC Battery & Fuel: 12 gal.(45L)
High Idle 3650 Bore x Stroke inch (mm)
Net intermittent Full Load 3500
3600 RPM naturally aspirated Low Idle 2450 water cooled engine
2.64 x 2.68
(67 x 68 mm)
(Group 58; 550 Radiator Coolant: cold crank amps) 3.85Qts. (3.6L)
Battery Charger
Oil: 3.4Qts. (3.2L)
Welding Process
DC Constant Current
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Output
Current/Voltage/Duty Cycle
305A / 29V / 100%
300A / 29V / 100%
250A / 30V / 100%
300A / 29V / 100%
Output Range
20 TO 305 AMPS
40 TO 300 AMPS
20 TO 250 AMPS
14 TO 29 VOLTS
RATED OUTPUT @ 104° F (40° C) .
- GENERATOR
Auxiliary Power 1
10,000 Watts Peak, / 9,500 Watts Continuous, 60 Hz 120/240 Volts
Max. Weld OCV
@Rated Load RPM
60 Volts
Sound Levels
Sound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m )
WIDTH
PHYSICAL DIMENSIONS
DEPTH HEIGHT
30.00* in.
21.50 in 52.25 in.
WEIGHT
698 lbs. (317kg.)
762.0 mm 546.0 mm 1327.0 mm
ENGINE
LUBRICATION
Full Pressure
EMISSIONS with Full Flow Filter Certified to EPA Tier I Fuel Pump (Code 11188, 11275), Auto air bleed system Electric shutoff solenoid Indirect fuel injector
AIR CLEANER ENGINE IDLER
FUEL SYSTEM
Electric Fuel Pump (Code 10926, 11121) or Mechanical
Single Element Automatic Idler
MUFFLER
Low noise Muffler:
Top outlet can be rotated.
Made from long life, aluminized steel.
GOVERNOR
Mechanical
Governor
ENGINE PROTECTION
Shutdown on low oil pressure & engine 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
(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.
Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
* Top of enclosure add 6 in. (152mm) for exhaust pipe.
** Engine warranty may vary outside of the USA. (See Engine warranty for details)
RANGER 305D
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS -
RANGER 305D (CE) K2279-1 (UK) Code 11027, 11122, 11189, 11314
& K2279-2 (EUROPE) Code 11039, 11123, 11190, 11315
Make/Model Description
INPUT - DIESEL ENGINE
Speed (RPM) Displacement cu. in. (cu. cm.)
Starting
System
Capacities
A-3
Kubota
(3)
D722
15.9 HP
(12 KW)
Net intermittent
3000 RPM naturally aspirated water cooled engine
High Idle 3100 Bore x Stroke inch (mm)
Full Load 3000
Low Idle 2200
43.88(789)
2.64 x 2.68
(67 x 68 mm)
12VDC Battery & Fuel:
Oil:
3.2L(3.4 US. Qts.)
(Group 58; 550 Radiator Coolant: cold crank amps) 3.6L(3.85 U Qts)
Battery Charge
Welding Process
DC Constant Current
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
RATED OUTPUT @ 40° C (104° F) - WELDER
Welding Output
Current/Voltage/Duty Cycle
250A / 30V / 100%
250A / 30V / 100%
250A / 20V / 100%
250A / 27V / 100%
Output Range
20 TO 305 AMPS
40 TO 300 AMPS
20 TO 250 AMPS
14 TO 29 VOLTS
Max. Weld OCV
@Rated Load RPM
60 Volts
RATED OUTPUT @ 40° C (104° F) - GENERATOR
Auxiliary Power
(1)
8,500 Watts Peak, / 8,000 Watts Continuous, 50 Hz 115 & 230 Volts - 1 Phase
Sound Levels
Sound Power: 98 dB Lwa
8,500 Watts Peak, / 8,000 Watts Continuous, 50 Hz 400 Volts - 3 Phase
HEIGHT
762mm
30.0 in.
(2)
PHYSICAL DIMENSIONS
WIDTH DEPTH
546mm
21.50 in.
1524mm
60.0 in.
WEIGHT
341kg. (752lbs.)
ENGINE
LUBRICATION
Full Pressure
EMISSIONS with Full Flow Filter Certified to EPA Tier I Fuel Pump (Code 11189, 11190, 11314, 11315), Auto air bleed system Electric shutoff solenoid Indirect fuel injector
AIR CLEANER ENGINE IDLER
FUEL SYSTEM
Electric Fuel Pump (Code 11027, 11039, 11122, 11123) or Mechanical
Single Element Automatic Idler
MUFFLER
Low noise Muffler:
Top outlet can be rotated.
Made from long life, aluminized steel.
GOVERNOR
Mechanical
Governor
ENGINE PROTECTION
Shutdown on low oil pressure & engine temperature
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor) (3)
MODEL NUMBER
Receptacles
RECEPTACLES AND CIRCUIT BREAKERS
Residual Current Device (RCD)
Circuit Breakers (Thermal/Magnetic)
K2279-1 (UK)
400V (3 Ph) x 1
230V (1 Ph) x 1
115V x 1 (4)
14 Pin Connector
6 Pin Connector
4-pole, 25 Amp
(30mA trip current)
3 Phase, 20 Amp x 1
1 Phase, 15 Amp x 5
K2279-2 (EUROPE)
400V (3 Ph) x 1
230V (1 Ph) x 2
14 Pin Connector
6 Pin Connector
4-pole, 25 Amp
(30mA trip current)
3 Phase, 20 Amp x 1
1 Phase, 15 Amp x 4
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
(2) To top of enclosure, add 152mm (6 “) to top of exhaust elbow.
(3) Engine warranty may vary outside of the USA. (See Engine warranty for details)
(4) Center-Tapped to ground.
RANGER 305D
A-4
INSTALLATION
Read this entire installation section before you start installation.
STORING
SAFETY PRECAUTIONS
WARNING
A-4
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 canʼt be accidentally damaged from construction activities, moving vehicles, and other hazards.
Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.
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ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrode with skin or wet clothing.
• Always wear dry insulating gloves.
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 “NO 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 parts. See the
section for details on changing oil.
-----------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
4. Remove the battery, recharge it, and adjust the electrolyte level. Store the battery in a dry, dark place.
-----------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
• 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 service this equipment.
-----------------------------------------------------------------------
5. If 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 Operatorʼs manual.
Fuel should also be drained when stored for long periods or a fuel additive should be used.
STACKING
Ranger 305D machines CANNOT be stacked.
ANGLE OF OPERATION
LOCATION AND VENTILATION
The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Allow a minimum 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 outside area.
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
A-5
INSTALLATION
A-5
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
WARNING
• Lift only with equipment of adequate 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 • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury.
• Do not operate machine while suspended from lift bail.
-------------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For maximum 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 adjustments can be made for operation in higher elevations locally.
HIGH TEMPERATURE OPERATION
At temperatures above 104°F(40°C), Welder output derating is necessary. For maximum output ratings, derate the welder output 2 volts for every 50°F(10°C) above 104°F(40°C).
Cold Weather Starting & Operation:
The Kubota engine used in the Ranger 305D can be started in temperatures as low as 5°F (-15°C). At temperatures below 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
section of this manual.
WARNING
DO NOT USE ETHER OR STARTING FLUID FOR
STARTING. SEVERE DAMAGE TO THE ENGINE
WILL RESULT.
The recommended trailer for use with this equipment for road, inplant and yard towing by a vehicle is Lincolnʼs K957-1. (See
Accessories Section of this manual for trailer and trailer options).
If the user adapts a non-Lincoln trailer, he must assume responsibility 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 welding equipment so there will be no undue stress to the framework.
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 surface on which the trailer will be operated; environmental conditions; like maintenance.
1
5. Conformance with federal, state and local laws.
1
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 components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufacturerʼs instructions.
------------------------------------------------------------------------
RANGER 305D
A-6
INSTALLATION
A-6
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instructions supplied with this machine.
BATTERY CONNECTION
WARNING
WARNING
• Keep hands away from the engine muffler or HOT engine parts.
• Stop the engine and allow it to cool before fueling.
• Do 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 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 Operatorʼs Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operatorʼs
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
NOTE: Close the fuel shutoff valve located on the prefilter if not running the welder for extended periods.
the tank contains approximately 2 gallons
(7.6 liters) of reserve fuel.
ENGINE COOLING SYSTEM
WARNING
HOT COOLANT can burn skin.
•Do not remove cap if radiator is hot.
•The engine and radiator or this machine are filled with a 50% mixture of ethylene-glycol based permanent type antifreeze. See the
section and the engine Operationʼs Manual for more information.
BATTERY ACID CAN BURN EYES AND SKIN.
•Wear gloves and eye protection and be careful when working near a battery.
Follow the instructions printed on the battery.
•Use caution as the electrolyte is strong acid that can burn skin and damage eyes.
------------------------------------------------------------------------
The RANGER 305D is shipped with the negative battery cable disconnected. Make certain that the RUN-
STOP switch is in the STOP position. Access the negative 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 battery with the correct polarity. See battery charging instructions in the
section.
MUFFLER OUTLET PIPE
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 socket 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 locations where unarrested sparks may present a fire hazard. 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
section for more information.
CAUTION
An incorrect spark arrestor may lead to damage to the
------------------------------------------------------------------------
The K930-2 TIG Module is suitable for use with the
Ranger 305D. The Ranger 305D and any high frequency generating equipment must be properly grounded. See the K930-2 operating manual for complete instructions on installation, operation, and maintenance.
RANGER 305D
A-7
INSTALLATION
A-7
REMOTE CONTROL
The RANGER 305D 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
section for more information.
NOTE: Both the 6-pin and 14-pin Amphenols share the same output control auto-sensing and contactor circuitry; for this reason, there can only be one device plugged into the Ranger 305D at any time.
MACHINE GROUNDING
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
Switch operation is covered in “Operation” section.
Do not ground this machine to a pipe that carries explosive or combustible material.
ELECTRICAL OUTPUT CONNECTIONS
See Figure A.1 for the location of the 120 and 240 volt receptacles, weld output terminals, and ground stud.
Output stud covers are provided on code 11275 and above.
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 connected 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 section 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
Note: Different models appearance may vary slightly.
1 2
RANGER 305D
3
4
Note: Output stud covers not shown.
Code 11275 and above
A-8
WELDING OUTPUT CABLES
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 front of the welder.
ground symbol is provided on the
A-8
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 terminal connection. Keep the cables isolated and separate from one another.
-----------------------------------------------------------
AUXILIARY POWER RECEPTACLES
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 connections should be checked periodically and tightened with a wrench.
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-
50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.
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 for long cable lengths to reduce voltage drops. Long lengths of cable should not be left coiled when welding.
CABLE INSTALLATION TABLE A.1
Cable Length
0-100Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
Cable Size for
305 Amps
100% Duty Cycle
1 / 0 AWG
2 / 0 AWG
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 equivalent 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 separate 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 breakers.
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.
150-200 Ft. (46-61 meters) 3 / 0 AWG
NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.
Install the welding cables to your RANGER 305D as follows.
STANDBY POWER CONNECTIONS
The RANGER 305D is suitable for temporary, standby or emergency power using the engine manufacturerʼs recommended maintenance schedule.
1. 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.
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 codes.The following information can be used as a guide by the electrician for most applications. Refer to the connection diagram in
RANGER 305D
A-9
INSTALLATION
1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customerʼs premises disconnect and service over-current protection.
A-9
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.
2. 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.
4. Plug this cable into th 50 amp, 120/240 VAC receptacle on the Ranger 305D case front.
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 equipment and may result in overheating of the Ranger
305D engine and/or alternator windings.
RANGER 305D
A-10
INSTALLATION
A-10
FIGURE A.2 CONNECTION OF RANGER 305D TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
120 VOLT
120 VOLT
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
50AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
WARNING
• Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that:
• The installation complies with the National Electrical Code and all other applicable electrical codes.
• The 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. 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.
RANGER 305D
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Section B-1
RANGER 305D
B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your Ranger 305D.
SAFETY INSTRUCTIONS
WARNING
WARNING
ENGINE EXHAUST can kill.
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.
B-2
------------------------------------------------------------------------
MOVING PARTS can injure.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Stop the engine before servicing it.
• Keep away from moving parts.
------------------------------------------------------------------------
Only qualified personnel should install, use, or service 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 circuit and single-phase power for the AC auxiliary outlets. The DC welding control system uses state of the art
(CT TM performance.
) for superior welding
• Wear eye, ear, and body protection.
RANGER 305D
B-3
OPERATION
DESIGN FEATURES
• Single, full-range output control dial.
• 4 welding modes: CC-stick, downhill stick welding on pipe, CV wire welding and Touch-Start TIG (eliminates high frequency and tungsten contamination).
• Output at welding terminals controlled by electronic contactor. Can be switched to “On”, or to “Remotely
Controlled”.
• Many wire feeder combinations: 14-pin connector for
Lincoln wire feeders LN-25, LN-23P, LN-7, LN-8 oper-
B-3
• Conveniently located engine maintenance label under top engine door.
• Engine hour meter for scheduled maintenance.
• Electric start.
• Oil drain valve (no tools required).
• Smart machine! Remote operation and Magnum ® spool gun; 42VAC for LN-742 and Cobramatic ® feeders.
wire
• Easily check fuel level during operation and refuelling with highly visuable fuel gauge.
Some models have gauge located 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.
• See spec pages for receptacle information.
CONTROL AND SETTINGS
The diesel engine stop/start and idler controls are located on the case front panel. The welder controls are also located here. See
RANGER 305D
B-4
9
10
5
1
11
OPERATION
FIGURE B.1
6
NOTE: Layout and appearance vary between models.
8
7
3
2
4
16
14
15
12
13
B-4
ENGINE CONTROLS (Figure B.1)
1. RUN.STOP SWITCH: RUN position energizes the engine prior to starting. STOP position stops the engine.
2. GLOW PLUG PUSH BUTTON: When pressed, this button activates the engine glow plugs to preheat the engine for starting. This button also temporarily powers the fuel solenoid hold coil. On codes 10926 and 11121, the electric fuel pump is also temporarily activated.
3. 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 approximately 12 seconds and then go to low idle speed.
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, a 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.
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 regulator 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)
5. ELECTRIC FUEL GAUGE: (Codes 11121 and higher) gives accurate and reliable indication as to how much fuel is in the fuel tank.
6. ENGINE HOUR METER: Displays the total time that the engine has been running. This meter is useful for scheduling prescribed maintenance.
7. 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 “ON” position before starting the engine. If the Engine Protection or Battery Charging lights do NOT turn off shortly after starting the engine, stop the engine immediately and determine the cause.
8. 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
B-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 or the AC power load is turned off, a 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 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 an 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:
- CV-WIRE
- DOWNHILL PIPE
- CC-STICK
- TOUCH STARTING
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 welding 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 also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number 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 preferred 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 ARC CONTROL be set initially at 0.
B-5
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.
12. 14-PIN 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 circuits described in the 6-PIN AMPHENOL section below.
13. 6-PIN AMPHENOLPrimarily used to connect a remote control device, such as the K857, or a TIG Amptrol, such as the K870 or K812.
Both the 6 and 14-Pin amphenols are connected to a remote control auto-sensing circuit that transfers all or partial output control functions from the front panel output control dial to the remote output control device.
When in TOUCH START TIG mode, a remote output control 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 contactor 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.
NOTE: Both the 6 pin and 14 pin Amphenols share the same output control auto-sensing and contactor circuitry; for this reason, there can only be one device plugged into the Ranger 305D at any time.
14. WELD TERMINALS CONTROL SWITCHIn the
WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is closed.
15. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.
16. DIGITAL OUTPUT METERS:
The digital meters allow the output voltage (“CV-
WIRE” mode) or current (“CC-STICK”, “DOWNHILL
PIPE” and “TOUCH START TIG” modes) to be preset prior to welding using the output control dial. 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
B-6
ENGINE OPERATION
WARNING
Check and fill the engine fuel tank:
WARNING
OPERATION
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 on the engine.
Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed.
Read and understand all safety instructions included in the engine operatorʼs 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. Add oil (if necessary) to bring the level up to the fullmark. Do not overfill. Close the engine door.
4. Open the left side engine door and check the coolant level in the coolant recovery tank. Add coolant if necessary. See Maintenance section of this manual for details.
5. See the
section for specific oil and antifreeze 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 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. The engine will run at high idle speed for approximately 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
B-6
• 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.
• If 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.
NOTE: When starting a RANGER 305D for the first time, or after and extended period of time of not operating, 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 prefilter.
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
section and engine manual for specific fuel recommendations.
RANGER 305D
B-7
OPERATION
BREAK-IN PERIOD
Any engine will use a small amount of oil during its “breakin” 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 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
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.
Constant Current (CC-STICK) Welding
B-7
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 control 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 sticking. Start with the dial set at 0.
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:
DOWNHILL PIPE Welding
This slope controlled setting is intended for "out-of-position" 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(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 preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds.
TABLE B.2
TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES 2
Tungsten Electrode
Diameter in. (mm)
DCEN (-) DCEP (+)
1%, 2% Thoriated
Tungsten
3
3
3
10-20
15-30
25-40
40-55
55-80
180-125
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
Aluminum Stainless Steel
TIG TORCH
Nozzle Size 4, 5
0.010
0.020
0.040
1/16
3/32
1/8
5/32
3/16
1/4
(.25)
(.50)
(1.0)
(1.6)
(2.4)
(3.2)
(4.0)
(4.8)
(6.4)
1%, 2% Thoriated
Tungsten
2-15
5-20
15-80
70-150
150-250
250-400
400-500
500-750
750-1000
3-8
5-10
5-10
5-10
13-17
15-23
21-25
23-27
28-32
(2-4)
(3-5)
(3-5)
(3-5)
(6-8)
(7-11)
(10-12)
(11-13)
(13-15)
3-8
5-10
5-10
9-13
11-15
11-15
13-17
18-22
23-27
(2-4)
(3-5)
(3-5)
(4-6)
(5-7)
(5-7)
(6-8)
(8-10)
(11-13)
#4, #5, #6
#5, #6
#6, #7, #8
#8, #10
1
2
3
4
5
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 Society (AWS):
Pure
1% Thoriated
EWP
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.
DCEP is not commonly used in these sizes.
TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = 1/2 in.
#10 = 5/8 in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(16 mm)
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
B-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.
B-8
ARC GOUGING
The RANGER 305D can be used for limited arc gouging. For optimal performance, set the MODE switch to
CC-STICK and the ARC CONTROL to +10.
Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B.3
The ARC CONTROL is not active in the TIG mode.
The Ranger 305D can be used in a wide variety of DC TIG welding applications. In general the “Touch Start” feature allows contamination-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.
TABLE B.3 - CURRENT RANGE
PER ELECTRODE DIAMETER
Carbon Diameter
1/8"
5/32"
3/16"
Current Range (DC, electrode positive)
75-140 Amps
90-150 Amps
200-250 Amps c. Set the “WELD TERMINALS” switch to the “REMOTELY
CONTROLLED” position. This will keep the solid state contactor 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.
AUXILIARY POWER
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.
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 welding). Welding can be finely tuned using the ARC CONTROL.
Turning the ARC CONTROL clockwise for -10 (soft) to +10
(crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with the dial set at 0.
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 VAC receptacle can be split for single-phase 120
VAC operation.
Some recommended Innershield electrodes are: NR-311, NS-
3M, NR-203 Ni 1%, NR-204H. Recommended Outershield electrodes are :0S-70, OS-71M.
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 equivalent to volt-amperes at unity power factor. The maximum permissible, 40 amps continuous current of the
240 VAC output is 42 amps maximum.
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.
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
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 outlet to two separate 20 amp branch circuits. (These circuits cannot be paralleled.) Output voltage is within +/-
10% at all loads up to rated capacity.
B-9
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.
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. For extension cord lengths, see Table B.5.
SIMULTANEOUS WELDING AND
AUXILIARY POWER LOADS
The above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified 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 @
0
100
150
200
250
300
9500
7100
5600
4500
2800
0
120 VAC*
40*
40*
32
16
0
240 VAC
40*, (42* Peak) 40, (42 Peak)
30
23
16
0
8
* 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.
Current
(Amps)
15
20
15
20
33
Voltage
(Volts)
120
120
240
240
240
Load
(Watts)
1800
2400
3600
4800
8000
14 AWG
30
60
(9)
(18)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG
40
30
75
60
(12)
(9)
(23)
(18)
10 AWG
75
50
150
100
(23)
(15)
(46)
(30)
88
8 AWG
125
225
175
(38)
(27)
(69)
(53)
60 (18) 100 (30)
Conductor size is based on maximum 2.0% voltage drop.
6 AWG
175
138
350
275
175
(53)
(42)
(107)
(84)
(53)
4 AWG
300
225
600
450
250
(91)
(69)
(183)
(137)
(76)
RANGER 305D
B-10
NOTES
B-10
RANGER 305D
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Connection of the LN-25 with 42V Remote Output Control Module..............................C-5
Section C-1
RANGER 305D
C-2
OPTIONS / ACCESSORIES
ACCESSORIES
T12153-9 50 AMP, 120/240V POWER PLUG -
Provides one dual voltage plug for full KVA power.
FIELD INSTALLED OPTIONS
The following options/accessories are available for your Ranger 305D from your Lincoln distributor.
C-2
TIG WELDING ACCESSORIES
K1783-9 TIG TORCH - For TIG welding with shielding gas. Includes 25 feet of cable.
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.
K963-2 - Hand Amptrol.
K870 - Foot Amptrol
NOTE: TIG welding requires a Magnum TM TIG Gun, appropriate Magnum Parts Kit and argon gas.
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.
SEMIAUTOMATIC FCAW AND MIG
WELDING ACCESSORIES
LN-25 WIRE FEEDER K449 - This portable unit provides 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 K444-1 Remote Voltage
Control Kit or K857 Remote Control is required. Refer to connection instructions later in this section.
K1789-1 ROLL CAGE - Gives added damage protection.
LN-7 OR LN-8 WIRE FEEDER - Semiautomatic, constant speed wire feeders.
K886-2 CANVAS COVER - Protects machine when not in use.
NOTE: Gas-shielding welding requires a Magnum
Gun. Gasless welding requires an Innershield Gun.
K1898-1 SPARK ARRESTER - Attaches between muffler or exhaust elbow.
LN-742 WIRE FEEDER - A semiautomatic wire feeder with “cold” electrode. Refer to connection instructions later in this section.
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 filter, G300 work clamp and Cooltong 300 electrode holder. Cables are rated at 300 amps, 40% duty cycle.
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.
K857 28 ft (8.5m) 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.
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.
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 current 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.
K444-1 REMOTE VOLTAGE CONTROL - Provides voltage adjustment control at the feeder. Includes 25 feet of cable.
K126-2 INNERSHIELD GUN - For gasless welding.
Includes 15 feet of cable.
K470-2 MAGNUM GUN CONNECTOR KIT - For gasshielding welding.
K466-1 MAGNUM GUN CONNECTOR KIT - For connecting the Magnum 300 MIG Gun to the feeder for gas-shielding welding.
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.
RANGER 305D
C-3
ACCESSORIES
C-3
K18161 FULL KVA ADAPTER KIT
Plugs into the 120/240V NEMA 14-0R receptacle on the casefront (which accepts 4-prongs plugs) and converts it to a NEMA 6-50R receptacle, (which accepts 3prong plugs.)
CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS
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 following NOTES, indicated on the figure:
WARNING
ELECTRIC SHOCK can kill.
. 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.
TO
K867
2
4
TO
WIRE
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 welding output, use an isolation relay to close leads 2 and 4.
C. Refer to the
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
------------------------------------------------------------------------
CONNECTION OF THE RANGER 305D TO
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 discussion and connection diagram explain in general how to make the proper connections.
1. Shut the welder off.
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 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 “+” or “-” depending on the polarity chosen.
7. Set the 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
81
82
SPARE
2
4
41
42
31
32
GND
21
77
76
75
NOT USED ON RANGER POWER SOURCES
CONNECT TOGETHER FOR
WELDING OUTPUT
42 VAC
115 VAC
C
B
A
POWER SOURCE FRAME CONNECTION
WIRE FEEDER VOLTMETER CONNECTION
CONNECTS TO (WORK TERMINAL) OF POWER SOURCE
10K
REMOTE OUTPUT CONTROL
MIN.
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
RANGER 305D
C-4
ACCESSORIES
CONNECTION OF THE LN-25 TO THE
RANGER 305D “ACROSS THE ARC”
(SEE FIGURE C.2.)
1. Shut the welder off.
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.
NOTE: Figure C.2 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.
NOTE: Welding cable must be sized for current and duty cycle of application.
3. Set the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen.
4. Set the “MODE” switch to the “CV-WIRE” position.
C-4
5. Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead. This is only a control lead - it carries no welding current.
6. Place the “IDLER” switch in the “AUTO” or “HIGH” position as desired.
CAUTION
If you are using an LN-25 without an internal contactor, 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 the
LN-25 if optional remote control kit is used.
9. Set the ARC control to “0” initially and adjust to suit.
FIGURE C.2 - Ranger 305D/LN-25 ACROSS THE ARC CONNECTION DIAGRAM
14-PIN
AMPHENOL
6-PIN
AMPHENOL
+
-
TO WORK
OPTIONAL K444-1
REMOTE CONTROL
LN-25
WIRE FEEDER
WORK CLIP LEAD
TO WORK
ELECTRODE CABLE
RANGER 305D
C-5
ACCESSORIES
CONNECTION OF THE LN-25 TO THE
RANGER 305D WITH 42 VOLT REMOTE
OUTPUT CONTROL MODULE
(SEE FIGURE C.3.)
C-5
5. Set the “MODE” switch to the “CV-WIRE” position.
6. Place the “IDLER” switch in the “AUTO” or “HIGH” position as desired.
CAUTION
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 connected 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 “-” depending on the polarity chosen.
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 circuit may be damaged. The engine governor setting is preset at the factory - do not adjust above RPM specifications 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
C-6
ACCESSORIES
CONNECTION OF THE LN-25 TO THE
RANGER 305D “ACROSS THE ARC”
WITH K857 REMOTE CONTROL
(SEE FIGURE C.4.)
1. Shut the welder off.
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.
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
C-6
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 “-” depending on the 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 ARC control to “0” 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
OPTIONAL K857
REMOTE CONTROL
LN-25
WIRE FEEDER
WORK CLIP LEAD
TO WORK
ELECTRODE CABLE
RANGER 305D
C-7
ACCESSORIES
CONNECTION OF THE LN-7 TO THE
RANGER 305D USING K584 CONTROL
CABLE
(SEE FIGURE C.5.)
C-7
4. Set the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen.
5. Set the “MODE” switch to the “CV-WIRE” position.
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 terminals.
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.
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 circuit may be damaged. The engine governor setting is preset at the factory - do not adjust above RPM specifications 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 control is used.
9. Set the ARC control to “0” 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
K584-XX CONTROL CABLE
ELECTRODE CABLE
TO WIRE FEED UNIT
OPTIONAL K857
REMOTE CONTROL
RANGER 305D
C-8
ACCESSORIES
CONNECTION OF THE LN-8 TO THE
RANGER 305D USING K595 CONTROL
CABLE
(SEE FIGURE C.6.)
5. Place the “IDLER” switch in the “HIGH” position.
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.
C-8
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 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 “+” or “-” depending 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 “0” initially and adjust to suit.
FIGURE C.6 - Ranger 305D/LN-8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM
TO LN-8 INPUT
CABLE PLUG
K595 CONTROL CABLE
14-PIN
AMPHENOL
+
-
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
RANGER 305D
C-9
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 the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen.
5. Set the “MODE” switch to “CV-WIRE” position.
CAUTION
C-9
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 circuit may be damaged. The engine governor setting is preset at the factory - do not adjust above RPM specifications 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.
6. Place the “IDLER” switch in the “AUTO” or “HIGH” position, as desired.
14-PIN
AMPHENOL
FIGURE C.7 - Ranger 305D/LN-742 CONNECTION DIAGRAM
TO LN-742 INPUT
CABLE PLUG
K619 CONTROL CABLE
+
-
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
RANGER 305D
C-10
NOTES
C-10
RANGER 305D
Section D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance ..........................................................................................................................Section D
Section D-1
RANGER 305D
D-2
SAFETY PRECAUTIONS
MAINTENANCE
ROUTINE AND PERIODIC
MAINTENANCE
WARNING
• Have qualified personnel do all maintenance and troubleshooting work.
ENGINE MAINTENANCE
CAUTION
• Turn the engine off before working inside the machine.
• Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. If 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 Operatorʼs Manual before working on this machine.
D-2
To prevent the engine from accidentally starting, disconnect the negative battery cable before servicing the engine.
------------------------------------------------------------------------
See
for a summary of maintenance intervals for the items listed in
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
for major component locations.
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.
At the end of each dayʼs 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 oil 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
D-3
MAINTENANCE
TABLE D.2 - KUBOTA D722 ENGINE MAINTENANCE SCHEDULE
INTERVAL
Daily
First 50 Hours
75 Hours
100 Hours
150 Hours
200 Hours
400 Hours
500 Hours
800 Hours
1500 Hours
3000 Hours
Every Year
Every Two Years
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)
Check engine oil and oil filter
Check engine oil
Clean fuel filter
Check battery electrolyte level
Change oil filter
Check radiator hoses and clamps
Replace fuel filter
Replace fan belt
Flush radiator
Remove sediment from fuel tank
Check and adjust valve clearances (2)
Check fuel injector nozzle pressure (2)
Check fuel injection pump and timer (2)
Replace air cleaner element (1)
Replace 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.
RANGER 305D
D-3
D-4
MAINTENANCE
D-4
Wash your hands with soap and water after handling used oil.
Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well.
• Be sure the unit is off. Disconnect the negative battery cable to ensure safety.
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.
• Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder.
Oil Filter Change
• Drain the oil.
• 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.
• Remove the oil filter with an oil filter wrench and drain the oil into a suitable container. Discard the used filter. Note: Care should be taken during filter removal to not disrupt or damage in any way the fuel lines.
• Close the drain valve by pushing in and twisting clockwise. Replace the cap.
• Clean the filter mounting base and coat the gasket of the new filter with clean engine oil.
• Re-fill the crankcase to the upper limit mark on the dipstick with the recommended oil (see engine operation manual OR engine service items decal OR below). Replace and tighten the oil filler cap securely.
• Screw the new filter on by hand until the gasket contacts 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 • Push oil drain hose and valve back into unit, re-connect 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)
• 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.
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 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 classifications.)
SAE 10W30 is recommended for general, all temperature use, 5F to 104F (-15C to 40C).
See engine ownerʼs manual for more specific information on oil viscosity recommendations.
RANGER 305D
D-5
MAINTENANCE
Service Instructions & Installation Tips
For Engine Air Filter
Release the
1
Seal Carefully
Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they donít hinder filter removal/installation. Most latches are spring loaded to fold back when open.
The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter of the filter endcap. 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.
Avoid Dislodging
2
Dust from the Filter
Gently pull the filter off the outlet tube and out of the housing. Avoid knocking the filter against the housing.
3
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.
5
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 is a telltale sign.
Remove any cause of leaks before installing new filter.
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, apply 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!
Inspect the New
6
Filter for Damage
Inspect the new filter carefully, paying attention to the inside of the open end, which is the sealing area.
NEVER install a damaged filter.
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.
Insert the New
7
RadialSeal
ô
Filter by Hand
Insert carefully. Seat the new filter by hand,
Check Connections
8
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.
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 cover and push
(by hand) the filter further into the air cleaner and try again.
The cover should go on with no extra force.
Clean the Inside of
4
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 ëdustí an engine!) Be careful not to damage the sealing area on the tube.
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 ñ 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
D-5
D-6
WARNING
MAINTENANCE
COOLING SYSTEM
WARNING
Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.
D-6
HOT COOLANT can burn skin.
• Do not remove cap if radiator is hot.
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:
------------------------------------------------------------------------
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 coolant to radiator. Fill up to the top of the tube in the radiator filler neck which includes a connecting hose coming from the thermostat 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.
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 lbs. (7 to 9 mm/10Kg).
RANGER 305D
D-7
MAINTENANCE
D-7
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. See the Engine Operatorʼs Manual for instructions on replacing the fuel filter.
BLEEDING THE FUEL SYSTEM
2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre-filter.
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.
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.
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. 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
(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 system. It is generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system. Operate the priming lever on the pump to assist starting and after extended periods of non-use or out of fuel conditions.
WARNING
GASES FROM BATTERY can explode.
• 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.
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 handle) 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 accumulation or sediment.
• CONNECTING A BATTERY CHARGER —
Remove battery from welder by disconnecting negative cable first, then positive cable and battery 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.
• Wear gloves and eye protection and be careful when working near battery.
• Follow instructions printed on battery.
RANGER 305D
D-8
MAINTENANCE
CLEANING THE BATTERY
Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113
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 battery 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.
WELDER / GENERATOR
MAINTENANCE
D-8
STORAGE: Store the RANGER 305D in clean, dry protected areas.
CLEANING: Blow out the generator and controls periodically 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.
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.
BRUSH REMOVAL AND REPLACEMENT: Itʼs normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary.
CHARGING THE BATTERY
When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The RANGER 305D positive (+) battery terminal has a red terminal cover.
CAUTION
Do not attempt to polish slip rings while the engine is running.
WARNING
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 battery cable first and the negative cable last. Failure to do so can result in damage to the internal charger components.
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.
Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.
OPTIONAL SPARK ARRESTOR
WARNING
MUFFLER MAY BE HOT.
Allow the engine to cool before installing the spark arrestor!
Clean the spark arrestor after every 100 hours of use.
RANGER 305D
D-9
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 receptacle:
• 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 equipment is providing at least 80 volts to the receptacle 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 operation.
• 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 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 working 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 necessary or replace the device.
D-9
RANGER 305D
D-10
MAINTENANCE
1. CASE FRONT ASSEMBLY
FIGURE D.1 – MAJOR COMPONENT LOCATIONS
2. CONTROL PANEL ASSEMBLY
3. STATOR & ROTOR ASSEMBLY
77
4. BLOWER BAFFLE ASSEMBLY
5. BASE, FUEL TANK ASSEMBLY
6. ENGINE ASSEMBLY
7. CASE COVERS
66
33
44
22
11
55
D-10
RANGER 305D
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation..............................................................................................................Section E
Section E-1
FIGURE E.1 – RANGER 305D BLOCK LOGIC DIAGRAM
POWER
MODULE
IGBTs
CHOKE
SHUNT
-
+
ENGINE
PROTECTION
LIGHT
ENGINE
PROTECTION
CIRCUIT
CHARGING
SYSTEM LIGHT
(CODE 10926 ONLY)
ENGINE
SENSORS
GLOW
PLUGS
ENGINE
ALTERNATOR
12V.
BATTERY
GLOW
PLUG
BUTTON
RUN
STOP
SWITCH
FUEL
PUMP
FUEL
SOLENIOD
HOLD COIL
PULL COIL
START
BUTTON
ENGINE
STARTER
IDLE
SOLENOID
PULL
COIL
HOLD
COIL
PULL COIL
PC BOARD
WELD
WINDING
ROTOR
STATOR
EXCIT ER
WINDING
120/240 VAC
AUX.WINDING
FLASHING
42 VAC
WINDING
240
VAC
RECEPTACLES
CURRENT
SENSOR
14
PIN
AMPHENALS
WELD CONTROL
P.C. BOARD
OUTPUT
CONTROL
MODE
SWITCH
WELDING
TERMINAL
SWITCH
ARC
CONTROL
IDLE
SWITCH
AMP
DISPLAY
VOLT
DISPLAY
RANGER 305D
E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, ENGINE, ENGINE PROTECTION, CHARGING, IDLE CONTROL
E-2
SHUNT
POWER
MODULE
IGBTs
CHOKE
-
+
ENGINE
PROTECTION
LIGHT
ENGINE
PROTECTION
CIRCUIT
CHARGING
SYSTEM LIGHT
(CODE 10926 ONLY)
ENGINE
SENSORS
GLOW
PLUGS
ENGINE
ALTERNATOR WELD
WINDING
FUEL
PUMP
FUEL
SOLENIOD
HOLD COIL
PULL COIL
ENGINE ROTOR
START
BUTTON
STARTER
IDLE
SOLENOID
PULL
COIL
HOLD
COIL
PULL COIL
PC BOARD
STATOR
EXCIT ER
WINDING
120/240 VAC
AUX.WINDING
FLASHING
42 VAC
WINDING
240
VAC
RECEPTACLES
CURRENT
SENSOR
120 vac
14
PIN
AMPHENALS 6
PIN
WELD CONTROL
P.C. BOARD
AMP
DISPLAY
VOLT
DISPLAY
12V.
BATTERY
GLOW
PLUG
BUTTON
RUN
STOP
SWITCH
GENERAL DESCRIPTION
The Ranger 305D is a diesel engine-driven welding power source capable of producing 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 Chopper
Technology to produce DC current for multi-purpose
welding applications. The Ranger 305D is also capable 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.
IDLE
SWITCH
OUTPUT
CONTROL
MODE
SWITCH
WELDING
TERMINAL
SWITCH
ARC
CONTROL
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 cranks 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
E-3
THEORY OF OPERATION
FIGURE E.3 –ENGINE IDLE SYSTEM, IDLE SWITCH & IDLE SOLENOID
E-3
SHUNT
POWER
MODULE
IGBTs
CHOKE
-
+
ENGINE
PROTECTION
LIGHT
ENGINE
PROTECTION
CIRCUIT
CHARGING
SYSTEM LIGHT
(CODE 10926 ONLY)
ENGINE
SENSORS
GLOW
PLUGS
ENGINE
ALTERNATOR WELD
WINDING
FUEL
PUMP
ENGINE ROTOR
FUEL
SOLENIOD
HOLD COIL
PULL COIL
START
BUTTON
STARTER
IDLE
SOLENOID
PULL
COIL
HOLD
COIL
STATOR
EXCIT ER
WINDING
120/240 VAC
AUX.WINDING
FLASHING
42 VAC
WINDING
240
VAC
RECEPTACLES
CURRENT
SENSOR
120 vac
14
PIN
AMPHENALS 6
PIN
WELD CONTROL
P.C. BOARD
AMP
DISPLAY
VOLT
DISPLAY
12V.
BATTERY
GLOW
PLUG
BUTTON PULL COIL
PC BOARD
RUN
STOP
SWITCH
IDLE
SWITCH
OUTPUT
CONTROL
MODE
SWITCH
WELDING
TERMINAL
SWITCH
ARC
CONTROL
Engine Idle System Idle Solenoid Operation:
Idle Switch Operation:
When the engine is started it operates at high RPM. If the idle switch is in the high position operate at high RPM.
the automatic idle system is inactive and the engine will continue to
The 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 preset low RPM setting.
If the engine is started with the idle switch in the auto position, or 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 significant 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 second 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 deactivated, allowing the engine governor to increase the RPM to high speed.
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 needed power to reliably move the speed control lever to the low idle position.
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
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
RANGER 305D
E-4
THEORY OF OPERATION
FIGURE E.4 – GENERATING POWER & OUTPUT
E-4
POWER
MODULE
IGBTs
CHOKE
SHUNT
-
+
ENGINE
PROTECTION
LIGHT
ENGINE
PROTECTION
CIRCUIT
CHARGING
SYSTEM LIGHT
(CODE 10926 ONLY)
ENGINE
SENSORS
GLOW
PLUGS
ENGINE
ALTERNATOR WELD
WINDING
ROTOR FUEL
PUMP
FUEL
SOLENIOD
HOLD COIL
PULL COIL
START
BUTTON
ENGINE
STARTER
IDLE
SOLENOID
PULL
COIL
HOLD
COIL
PULL COIL
PC BOARD
STATOR
EXCIT ER
WINDING
120/240 VAC
AUX.WINDING
FLASHING
42 VAC
WINDING
240
VAC
RECEPTACLES
CURRENT
SENSOR
120 vac
14
PIN
AMPHENALS 6
PIN
WELD CONTROL
P.C. BOARD
AMP
DISPLAY
VOLT
DISPLAY
12V.
BATTERY
GLOW
PLUG
BUTTON
RUN
STOP
SWITCH
OUTPUT
CONTROL
MODE
SWITCH
WELDING
TERMINAL
SWITCH
ARC
CONTROL
IDLE
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 generate 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 the output of the main generator until the design voltage 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 battery 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 converted to DC by a three phase output rectifier then filtered 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
E-5
THEORY OF OPERATION
FIGURE E.5 – WELD POWER & CONTROL
E-5
POWER
MODULE
IGBTs
CHOKE
SHUNT
+
-
ENGINE
PROTECTION
LIGHT
ENGINE
PROTECTION
CIRCUIT
CHARGING
SYSTEM LIGHT
(CODE 10926 ONLY)
ENGINE
SENSORS
GLOW
PLUGS
ENGINE
ALTERNATOR WELD
WINDING
FUEL
PUMP
FUEL
SOLENIOD
HOLD COIL
PULL COIL
START
BUTTON
STARTER
ENGINE
IDLE
SOLENOID
PULL
COIL
HOLD
COIL
PULL COIL
PC BOARD
ROTOR
STATOR
EXCIT ER
WINDING
120/240 VAC
AUX.WINDING
FLASHING
42 VAC
WINDING
240
VAC
RECEPTACLES
CURRENT
SENSOR
120 vac
AMPHENALS 6
PIN
WELD CONTROL
P.C. BOARD
AMP
DISPLAY
VOLT
DISPLAY
12V.
BATTERY
GLOW
PLUG
BUTTON
RUN
STOP
SWITCH
OUTPUT
CONTROL
MODE
SWITCH
WELDING
TERMINAL
SWITCH
ARC
CONTROL
IDLE
SWITCH
Weld Power and Control
Weld Power:
Approximately 90VDC power, as described earlier under the heading “Generating Power”, is supplied to the IGBTʼs, (See IGBT Operation) and to the control circuitry in the power module, as well as the weld control
PC board.
The IGBTʼs 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.
The DC power that is being controlled by the IGBTʼs is now applied to the choke. The choke is a heavy conductor 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 discharge 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 IGBTʼs off times.
Weld Control and Feedback:
The operator provides input to the weld control circuitry by means of the output control and arc control potentiometers, and the mode switch. These operator inputs are used by the microprocessor, together with pre-programmed internal parameters, current feedback from the shunt, and voltage feedback from the output studs, to control the IGBTʼs via the PWM signal discussed earlier.
RANGER 305D
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 output 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 potentiometer varies the output from minimum to maximum value set 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 accomplished 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 activating 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 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 outputs Amps and Volts. When no current is flowing, the machine is in “preset” mode and only one of the displays 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 indicate actual weld volts and amps.
E-6
RANGER 305D
E-7
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.
E-7
Hence 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
ALTERNATOR
DC RECTIFIER
AND FILTER
SOLID STATE
SWITCH
ARC
CONTROL
INDUCTOR
AND DIODE
ARC
In this system, the engine drives a three-phase alternator, which generates power that is rectified and filtered to produce about 90 VDC. The current is applied through a solid state switch to an inductor. By turning 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:
90 VDC
INDUCTOR
SWITCH
DIODE
CURRENT WITH SWITCH OPEN
CURRENT WITH SWITCH CLOSED
ARC
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 controlled. This is the basis for Chopper Technology:
Controlling the switch in such a way as to produce superior welding.
RANGER 305D
E-8 THEORY OF OPERATION
FIGURE E.6 – IGBT OPERATION
E-8
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 signal 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 microseconds 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 maximized. The darkened area under the top curve can be compared to the area under the bottom curve. The more darkened area under the curve, the more power is present.
RANGER 305D
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
Output Rectifier Bridge and Choke Removal and Replacement...................................F-83
Section F-1
Normal Open Circuit Voltage Waveform (120 VAC Supply)..........................................F-97
RANGER 305D
F-2
TROUBLESHOOTING & 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 malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM” (SYMP-
TOMS). This column describes possible symptoms that the machine may exhibit. Find the listing 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 contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted 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 subject 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 electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.
F-2
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
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
F-3
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do 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 problems 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. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC Board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
• Remove your bodyʼs static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.
• If you donʼt have a wrist strap, touch an unpainted, grounded, part of the equipment frame.
Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.
• 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 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 proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
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 control wiring harness, junction blocks, and terminal 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
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Major mechanical or electrical damage is evident.
POWER OUTPUT PROBLEMS
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. Contact the Lincoln Electric
Service Department at 1-888-
935-3877.
No welding output or auxiliary power. The engine operates normally.
1. Check for loose or faulty connections at any leads, cables or cords attached to either the auxiliary output receptacles and/or the weld output terminals.
1. Check the brushes for wear and proper contact to the rotor slip rings.
3. Perform the Rotor Voltage Test.
4. Perform the
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 problem is solved, the fault may be in the external control cable, or the attached wire feeder, amptrol, arc start switch, etc. (if used)
2. 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” position; check for the presence of approximately 58VDC, OCV
(open circuit voltage) at the weld output terminals.
3. If the correct OCV is present at the welding output terminals, check the cables,connectors, welding 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 assemblies for damage and faulty connections.
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
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
No auxiliary power at one or more receptacles, or at the 14 pin
Amphenol receptacle. Weld output is normal, and the engine operates normally.
POWER OUTPUT PROBLEMS
1. Check for loose or faulty connections at any cords attached to the auxiliary output receptacles, or to the 14 pin Amphenol receptacle.
RECOMMENDED
COURSE OF ACTION
1. Check for tripped circuit breakers and/or tripped GFCI receptacles.
2. Perform the
The machine has low welding output and low auxiliary output.
1. The engine RPM may be too low.
2. The brushes may be worn, sticking, or poorly seated.
1. The high idle speed may be low.
Perform the
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 horsepower, and may be in need of service.
NOTE: Normal Full load engine speed should be about 3500 RPM.
2. Inspect and, if necessary, service the brushes and slip rings per the
3. Perform the
4. Perform the
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
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The machine will weld, but the welding arc is “cold”. The engine runs normally and the auxiliary power is normal.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELD OUTPUT PROBLEMS
1. Make sure the machine is properly set for the electrode and process being used. Check electrode size, mode switch setting, amps or voltage setting. If gas is used, make sure the correct type of gas is used and that the gas flow is set correctly.
2. Make sure that the process does not demand more power than the machines able to produce.
3. If the current seems about right, but the electrode easily sticks in the puddle, try increasing the
“ARC CONTROL” setting.
4. Check for loose or faulty connections at the weld output terminals and welding cable connections.
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.
RECOMMENDED
COURSE OF ACTION
1. The engine RPM may be too low.
Perform the
2. Connect the machine to a resistive 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
for recommended methods of measuring engine RPM.
3. 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 ON” position.
4. Make sure that nothing is plugged into either of the
Amphenol receptacles.
5. Start the machine and allow the engine to run for about a minute. Apply a load with the resistance load bank, and adjust 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
F-7
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING GUIDE
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 excessive electrical inductance in the weld circuit. Try welding after uncoiling the cables, or disconnect the existing cables and weld with a set of adequately sized, short test cables.
RECOMMENDED
COURSE OF ACTION
6. With the above load applied, the engine should maintain at least
3350 RPM. If the 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 damaged. If this doesnʼt help, the engine should be serviced.
7. Compare the volt and amp readings shown on the external meters with the readings displayed on the machineʼs front panel. If these readings differ significantly, perform the
8. If the maximum weld output cannot be obtained even though the engine maintains correct
RPM, and the front panel displays are reading accurately.
Check for damaged conductors and loose or damaged connections at each of the large weldcurrent carrying conductors that connect the stator, output rectifier, chopper module, choke, shunt, and output terminals.
See the wiring diagram.
9. If all of the these connections are good, perform the
10. Perform the
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
F-8
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-8
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 colder.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELD OUTPUT PROBLEMS
1. 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.
2. 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
Lincolnʼs recommendations for that product.
3. 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.
4. Check for loose or faulty connections at the weld output terminals and welding cable connections.
5. Check for adequate connection between the work cable and the work piece. The 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.
6. The weld cables may be too long, and/or too small, causing excessive voltage drop between the machine and the arc.
RECOMMENDED
COURSE OF ACTION
1. The engine may not be maintaining correct RPM. Perform the
the engine has an adequate supply of clean, fresh fuel.
Check the fuel and air filters, replace if necessary.
2. If the engine still fails to maintain 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 board. Pull each plug from the weld control PC board and thoroughly insect the terminals in both the plugs and the PC board receptacles. Make sure the connections are clean and that the pins are properly seated in the plastic plug housing.
Check for loose or damaged pins and faulty crimp connections.
5. 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
F-9
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The machine welds, but it will not maintain a steady output. The arc may suddenly get hotter or colder.(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 excessive electrical inductance in the weld circuit. Try welding after uncoiling the cables, or disconnect the existing weld cables and attach a set of adequately sized, short test cables.
The weld output cannot be adjusted with the front panel output control 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.
1. Remote control devices completely disable the front panel control in all modes except touch start TIG mode. Make sure nothing is plugged into either of the Amphenol receptacles.
2. Check for dirt or moisture contamination in either 6 pin or the
14 pin amphenol receptacle.
RECOMMENDED
COURSE OF ACTION
6. The output control or arc control potentiometers may be defective or grounded. The mode switch may also be faulty.
Perform the
7. The Amphenol receptacles may be contaminated or defective.
Perform the
8. Replace the weld control PC board.
1. Perform the
2. The output control potentiometer may be defective.
3. Perform the
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
F-10 F-10
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
The machine front panel output control is still active when the remote control unit is connected to one of the Amphenol Receptacles.
The machine seems to be locked into the “CC-STICK” mode of operation.
WELD OUTPUT PROBLEMS
1. The condition is normal in
“Touch Start TIG” mode.
See the operators’ manual.
2. The remote control unit may be defective.
3. Check the Amphenol receptacles. Look for damaged or corroded contact pins in the receptacle and in the plug of the remote control unit.
1.. Check plug #P1 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 tightly together.
2. There may be a poor connection between the weld control PC board and the Amphenol receptacles.
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 pin “G”.
P1-11 to 6 pin Amphenol pin “A” and to 14 pin Amphenol pin “E”.
1. 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.
P1-14 to 6 pin Amphenol “B” and to
14 pin Amphenol pin “F”.
3. The weld control Pc board may be defective.
1. Check that plug P-7 is fully seated 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 and solder connections as well as damaged wiring or insulation.
See wiring diagram.
2. Perform the
3. 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
F-11
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-11
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The arc quality is poor with excessive spatter. The arc heat can be controlled and maintained normally, the auxiliary output is normal, and the engine operates normally.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELD OUTPUT PROBLEMS
1. The arc Control may be set too high. Try using a lower setting.
2. The output control may be set too high for the electrode being used. Try welding at a lower setting.
3. 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
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 excessive electrical inductance in the weld circuit. Try welding after uncoiling the cables, or disconnect the existing weld cables and attach a set of adequately sized, short test cables.
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. The resistance should be very high, a reading of 500,000 (500k) ohms or higher is acceptable.
2. The weld control system may be grounded or malfunctioning.
Perform the
3. The Chopper module may be defective.
Perform the
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
F-12
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-12
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The machine welds normally in all modes and the range of weld output 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.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
MISC. WELD ISSUES
1. It is normal for one of the displays to be off when there is no load across the weld output terminals. In CV-WIRE mode, only the “VOLTS” display will be illuminated, in all other modes only the “AMPS” display will be illuminated.
RECOMMENDED
COURSE OF ACTION
1. NOTE: Both the “AMPS” and the “VOLTS” front panel displays use the same part numbered 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 malfunctioning display.
2. If the known good display functions normally when plugged in, in place of the malfunctioning display, the weld control PC board is good and only the malfunctioning display unit should be replaced.
3. If the known good display exhibits the same type of problem as the malfunctioning display, the weld control PC board is defective and should be replaced.
A control cable type wire feeder does not function when connected to the 14 pin amphenol receptacle.
Machine operates normally in CC-
STICK mode, and has normal AC auxiliary output.
1. Check circuit breaker CB1 if using a 115-120 VAC wire feeder. Check CB8 if using a 42
VAC wire feeder. Reset circuit breaker if tripped.
2. Check the Amphenol receptacle for damaged, corroded, or dirty contact pins.
3. The wire feeder control cable may be defective.
4. The wire feeder may be defective.
1. 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.
2. NOTE: Be careful that meter probes do not deform or damage the contact pins in the
Amphenol receptacle.
3. Perform the
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
F-13
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-13
TROUBLESHOOTING GUIDE
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
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, typically “CV-WIRE” mode.
3. Check for poor weld cable connections 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 properly connected to the work piece, and is in good condition.
5. The wire feeder may be defective.
RECOMMENDED
COURSE OF ACTION
1. Use a volt meter to check for the presents about 58 VDC open circuit voltage (OCV) across the output studs of the machine.
2. If the OCV is low, there may be a problem with the mode switch.
Perform the
3. If there is no OCV, see the troubleshooting section for “No
welding output in any mode”
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
F-14
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-14
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The engine will not crank when start button is pushed.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE AND IDLE PROBLEMS
1. Check circuit breaker (CB7).
Reset if tripped.
2. Make sure the run/stop switch is in the “RUN” position.
1. Check wiring and connections at the starter motor, glow plug button. CB7 circuit breaker.
run/stop switch, and the start button. See wiring diagram.
3. Check for loose or faulty battery cable connections. See wiring diagram.
2. Check the chassis ground connections between the engine block and the negative battery terminal.
4. The battery may be low or faulty. If the battery is low, recharge it. If the battery will not accept a charge, replace it.
3. Place the run/stop switch to the
“RUN” position. Press the start button, while checking for voltage between a good clean chassis ground connection (-) and lead #211(+) at the starter solenoid. See the wiring diagram.
The battery does not stay charged. 1. Check for loose, corroded, or faulty connections at the battery.
2. Check for loose or damaged alternator drive belt.
3. The battery may be faulty.
4. If no voltage is present, check the start button, the run/stop switch, and the CB7 circuit breaker. See the wiring diagram.
5. 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.
1. Perform the
2. There may be a defective component or fault wiring, causing a current draw when the run/stop switch is in “stop” position.
3. Check the Run/stop switch, the glow plug button, the alternator and the starter solenoid. Also check for damaged wiring and insulation.
4. If the engine charging system is operating properly but the battery is not staying charged, the battery is defective and should be replaced.
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
F-15
TROUBLESHOOTING & REPAIR
F-15
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The engine cranks when the start button is pressed but will not start.
TROUBLESHOOTING GUIDE
POSSIBLE AREAS OF
MISADJUSTMENT(S)
ENGINE AND IDLE PROBLEMS
1. 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 producing adequate voltage, and replaced if it will not accept a full charge.
RECOMMENDED
COURSE OF ACTION
1. The fuel solenoid may be faulty or not operating properly.
Check lead #231 and perform the
2. The engine may be in need of mechanical repair.
2. Make sure the glow plug button is pressed while pushing the start button. See the operatorʼs manual, or the operation section of this manual for the proper starting procedure.
3. Make sure the fuel valve on the fuel sediment filter is in the open position.
4. Check that the machine has an adequate supply of fresh, clean fuel.
5. The fuel filter may be clogged.
Replace the fuel filter if necessary.
The engine starts, but shuts down immediately when the start button is released.
6. Check the oil level.
1. 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
1. The fuel solenoid may be faulty or not operating properly.
Check lead #225B and perform the
the wiring diagram.
AFTER THE ENGINE STARTS)
See the operatorʼs manual, or the operation section of this manual for the proper starting procedure.
2. 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.
2. Check the oil level. Be certain that the engine is not overheated.
3. The engine protection relay may be faulty. The engine may have inadequate oil pressure.
3. Check that the machine has an adequate supply of fresh, clean fuel.
4. The oil pressure switch or coolant temperature switch may be faulty.
4. The fuel filter may be clogged.
Replace the fuel filter if necessary.
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
F-16
Observe Safety Guidelines detailed in the beginning of this manual.
F-16
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The engine shuts down shortly after starting.
ENGINE AND IDLE PROBLEMS
1. Check for adequate supply of clean, fresh fuel.
1. The oil pressure switch or coolant temperature switch may be faulty.
2. Check fuel and air filters, replace if necessary.
2. Check for faulty run/stop switch or engine protection relay.
3. Check oil level, add oil as required, and look for oil leakage.
4. Check for loose or faulty battery cable connections.
3. Check for damaged insulation in the wiring between the engine projection relay and the oil pressure and coolant temperature switches. See wiring diagram.
4. Check for poor electrical connections at the run/stop switch, the engine protection relay, the
D4 diode bridge, and the fuel solenoid. See wiring diagram.
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 resetting of the circuit breaker can damaged it, or alter its trip point. If the breaker has been tripped and reset many times, it should be replaced.
5. The fuel solenoid may be faulty.
Perform the Fuel Solenoid Test.
1. Examine the CB7 circuit breaker, run/stop switch, stop button,
Shut-down and idle solenoids, pull coil PC board, engine protection relay, fuel gauge and sender, alternator, and all the wiring connecting these components. Look for any damaged or out of place wiring that may be in contact with other conductors or chassis ground.
See the wiring diagram.
2. Perform the Idle Solenoid Test.
Perform the
3. The Pull coil PC board may be defective.
Disconnect lead 232 from terminal B1 of the pull coil
PC board and insulate it or position 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 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
F-17
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-17
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The engine will not develop full power.
ENGINE AND IDLE PROBLEMS
1. The fuel may be old or contaminated. Supply the engine with fresh, clean fuel.
1. The engine may be in need of adjustment or repair.
2. The fuel filter may be clogged; replace the filter if necessary.
3. The air filter may be clogged; replace if necessary.
The engine will not idle down 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 restrictions in the idler solenoid linkage.
1. Perform the
2. Check for damaged wiring or faulty connections at idle solenoid, the pull coil PC board, the run/stop switch, and the start button.
3. 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.
4. Set the idle switch in the
“AUTO” position. Set the mode switch to the CC-STICK position. Make sure that no lead is applied to either weld output or the auxiliary output.
5. Start the machine and allow it to run for about 30 seconds.
6. Manually move the idle solenoid plunger to the idle position. If the solenoid engages and holds in the idle position, the pull coil
PC board is probably defective; replace 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
F-18
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-18
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
ENGINE AND IDLE PROBLEMS
RECOMMENDED
COURSE OF ACTION
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 assembly and the output terminals.
See wiring diagram.
9. Note: The bypass filter assembly 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 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
F-19
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-19
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The engine will not go to high idle when using auxiliary power.
Auxiliary power is normal when the idler switch is in the “HIGH” position. And the automatic idle function works properly when welding.
ENGINE AND IDLE PROBLEMS
1. The load on the auxiliary receptacle may be too low. The automatic idle system will not function reliably if the load is less than 100 watts.
2. The device connected to the auxiliary power may be defective; try using another device.
3. Make sure that the connections to the auxiliary devices are tight.
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 place.
2. Check the toriodal current sensor for an signs of damage.
4. Some devices are designed to sense for adequate input power.
Products of this type may not turn on due to the low voltage and frequency of the idling machine. If this happens, the current draw will likely be insufficient to activate the automatic idle system. Devices of this type may require that the idler switch be in the “HIGH IDLE” position.
3. 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.
4. Unplug plug P3 from the control
PC board and check for damaged, dirty, or corroded pins.
5. Measure the resistance of the toridal current sensor. Measure between P3-3 and P3-4; the meter should read about 10 to
14 ohms
6. If the current sensor is shorted or open, replace it.
7. The control PC board may be defective.
The engine will not go to high idle when striking an arc. The automatic idle system functions normally when using auxiliary power.
Welding and auxiliary outputs are normal when the idle switch is in the “HIGH IDLE” position.
1. Check that the welding cables are in good condition and the connections are tight. Make sure that work clamp is attached to clean, bare metal.
1. 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
F-20
Observe Safety Guidelines detailed in the beginning of this manual.
INSTALLATION
F-20
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
ENGINE AND IDLE PROBLEMS
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 terminals or the auxiliary receptacles.
2. Check that the welding cables and the auxiliary power lead connections are tight and that the insulation is undamaged.
1. The idler solenoid linkage may be damaged or out of adjustment. Make sure the solenoid plunger is able to fully seat against the internal stop of the solenoid coil assembly.
2. The low idle RPM may be too low. Perform the
3. The solenoid hold coil power circuit may be faulty. Check wiring and connections on lead
#210A and lead #215.
4. 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
F-21
TROUBLESHOOTING & 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.
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.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case sheet metal cover and engine access doors.
MATERIALS NEEDED
Miscellaneous hand tools
Rubber mallet
F-21
RANGER 305D
F-22
TROUBLESHOOTING & REPAIR
F-22
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.1 – DOOR REMOVAL
RANGER
305D
ENGINE
SERVICE
ACCESS
DOOR
LOCKING TAB
HINGES
REMOVAL PROCEDURE
1. Turn the engine off.
2. Unlatch and open the engine service access doors.
3. To remove each door, partially close the door until the locking tabs at the hinges disengage 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.
4. Remove the 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 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.
2. Remove the fuel cap, then carefully set the case cover in place. Replace the fuel cap and the lift bail cover seal.
3. Install the exhaust pipe extension.
4. Install the screws that hold the case cover in place.
5. Install each door by positioning it as described in step 3 of the removal procedure, then slide it fully on the hinge.
6. Close and latch the doors.
RANGER 305D
F-23
TROUBLESHOOTING & 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 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will insure that the large capacitors in the chopper module have been discharged. This procedure should be performed whenever work is to be attempted on or near the chopper module.
MATERIALS NEEDED
Miscellaneous hand tools
Volt/Ohmmeter
Resistor (25-1000 ohms and 25 watts minimum)
Lincoln part #S01404-114 works well for this purpose
Jumper leads
Wiring Diagram
F-23
RANGER 305D
F-24
TROUBLESHOOTING & REPAIR
F-24
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
procedure.
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.
NEVER USE A SHORTING STRAP TO DIS-
CHARGE CAPACITORS. If the Lincoln recommended 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 B4 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 resistor. The leads can then be used to connect terminals B1 to B2, and B4 to B5.
4. Using the volt/ohmmeter, check the voltage across B1 and B2, then B4 and B5. It should be zero volts in both cases.
RANGER 305D
F-25
TROUBLESHOOTING & 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.
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.
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.
MATERIALS NEEDED
Wiring Diagram
Volt/Ohmmeter
Miscellaneous hand tools
12 volt D.C. power source, (an automotive battery works well)
F-25
RANGER 305D
F-26
TROUBLESHOOTING & REPAIR
FUEL SHUTDOWN SOLENOID TEST (continued)
FIGURE F.3 – FUEL SHUTDOWN SOLENOID LOCATION
SHUTDOWN
SOLENOID
F-26
IDLE
SOLENOID
TEST PROCEDURE
1. Turn the engine off.
2. Open the right side engine service access door.
3. Locate the fuel solenoid, located on top of the engine.
4. Locate and unplug harness connection P/J
73. Cut any necessary cable ties.
See Wiring Diagram.
5. 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 a clean, unpainted chassis ground. The resistance should be very high, 500,000
Ohms or more. If any of the above resistance 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, 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 restrictions 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.
7. If finished testing, close the engine service access doors.
RANGER 305D
F-27
TROUBLESHOOTING & REPAIR
FUEL SHUTDOWN SOLENOID TEST (continued)
FIGURE F.4 – FUEL SOLENOID CONNECTIONS
F-27
P73
RED
FUEL SOLENOID
CONNECTOR
(LEAD ENTRY VIEW)
BLACK
WHITE
J73
GND-L
TO FRAME
FUEL SOLENOID
WIRING HARNESS
CONNECTOR
(LEAD ENTRY VIEW)
225B
TO "D-4"
231
TO STARTER
SOLENOID
RANGER 305D
F-28
NOTES
F-28
RANGER 305D
F-29
TROUBLESHOOTING & 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 troubleshooting 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 operating 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
F-29
RANGER 305D
F-30
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.5 – STROBE MARK LOCATION
ENGINE SPEED
CONTROL LEVER
FAN HUB
F-30
STROBE
TACH
MARK
TEST PROCEDURE
Strobe-Tach Method
1. Turn the engine off
2. open the top and right side engine service access doors.
3. Place a highly visible mark on the engine cooling fan hub. See Figure 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 synchronize the light with the rotating mark. See the strobe-tach manufacturer instructions.
The tach should read between 3625 and
3675 RPM.
7. 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.
8. Synchronize the strobe-tach to read the low idle RPM.
If either of the readings is incorrect, proceed to the “THROTTLE ADJUSTMENT PROCE-
DURE” later in this section.
RANGER 305D
F-31
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.6 – SOLENOID
Electric Fuel Pump
(codes 10926 &11121 only)
Solenoid & Fuel
Pump Bracket Engine
Engine Speed
Control Lever
F-31
High Idle
Screw &
Jam Nut
Rubber
Boot Solenoid
Low Idle
Jam Nuts
Swivel
Fitting
INCREASE
(RPM)
MOVING ENGINE
SPEED CONTROL
LEVER
DECREASE
(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 instructions for your frequency counter or multimeter.
1. Set your frequency counter per the meter manufacturer instructions, and plug it into one of the 120VAC auxiliary receptacles.
2. 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, proceed 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
F-32
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
Vibratach Method
A Vibratach is used to measure the vibrations caused by the running engine. It can be positioned 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 against the top of the engine.
Read and understand the manufacturerʼs instructions for the Vibratach.
1. Start the 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, proceed to the “THROTTLE ADJUSTMENT
PROCEDURE” later in this section.
THROTTLE ADJUSTMENT PROCEDURE
IMPORTANT: Both the high and low idle settings 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 solenoid 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.
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 swivel 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.
3. Re-check the low idle RPM, and then proceed 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. If 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.
3. Re-check the high idle RPM.
4. Close the engine service access doors and shut off the engine.
F-32
RANGER 305D
F-33
TROUBLESHOOTING & 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.
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.
TEST DESCRIPTION
This test will determine if the idler solenoid resistance values are normal, and also determine if it will function normally when it is energized with 12VDC.
MATERIALS NEEDED
Miscellaneous hand tools
External 12VDC supply (30 amps) (automotive battery works well)
Wiring Diagram
Volt/Ohmmeter
F-33
RANGER 305D
F-34
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST (continued)
FIGURE F.7 – PLUG(S) PIN LOCATION
P-72
BLACK
WHITE
3
4
1
2
IDLE SOLENOID
CONNECTOR
(LEAD ENTRY VIEW)
RED
J-72
215
TO CONTROL
P.C. BOARD
1
2
3
4
IDLE SOLENOID
WIRING HARNESS
CONNECTOR
(LEAD ENTRY VIEW)
210A
START BUTTON
232
PULL COIL
P.C. BOARD
F-34
TEST PROCEDURE
1. Turn the engine off.
2. Open the right side engine service access door.
3. Locate the idler solenoid mounted on the fuel injection pump. (See illustration in
4. Locate and unplug harness connection P/J
72. Cut any necessary cable ties. See
Wiring Diagram.
5. 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 approximately 12 to 15 ohms. Check the resistance 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 resistance 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 solenoid should activate.
REMOVE THE
VOLTAGE IMMEDIATELY to avoid damage to the unit.
Apply 12VDC to the hold-in coil at pin #3
(black wire +) and pin #2 (red wire -). While the voltage is applied, manually move the solenoid to the low idle position. The solenoid plunger should hold this position until the voltage is removed. See Figure F.7.
7. If either coil does not operate as described, check for mechanical restrictions or other problems with the linkage.
8. If the linkage is intact and the solenoid does not operate correctly when the
12VDC is applied, the solenoid may be faulty. Replace.
9. Re-connect idle solenoid and replace any previously removed cable ties.
10. If finished testing, close the engine service access door.
RANGER 305D
F-35
TROUBLESHOOTING & REPAIR
ENGINE ALTERNATOR 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 troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the engine alternator is properly charging the battery.
MATERIALS NEEDED
Miscellaneous hand tools
Volt meter
Wiring Diagram
F-35
RANGER 305D
F-36
TROUBLESHOOTING & REPAIR
ENGINE ALTERNATOR TEST
(continued)
FIGURE F.8 – LEAD LOCAIONS
BATTERY
209
IGNITION
OIL PRESSURE SWITCH
210
TEST PROCEDURE
1. Turn the engine off.
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.
2. Open the engine access door and check the voltage at the battery terminals. It should be approximately 12 volts DC.
3. Attach the meter leads to the battery terminals, being careful to position them so they stay clear of moving parts while the engine is running.
4. Place the idle switch in the “HIGH IDLE” position, start the engine, and allow it to run at high idle speed for about 15 to 30 seconds.
5. The meter should read about 13.7 to 14.2
VDC.
6. If the meter reads correctly the engine alternator is producing adequate power to charge the battery and this test is complete.
6. 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 measurement taken when the engine was not running, proceed with the following tests.
9. Place the negative meter probe on a good chassis ground, or the negative battery terminal. Place the positive meter probe on the battery terminal on the back of the alternator.
(Lead #209) See Figure F.8. See Wiring
Diagram.
10. The meter should read about 13.7 to 14.2
VDC.
11. Move the positive probe to the IGN terminal on the back of the alternator. (Lead @210C)
See Figure F8.
12. The meter should read about 13.7 to 14.2
VDC.
13. If the meter reads correctly, check the connections between the alternator and the battery. See wiring diagram.
14. If the voltage at both of the above test points reads the same or less than the battery voltage measurement taken when the engine was not running, the alternator is defective.
Repair or replace it.
7. Turn off the engine, disconnect the meter from the battery, and open the engine access door on the left side of the machine.
15. If battery voltage is present at the battery terminal 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
F-36
F-37
TROUBLESHOOTING & REPAIR
BRUSH AND SLIP RING SERVICE 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.
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 1-800-833-9353 (WELD).
DESCRIPTION
This procedure provides guidance in testing and maintaining the brush and slip ring system.
MATERIALS NEEDED
Volt/Ohmmeter
Miscellaneous hand tools
500 or 600 grit emery cloth
180 grit sand paper
F-37
RANGER 305D
F-38
TROUBLESHOOTING & REPAIR
BRUSH AND SLIP RING SERVICE PROCEDURE
(continued)
TEST PROCEDURE
2. 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.
3. 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.
4. 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 connected to the carbon brush and to the connection terminal.
5. If the slip rings are discolored, display evidence of excessive sparking, or the brushes have worn prematurely; these may be signs of a grounded or shorted rotor. Perform the
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 have been sticking in the brush holders, a new brush holder and brush assembly should be installed..
Cleaning slip rings:
1. 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. 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.
2. Use a low pressure compressed air to thoroughly blow the carbon, commutator stone, and sandpaper dust from the machine before operating.
3. Perform the
Note:
for general locations.
F-38
RANGER 305D
F-39
TROUBLESHOOTING & 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 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 assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if th rotor winding is open, shorted, or grounded.
MATERIALS NEEDED
Miscellaneous hand tools
Ohmmeter Analog type meter required for dynamic resistance test.)
Wiring Diagram
F-39
RANGER 305D
F-40
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (STATIC) (continued)
F-40
FIGURE F.9 – ROTOR BRUSH LEADS
SLIP RINGS
BRUSHES
LEADS
200A
200
+
LEADS
201
5H
-
TEST PROCEDURE
1. Turn the engine off.
2. Perform the
procedure.
3. 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.
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 unpainted chasms ground. The resistance should be very high, at least 500,000 (500k) ohms.
6. If the test does not meet the resistance specifications, then the rotor may be faulty and should be replaced.
7. If this test meets the resistance specifications, continue testing using the dynamic rotor resistance and ground test.
RANGER 305D
F-41
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (DYNAMIC)
(Also referred to as flying 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 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-41
DESCRIPTION
This test checks for faults in the rotor winding, while these windings are being stressed by the mechanical forces encountered during normal operation.
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.
RANGER 305D
F-42
TROUBLESHOOTING & REPAIR
ROTOR RESISTANCE AND GROUND TEST (DYNAMIC)
(continued)
F-42
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 disconnected 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 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 ohmmeter 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 the
procedure.
*NOTE: The resistance of the windings will change with temperature. Higher temperatures will produce higher resistance, and lower temperatures will produce lower resistance.
RANGER 305D
F-43
TROUBLESHOOTING & 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.
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.
TEST DESCRIPTION
This test will determine if the rotor winding is operating at normal charge.
MATERIALS NEEDED
Miscellaneous hand tools
Voltmeter
Wiring Diagram
F-43
RANGER 305D
F-44
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST (continued)
FIGURE F.10 – LEAD LOCATIONS
F-44
SLIP RINGS
BRUSHES
+
LEADS
200A
200
LEADS
201
5H
-
TEST PROCEDURE
1. Perform the
procedure.
2. Connect the voltmeter probes to the brush terminals. See Figure F.10. See the wiring diagram.
3. 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.
4. Set the RUN/STOP 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
and the
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 voltage stator windings to the stator exciter winding. Perform the
9. 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 windings or other exciter circuit components or connections. Perform the
testing described below, under the heading
“If the voltage measures about 3 to 5
VDC”
RANGER 305D
F-45
TROUBLESHOOTING & REPAIR
ROTOR VOLTAGE TEST (continued)
10. 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
and
11. If the voltage measures about 3 to 5
VDC, the generator is not building-up to normal output even though the flashing circuit appears to be functioning normally.
This condition could be caused by one of several failed components or connections.
Continue with the following test.
12. Check the field bridge rectifier, (D3) and capacitor (C3); also check the wiring and terminals connecting them. See the wiring diagram.
13. Perform the
14. Perform the
15. When 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 disconnected 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 insulation, etc. If necessary, disconnect and isolate the stator output leads as close to the starter as possible. See wiring diagram.
17. All 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.
18. Re-start the machine and measure the rotor voltage.
19. If rotor voltage continues to read significantly lower than 50 VDC, the Stator is probably defective and should be replaced.
Note: The field bridge rectifier and field capacitor may appear to function normally when tested independently, but may malfunction when placed under the stress or normal operation.
For this reason, It is recommended that the bridge rectifier and the capacitor be replaced with known good components before replacing the stator.
F-45
RANGER 305D
F-46
NOTES
F-46
RANGER 305D
F-47
TROUBLESHOOTING & REPAIR
FLASHING VOLTAGE TEST
(Engine Not Running)
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 troubleshooting assistance before you proceed. Call 1-888-93-3877.
F-47
DESCRIPTION
This test checks the flashing voltage with the engine stopped, by simulating a running condition.
MATERIALS NEEDED
Miscellaneous hand tools
Voltmeter
Wiring Diagram
RANGER 305D
F-48
TROUBLESHOOTING & REPAIR
FLASHING VOLTAGE TEST
(continued)
TEST PROCEDURE
1. Perform the
2. Make sure that the battery is fully charged and in good condition, and the battery connections are clean and tight.
3. Remove lead #229 from the oil pressure switch; see wiring diagram and Figure #1.
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 #229 bypass the oilpressure 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 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.
10. Perform the
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 winding.
12. Perform the
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 following locations on the control PC board.
(-) Lead #5K (P2-3) to (+) Lead #210H (P2-7)
(-) Lead #5K (P2-3) to (+) Lead #224B (P2-9)
(-) Lead #5K (P2-3) to (+) Lead #200N (P2-1)
NOTE: Lead #210H supplies 12VDC battery voltage to the control PC board whenever the run/stop switch is in the run position.
Lead #200N 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
#5H, also check leads #200, #200N, and the 25 Ohms flashing resistor, R3. Make sure all terminals are crimped tightly to the flex leads and arc free of corrosion.
F-48
RANGER 305D
F-49
TROUBLESHOOTING & REPAIR
FLASHING VOLTAGE TEST
(continued)
FIGURE F.11 – EXCITER LEADS T1, T2, T3
ENGINE ALTERNATOR
#229
F-49
OIL PRESSURE SWITCH
OIL FILTER
16. If battery voltage is present at leads #210H and #224B, but not present at leads #200N
The Control PC board is probably defective.
Replace.
17. If battery voltage 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 diagram. 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 check the run/stop switch. Also check the ground PC board chassis ground wire, lead
#5K and the stud where it connects to the chassis.
RANGER 305D
19. Set the RUN/STOP switch to the “STOP” position.
20. Re-connect lead #229 to the oil pressure switch.
21. If testing is completed, perform the
procedure.
F-50
NOTES
F-50
RANGER 305D
F-51
TROUBLESHOOTING & 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 troubleshooting 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 approximately 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 voltages is correct.
MATERIALS NEEDED
Miscellaneous hand tools
Voltmeter
Test pins
F-51
RANGER 305D
F-52
CONTACTOR
CONTROL
TROUBLESHOOTING & REPAIR
STATOR VOLTAGE TESTS (continued)
FIGURE F.12 – RECEPTACLE LEAD LOCATIONS (TYPICAL)
AMPHENOL 1
GROUND
REMOTE
CONTROL
E
F
C
D
L
M N
B
K
I
G H
A
J
120 VAC FOR WIRE FEEDER
40 VAC FOR WIRE FEEDER
F-52
21 WORK SENSE
KEY
L4
2 TIMES THRU FERRITE
LEADS 75A, 76A, & 77A
TEST PROCEDURE
1. Perform the
procedure.
NOTE: Voltage tests of the 120 and 120/240 VAC receptacles can be performed by placing the meter probes directly into the appropriate connection 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, 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.
RANGER 305D
3. Start the engine and run it at high idle (3650
RPM).
4. Check the 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 diagram.
2. Start the engine and run it at high idle (3650
RPM).
3. Check the AC voltage reading. It should read between 236 and 252 VAC.
4. If these voltage readings are not within the specified limits, check for tripped or defective circuit breakers, loose connections, or broken wires between the test points and the stator windings. If there are no wiring problems, and the circuit breakers are not tripped or defective, the stator is defective and should be replaced.
F-53
TROUBLESHOOTING & REPAIR
STATOR VOLTAGE TESTS (continued)
FIGURE F.13 – RECTIFIER BRIDGE DETAIL
POS.
NEG.
W3
W2
W1
W4,W5
W10
W6,W11
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 terminals 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 auxiliary winding test, this test can only reveal problems in connections or components between the
Amphenol and the stator winding.
FROM SHUNT
1. Connect the voltmeter probes to pins “A”
(lead #32) and “J” (lead #31) of the 14 pin
Amphenol. See figure #3 and wiring diagram.
2. Start the engine and run it at high idle (3625 to 3675 RPM).
3. The AC voltage reading should be between
120 and 135* VAC.
4. If these voltage readings are not within specifications, check for a tripped or defective circuit breaker, faulty connections, or broken wires between the test points and the stator windings. See wiring diagram.
F-53
RANGER 305D
F-54
TROUBLESHOOTING & 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 #42A) of the 14 pin
Amphenol.
2. Start the engine and run it at high idle (3625 to 3675 RPM).
3. The AC voltage reading should be between
40 and 50 VAC.
4. If these voltage readings are not within the specified limits, check for a tripped or defective circuit breakers, loose connections, or broken wires between the test points and the stator windings. If there are no wiring problems, 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 diagram.
2. Start the engine and run it at high idle (3625 to 3675 RPM).
3. Check for about 60 to 65 VAC from leads W1 to W2, W2 to W3, and W1 to W3.
4. 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. If there are no wiring problems, the stator is defective and should be replaced.
* These values ar maximum for a cold machine.
F-54
RANGER 305D
F-55
TROUBLESHOOTING & REPAIR
STATOR SHORT CIRCUIT & 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 troubleshooting 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
F-55
RANGER 305D
F-56
TROUBLESHOOTING & REPAIR
STATOR SHORT CIRCUIT & GROUND TEST (continued)
CONTACTOR
CONTROL
REMOTE
CONTROL
FIGURE F.14 – WELD CONTROL BOARD
AMPHENOL 1
GROUND
E
F
C
D
L
M N
B
K
G H
I
A
J
120 VAC FOR WIRE FEEDER
40 VAC FOR WIRE FEEDER
21 WORK SENSE
KEY
L4
2 TIMES THRU FERRITE
LEADS 75A, 76A, & 77A
TEST PROCEDURE
1. Perform
4) Lead #5 and lead #7 or #9. (This checks for a connection between the auxiliary winding and the weld winding). See
Wiring Diagram.
2. Perform
3. Unplug anything that may be connected to the auxiliary receptacles or the 14 pin amphenol.
5) Lead #5 and lead W1, W2, or W3. (This checks for a connection the auxiliary winding and the weld winding.) See Wiring
Diagram.
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.
6) Lead #7 or #9 and lead W1, W2, or W3.
(This checks for a connection between the exciter winding and the weld winding.)
See Wiring Diagram.
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 following 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 connection 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.)
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. If necessary, disconnect and isolate the stator leads as close to the stator winding as possible. See wiring diagram. 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 capacitor 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.
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).
RANGER 305D
F-56
F-57
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE 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 troubleshooting 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.
MATERIALS NEEDED
Miscellaneous hand tools
Analog Ohmmeter or diode tester (For testing diodes)
Ohm meter (any type for ground test)
F-57
RANGER 305D
F-58
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE TEST (continued)
FIGURE F.15
F-58
AC1
AC2
AC3
D1
D2
D3
D4
D5
D6
X1
DC+
DC-
TEST PROCEDURE
1. Turn the engine off.
2. Perform the
procedure.
3. Perform the
procedure.
Electrically isolate the three-phase input terminals of the output bridge rectifier as follows:
4. Mark leads W1, W2, and W3 so they can be properly reconnected after the test is complete. Remove these leads and position them so they do not come in contact with any part of the rectifier.
See wiring diagram.
Electrically isolate the DC output terminals of the rectifier:
5. Mark the leads connected to the positive and negative terminals of the output bridge rectifier to assure that they can be reconnected properly.
6. Remove leads W4, W5, and W10 from the positive terminal of the Rectifier, and remove leads W6 and W11 from the negative terminal. Position these leads so they do not come to contact with any part of the rectifier.
See the wiring diagram..
RANGER 305D
F-59
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE TEST (continued)
7. Check for grounds by placing one of the ohm meter probes on a clean, unpainted metal surface of the machine. Touch the other probe to each of the five rectifier terminals.
The resistance to chassis ground from each terminal 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 understand 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.
NOTE: A digital Ohmmeter is not recommended for this test. A typical digital Ohmmeter does not provide enough voltage or current flow to reliably test the diodes used in this rectifier.
10. Test all of the diode groups per the
F-59
FIGURE F.16 – SHUNT/RECTIFIER LEADS
W3
W2
W1
W4,W5
W10
POS.
NEG.
W6,W11
FROM SHUNT
OR
W1
W2
W3
TOP
CENTER
BOTTOM
OUTPUT
RECTIFIER
BRIDGE
CHOKE
RANGER 305D
F-60
TROUBLESHOOTING & REPAIR
TABLE F.1 – DIODE TEST TABLE
AC1
AC2
AC3
DC(-)
DC(-)
DC(-)
AC1
AC2
AC3
DC(+)
DC(+)
Test Instrument
(+) Lead (-) Lead
DC(+)
DC(+)
DC(+)
AC1
AC2
AC3
DC(-)
DC(-)
DC(-)
AC1
AC2
DC(+) AC3
11. Reconnect all leads.
12. Perform the
Case Cover replacement Procedure
RANGER 305D
Diode Bias and Expected
Test Result
FORWARD BIAS
(Low Resistance)
FORWARD BIAS
(Low Resistance)
FORWARD BIAS
(Low Resistance)
FORWARD BIAS
(Low Resistance)
FORWARD BIAS
(Low Resistance)
FORWARD BIAS
(Low Resistance)
REVERSE BIAS
(High Resistance)
REVERSE BIAS
(High Resistance)
REVERSE BIAS
(High Resistance)
REVERSE BIAS
(High Resistance)
REVERSE BIAS
(High Resistance)
REVERSE BIAS
(High Resistance)
F-60
F-61
TROUBLESHOOTING & 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 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-61
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.
MATERIALS NEEDED
Miscellaneous hand tools
Digital Multi-meter
Frequency counter or digital multi-meter with frequency counter function.
Wiring diagram
Control Inner-Connection diagram
RANGER 305D
F-62
TROUBLESHOOTING & REPAIR
CHOPPER MODULE FUNCTION TEST (continued)
FIGURE F.17 – POWER MODULE CONNECTIONS
B8 B7
HL W11
B1 B4
HL W6
B2 B5
HL W5
B3 B6
HL W4
HL W9 HL W8
SL302
SL13
TEST PROCEDURE
1. Perform the
2. Make sure that there is nothing plugged into either of the Amphenol receptacles.
3. Place idle switch in the “HIGH” position.
4. Place the mode switch in the “CC-STICK” position.
5. Place the Welding Terminal switch in the
“REMOTELY CONTROLLED” position.
6. Start the engine and allow it to stabilize at high idle RPM.
7. 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.
8. If the correct DC voltage is not present at terminals B1- to B2+ and B4- to B5+, check for damaged conductors or faulty connections between the chopper module, the output rectifier, and the stator weld winding. See Figure
F.17. See the wiring diagram. Perform the
SL301
SL14
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 #25 from the chopper module
PC board. If voltage is still present, the copper module is shorted and should be replaced.
10. If the voltage drops to 0 VDC after the #23 and #25 leads have been disconnected, the control PC board is driving the chopper module when it should not be doing so.
Reconnect the #23 and #25 leads and perform the
11. Reconnect leads #23 and #25, and place the
Welding Terminal switch in the “WELD TER-
MINALS ON” position.
12. Check for about 58 VDC between Chopper
Module Terminals B2+ to B3-, and B5+ to B6 and between the welder output terminals.
See Figure F.17. See the wiring diagram.
F-62
RANGER 305D
F-63
TROUBLESHOOTING & REPAIR
CHOPPER MODULE FUNCTION TEST (continued)
TEST PROCEDURE (CONTINUED)
13. If about 58 VDC is present at chopper module 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 output terminals. Check for damaged conductors or faulty connections, on leads W7,
W8, W9, and W10. Also check the shunt, the choke, and the connections at the back of the output terminals. See the wiring diagram.
14. If the voltage at terminals B2+ to B3-, and
B5+ to B6- of the Chopper module is significantly higher than 58 VDC, check for an open
R4 load resistor. See the Control Inner-
Connection diagram. Also check for damaged 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 kHZ PWM signal between leads #23 +and #25-, where they connect to the chopper module PC board.
16. If the 20 kHz signal is present, the chopper module is defective. Replace.
17. If the 20 kHz signal is not present, perform the
Weld Control Board PWM Gate Drive
18. If the weld control board is producing a PWM gate signal, check th e#23 and #25 leads for damaged conductors and faulty connections between the control PC board and the chopper module.
19. If testing is complete, Perform the
procedure.
F-63
RANGER 305D
F-64
NOTES
F-64
RANGER 305D
F-65
TROUBLESHOOTING & 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 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-65
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 some other PC board components may not be detected.
MATERIALS NEEDED
Miscellaneous hand tools
Digital Ohmmeter
Wiring diagram
RANGER 305D
F-66
TROUBLESHOOTING & REPAIR
CHOPPER MODULE RESISTANCE TEST (continued)
TEST PROCEDURE
1. Perform the
2. Perform the
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 digital Ohmmeter to test the module per
F-66
RANGER 305D
F-67
TROUBLESHOOTING & REPAIR
CHOPPER MODULE RESISTANCE TEST (continued)
TABLE F.2 – DIODE TEST TABLE
OHMMETER
(+) Lead (-) Lead
READING
Diode Bias and Expected
Test Result
B5 B6 6K to 9K
B6 B5 6K to 9K
B3
B4
B6
B2
B2
B4
B5
B4
B5
B4
B6
B4
B3
B2
B2
B4
200k or higher
400k or higher
200k or higher
400k or higher
6K to 9K
6K to 9K
200k or higher
400k or higher
B4 B3 200k or higher
B3 B4 400k or higher
5. Reconnect all leads.
6. The chopper module screw connection should be lightened to 50-60 inch-pounds.
7. Perform the
Case Cover Replacement procedure
RANGER 305D
F-67
F-68
NOTES
F-68
RANGER 305D
F-69
TROUBLESHOOTING & REPAIR
WELD CONTROL BOARD PWM GATE SIGNAL 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 troubleshooting 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 Transistor) on the chopper module. This test will also verify that the control PC board can turn the PWM gate signal on and off properly.
MATERIALS NEEDED
Digital Multi-meter
Frequency counter, or digital Multi-meter with frequency counter function
Wiring Diagram
Control Inner-Connection diagram
F-69
RANGER 305D
F-70
TROUBLESHOOTING & REPAIR
WELD CONTROL BOARD PWM GATE SIGNAL TEST
(continued)
F-70
TEST PROCEDURE
1. Perform the
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 #23+ (P3-
10) and #25- (P3-9).
9. If the 20KHz gate signal is present, place the weld terminals switch in th e”REMOTE-
LY CONTROLLED” position. The gate signal 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 13+
(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. 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 present at the weld control PC board, but there is no PWM gate signal, check the voltage between leads #2+ (P1-4) and #4 (P1-3).
See figure #1
The voltage should be about 0 VDC.
15. If about 5 VDC is detected, the welding terminal 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 diagram.
16. 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) at the control PC board.
17. 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 diagram.
18. If the above wiring and components are undamaged and functioning properly, the control PC board is defective and should be replaced.
19. If the voltage reads about 5 VDC, and the
PWM signal remains, the control PC board is defective and should be replaced.
20. Perform the
RANGER 305D
F-71
TROUBLESHOOTING & REPAIR
WELD CONTROL FEEDBACK 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 troubleshooting 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.
This test will only yield usable information if the machine is producing some weld output.
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
F-71
RANGER 305D
F-72
TROUBLESHOOTING & 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 manufacturerʼs 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 ammeter. If the machine will not produce 200 amps, apply as much load as you can.
7. Compare the readings shown on the external 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 displays 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, but the load should be released.)
12. 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 terminals. Repair or replace wiring components as needed and reconnect the plugs to the control board.
13. 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.
14. Using the voltmeter, measure and note the
DC voltage at the weld output terminals.
15. Check the voltage between leads #204S+
(P6-1) 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.
F-72
RANGER 305D
F-73
TROUBLESHOOTING & REPAIR
WELD CONTROL FEEDBACK TEST
(continued)
16. If the voltage readings are different, check the wiring and connections between the welding terminals and the control PC board.
See the wiring diagram.
17. Connect the millivolt meter probes between lead #206S+ (P6-2) and lead 204S- (P6-1).
See Wiring Diagram. If the machine is currently producing 200 amps the millivolt meter should read about 25 millivolts.
18. If the machine cannot produce 200 amps of weld current, the correct millivolt signal will need to be calculated by dividing the reading 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, (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 connected at the control PC board should be reading about 9.4 millivolts.
21. If the millivolt reading is incorrect, check the wiring between the shunt and the control PC board for damage, grounds, and faulty connections. If the wiring is good, the shunt and lead assembly is faulty and should be replaced.
22. Perform the
F-73
RANGER 305D
F-74
NOTES
F-74
RANGER 305D
F-75
TROUBLESHOOTING & REPAIR
CONTROL POTENTIOMETER AND MODE SWITCH RESIS-
TANCE 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-75
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
RANGER 305D
F-76
TROUBLESHOOTING & REPAIR
CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST
(continued)
TEST PROCEDURE
F-76
1. Turn the engine off
2. Perform the Case cover Removal
3. Unplug P7 from control board, see control
Inner-connection diagram, and visually check the plug and attached wiring for damage, corrosion, improperly seated or damaged contact pins. P7 will remain unplugged for following test.
4. Set the mode switch in the “CC-Stick” position.
5. Test the resistance between each of the leads in P7 and a good clean chassis ground connection. Be very careful that the connection pins in P7 are not damaged or spread out.
6. The resistance should be very high. A reading 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 replace the defective component within the assembly. See wiring diagram.
8. Perform the resistance tests per Table F.3.
9. If 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.
10. If testing is complete, plug P7 back into the
control PC board and perform the Case
RANGER 305D
F-77
TROUBLESHOOTING & REPAIR
CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCE TEST
(continued)
F-77
TABLE F.3
POT/MODE SWITCH RESISTANCE TEST
MODE SWITCH
SETTING
OHMMETER
CONNECTION
OHMMETER
READING
CC-STICK
CC-STICK
CC-STICK
CC-STICK
CC-STICK
CC-STICK
TOUCH START TIG
DOWNHILL PIPE
CV-WIRE
N/A
N/A
N/A
P7-9 (#214) TO P7-14 (#218)
P7-9 (#214) TO P7-15 (#220)
P7-9 (#214) TO P7-16 (#222)
P7-14 (#218) TO P7-15 (#220)
P7-14 (#218) TO P7-16 (#222)
P7-15 (#220) TO P7-16 (#222)
P7-15 (#220) TO P7-16 (#222)
P7-14 (#218) TO P7-16 (#222)
P7-9 (#214) TO P7-16 (#222)
P7-5 (#75) TO P7-1 (#77)
P7-1 (#77) TO P7-4 (#76)
P7-6 (#279) TO P7-8 (#277)
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
*
*
* about 10K sweep smoothly from 10K to 0 when ARC CONTROLis turned from Min. to Max.
about 10K
N/A P7-8 (#277) TO P7-7 (#278) 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 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 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
F-78
NOTES
F-78
RANGER 305D
F-79
TROUBLESHOOTING & REPAIR
REMOTE RECEPTACLE 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 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 troubleshooting 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.
MATERIALS NEEDED
Ohm Meter
Wiring Diagram
Control Inner-Connection diagram
F-79
RANGER 305D
F-80
TROUBLESHOOTING & REPAIR
REMOTE RECEPTACLE RESISTANCE TEST (continued)
FIGURE F.18
AMPHENOL 1
E
F
C
B
D
L
M N
G H
K
I
A
J
TEST PROCEDURE
1. Turn the machine off.
2. Perform the Case Cover Removal
3. Make sure that there are no devices of any kind plugged into either Amphenol receptacles.
4. 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.
Position the P1 plug so it can not make electrical contact with any other conductor 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. If the resistance values are found to be too low, due to contaminated electrical components 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.
8. 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 connected to that switch. See the wiring diagram. Repair any faulty connections or replace the switch if necessary.
9. Plug P1 back into the Control Pc board.
10. Perform the Case Cover Replacement
F-80
RANGER 305D
F-81
TROUBLESHOOTING & REPAIR
REMOTE RECEPTACLE RESISTANCE TEST (continued)
TABLE - F.4
AMPHENOL RESISTANCE TEST
WELDING TERMINAL
SWITCH SETTING
OHMMETER
CONNECTION
OHMMETER READING
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
PIN “G” (#75B) to PIN “Å” (#32)
PIN “G” (#75B) to PIN “B” (GND-A)
PIN “G” (#75B) to PIN “C” (#2B)
PIN “G” (#75B) to PIN “D” (#4B)
PIN “G” (#75B) to PIN “E” (#77B)
PIN “G” (#75B) to PIN “F” (#76B)
PIN “G” (#75B) to PIN “H” (#21)
PIN “G” (#75B) to PIN “I” (#41A)
PIN “G” (#75B) to PIN “J” (#31)
PIN “G” (#75B) to PIN “K” (#42A)
PIN “F” (#76B) to PIN “A” (#42)
PIN “F” (#76B) to PIN “B” (GND-A)
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
PIN “F” (#76B) to PIN “C” (#2B)
PIN “F” (#76B) to PIN “D” (#4B)
PIN “F” (#76B) to PIN “E” (#77B)
PIN “F” (#76B) to PIN “H” (21)
PIN “F” (#76B) to PIN “I” (#41A)
PIN “F” (#76B) to PIN “J” (#31)
PIN “F” (#76B) to PIN “K” (#42A)
PIN “E” (#77B) to PIN “A” (#32)
PIN “E” (#77B) to PIN “B” (GND-2)
PIN “E” (#77B) to PIN “C” (#2B)
PIN “E” (#77B) to PIN “D” (#4B)
PIN “E” (#77B) to PIN “H” (#21)
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
500K or Higher
N/A
N/A
PIN “E” (#77B) to PIN “I” (#41A)
PIN “E” (#77B) to PIN “J” (#31)
N/A PIN “E” (#77B) to PIN “K” (42A)
REMOTELY CONTROLLED PIN “C” (#2B) to PIN “D” (#4B)
500K or Higher
500K or Higher
500K or Higher
500K or Higher
WELD TERMINALS ON PIN “C” (#2B) to PIN “D” (#4B)
* Resistance should be very low, The Ohmmeter should read about the same value as one would get by touching the two meter probes together.
RANGER 305D
*
F-81
F-82
NOTES
F-82
RANGER 305D
F-83
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND
REPLACEMENT
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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-83
DESCRIPTION
The following procedure will aid the technician in removing and replacing the output rectifier bridge and the choke in the Ranger 305D.
MATERIALS NEEDED
Miscellaneous hand tools
Electrical joint compound (Dow Corning 340 - Lincoln T12837)
RANGER 305D
F-84
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACE-
MENT
(continued)
F-84
REMOVAL PROCEDURE
1. Turn the engine off.
2. Remove negative battery cable.
3. Perform the
4. Perform the
5. Remove the four screws holding the case front to the base of the machine.
6. 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 diagram.
7. 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.
8. Remove any additional wring and cable ties as needed. Carefully mark leads for accurate re-connection.
9. Swing the case front to the side to permit access to the Output Rectifier and Choke.
Removing the Output Choke
1. Remove the heavy leads from the choke.
Carefully mark the leads for accurate reconnection, and also note the order and position of the leads in multiple lead connections.
2. Remove the three long bolts, lock washers and nuts holding the choke the mounting bracket in the machine base. Note that there is no bolt in the lower right corner 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.
2. 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.
3. Reconnect the choke leads. Position the leads, bolts, washers, and nuts exactly as they had been originally connected.
Tighten the connection securely.
Removing the Output 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 holding 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
F-85
TROUBLESHOOTING & REPAIR
F-85
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 tighten.
6. Reconnect all of the leads and plugs that were disconnected during the removal procedure, and replace any cable ties that were removed.
7. Perform the
2. Apply a thin film of electrical joint compound, (Dow Corning 340 - Lincoln
T12837) between the surfaces of the “W” leads and the Output Rectifier.
Reconnect the Output Rectifier, positioning the leads, bolts, washers, and nuts exactly as hey had been originally connected. 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 protection relay to the center baffle assembly. See Wiring Diagram.
5. Attach the case front to the machine base with four screws.
RANGER 305D
F-86
NOTES
F-86
RANGER 305D
F-87
TROUBLESHOOTING & REPAIR
CHOPPER MODULE REMOVAL AND REPLACEMENT
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 troubleshooting 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 serviceable parts.
MATERIALS NEEDED
Miscellaneous hand tools
Electrical thermal joint compound - (Dow Corning 340 - Lincoln T12837)
F-87
RANGER 305D
F-88
TROUBLESHOOTING & REPAIR
CHOPPER MODULE REMOVAL AND REPLACEMENT
(continued)
FIGURE F.19 – EXCITER LEADS T1, T2, T3
B8 B7
F-88
HL W11
B1 B4
HL W6
B2 B5
HL W5
B3 B6
HL W4
HL W9 HL W8
SL302
SL301
SL14
PROCEDURE
Removal
1. Turn the engine off.
2. Perform the
3. Perform the
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.
SL13
7. Remove the Power Module assembly from the machine.
B4
B5
B6
B1
B2
B3
TERMINAL LEADS
HL W5, SL 13
HL W8
HL W6
HL W4, SL 301
HL W9, SL 302
RANGER 305D
F-89
TROUBLESHOOTING & REPAIR
CHOPPER MODULE REMOVAL AND REPLACEMENT
(continued)
F-89
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.
2. Connect leads 23 and 25 at their in-line couplers.
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 compound (Dow Corning 340 - Lincoln T12837) to the mating surfaces (but not the threads).
Tighten the fasteners to between 50-60 inlbs.
4. Replace any cable ties cut at disassembly.
5. When procedures are complete, perform the
procedure.
B1
B2
B3
B4
B5
B6
TERMINAL LEADS
HL W5, SL 13
HL W8
HL W6
HL W4, SL 301
HL W9, SL 302
RANGER 305D
F-90
NOTES
F-90
RANGER 305D
F-91
TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT
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 troubleshooting 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.
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)
F-91
RANGER 305D
F-92
TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT
(continued)
FIGURE F.20 – BATTERY PLACEMENT
Battery
Terminals
F-92
Remove
Through
Here
TEST PROCEDURE
1. Turn engine off.
2. 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.
3. Perform the
4. Perform the
5. Remove the four screws holding the battery access panel to the base.
6. Disconnect the battery cables. REMOVE
THE NEGATIVE BATTERY CABLE FIRST, and then remove the positive cable.
7. 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.
8. Slide the battery out of the base through access hole in the side. See Figure F.20.
9. Drain radiator and disconnect the radiator hoses and the overflow tube.
10. Remove the six screws 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 bracket; 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 mark all stator leads to insure proper reconnection. See wiring diagram.
15. Disconnect all of the stator winding leads.
Note how the leads are routed and connected as well as the order and placement of leads and hardware for each connection.
See wiring diagram and the Control Inner-
Connection Diagram.
16. 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 nothing can bind when the stator is removed later in this procedure.
See
Wiring Diagram.
17. 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.
18. Remove the wiring attached to the alternator side of the engine. This includes the connections to the alternator, starter, oil pressure switch, and engine ground cables and wires.
Be sure to mark leads for accurate re-connection.
RANGER 305D
F-93
TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT
(continued)
F-93
FIGURE F.21 – WIRE GUIDE HOLE
HOLE
FIGURE F.22 – ALTERNATOR LEADS
BATTERY
209
IGNITION
210
OIL PRESSURE SWITCH
RANGER 305D
F-94
TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT
(continued)
F-94
19. The wires connected to the solenoid side of the engine can remain attached, in most cases.
20. 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.
21. Remove the fuel return line from the fitting in the top of the fuel tank. Plug this line and fitting as well.
22. Remove the engine baffle.
23. 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.
24. 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.
25. Raise the hoist to lift the engine and generator assembly just high enough to clear the generator mounting studs. The center baffle will need to be gently pushed forward to provide clearance between the fan and the
Chopper module.
In some cases, the
Chopper module mounting screws may need to loosened or removed so the chopper module 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 additional engine wiring, and/or remove additional cable ties if necessary.
27. Replace the screws, which had been removed from those mounts, and tighten.
28. Use wooden blocks or other means to securely support the flywheel end of the engine, and remove the hoist from the lift bale.
29. The generator is now in position for easy removal.
30. 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.
31. 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.
32. 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 assembly. If the bearing is 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
F-95
TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT
(continued)
F-95
FIGURE F.23 – DISC/RING LOCATION
COUPLING
DISC
CLAMPING
RING
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 separated, 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.
3. Install a new bearing on the rotor shaft.
4. 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.
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 lifting straps and recheck the engine flywheel and coupling disc for anything that might prevent proper seating.
7. To attach the coupling disk to the engine flywheel, 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.
8. Evenly tighten all the screws to a torque of
17 to 19 Ft-Lbs.
RANGER 305D
F-96
TROUBLESHOOTING & REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT
(continued)
F-96
Replacing the Stator
1. Examine the stator frame assembly. Be sure the wiring, coils, mounting flange and bearing 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 or alignment 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.
3. 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 careful not to damage either the stator or rotor.
4. Align the rotor shaft bearing to the tolerance ring; also align the screw holes in the mounting 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 flange and bearing are seated properly and do not bind. Tighten the stator flange screws to 20 to 22 Ft-Lbs.
6. 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.
7. Install the flat washer and then the blower fan on the rotor shaft. The fan should be hand tightened only.
8. 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.
9. Make sure all of the wiring is routed correctly, and replace the fasteners securing the engine and generator.
10. Reverse the above procedures to reassemble the machine.
11. Reconnect all wiring and replace any cable ties that had been removed.
12. Refill the engine cooling system with the coolant that was drained earlier, or with a
50/50 mix of permanent type antifreezecoolant. See the engine operatorʼs manual for more detailed information.
RANGER 305D
F-97
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (120VAC SUPPLY)
F-97
HIGH IDLE – NO LOAD
16.4 ms
0 volts
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 represents 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
RANGER 305D
F-98
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)
MAX CONTROL POT - HIGH IDLE - NO LOAD
F-98
CH1
0 volts
50V 5ms
This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 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
RANGER 305D
F-99
TROUBLESHOOTING & REPAIR
NORMAL WELD VOLTAGE WAVEFORM (STICK CC)
MACHINE LOADED TO 300 AMPS AT 27 VOLTS
Trig +15V CH1
F-99
0 volts
20V 1ms
This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 1 millisecond in time.
The machine was loaded with a resistance 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
RANGER 305D
F-100
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)
F-100
MAX CONTROL POT - HIGH IDLE - NO LOAD
50V 5ms
This is the typical DC open circuit output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 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
RANGER 305D
0 volts
F-101
TROUBLESHOOTING & REPAIR
NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)
MACHINE LOADED TO 300 AMPS AT 28 VOLTS
F-101
20V 1ms
This is the typical DC voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 1 millisecond in time.
The machine was loaded with a resistance 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
RANGER 305D
0 volts
F-102
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
F-102
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machineʼs electrical characteristics. OR
• If you repair or replace any electrical components.
Mode
Low Idle
High Idle
ENGINE OUTPUT
No Load RPM
2400 - 2500
3625 - 3675
Load RPM
N/A
3350 - 3750
Mode Selector
Switch
Stick (CC)
WELDER DC (STICK) OUTPUT (ARC control @ -10)
Output Control
Maximum
Open Circuit
Volts
55-60
Load Volts
27-32
Load Amps
295-325
Mode Selector
Switch
CV
CV
WELDER CV (WIRE) OUTPUT (ARC Control @ +10)
Output Control
Maximum
Minimum
Open Circuit
Voltage
55-60
55-60
Load Volts
28-30
13-15
Load Amps
300
120
Mode Selector
Switch
TIG
TIG
TOUCH START TIG (ARC Control @ +10)
Output Control
Maximum
Minimum
Open Circuit
Voltage
10-15
10-15
Load Volts
20-24
Short Circuit
Load Amps
240-255
18-28
Open Circuit
Voltage
240-270*
AUXILIARY POWER OUTPUT
240 Volt Receptacle
Load Volts
216-240
Load Amps
40-45
Open Circuit
Voltage
120-135
120 Volt Receptacles
Load Volts Load Amps
115-130 18-22
* Upper limit reflects cold machine, voltage will be below 132/264 for machine at normal operating temperature.
Open Circuit Voltage
42-46
42 VOLT WIRE FEEDER POWER
Load Volts
40-44
Load Amps
7.0-9.0
RANGER 305D
Section G-1
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Electrical Diagrams ..............................................................................................................Section G
Section G-1
NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unserviceable. The Assembly drawings are provided for reference only.
RANGER 305D
G-2
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10926 (G4250)
ELECTRICAL DIAGRAMS
RANGER 305D- KUBOTA - WIRING DIAGRAM
G-2
Twisted
Pair
W10
208B
206S 204S
W10
SHUNT
50MV=400 AMPS
206B
206A
260
261
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42 VAC
42 41 21
208C
206A
TWISTED PAIR
6
3
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH
TOROID
6
3
L1 CHOKE
W9
W8
R4
HEATSINK
302
B3
C10
B2
301
C11
B1
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8
STATOR AUX. WINDING
3
6
GND-E 5 BOTTOM GND INSIDE CASEFRONT
GND-E
GND-N
GND-K
GND-R
W5
W4
W6
25
23
FIELD WINDING
7
42 VAC
9
W11
W5
W6
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W3
W1
W2
W3
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
42A
CB8
15A
41A
SHOWN IN
POSITIVE (+)
POSITION
5N
TOP GND. SCREW ON
INSIDE OF CASE FRONT
5K
5
5H
5C
FRAME GND.
5A
5B 5G
3
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
K
H
E
J
A
I
F
G
D
C
B
GND-A
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77B
76B
75B
2B
4B
GND-B
77A
76A
75A
2A
4A
31
32
41A
42A
21
77B
76B
75B
4B
2B
AMPHENOL 2
1 1 4 1 5
7
1
2
6
5
1
8 6 10
8
12 9 16
ELECTRICAL SYMBOLS PER E1537
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
GND. SCREW ON LEFT
INSIDE CASEFRONT
31
GND-N
FRAME GND.
GND-B
GND-G
GND-D
GND-C
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
GND-G
GND-D
GND-C
3E
WHITE
TERM.
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
4A
4
2
2A
J102
SILVER
J101
5A
32
20A
BLACK
3D
CB1
BLACK
6E
20A
CB2
6B
3A
3
6
SILVER 5B
J100
115/230V
6F
5C
BLACK
BLACK
WHITE
CB5
50A
3E
CB6
50A
3A
6B
3
6
6B
3A
5C
GND SCREW ON
FAN BAFFLE.
GND-K
GND-J
7
9
D3
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
223
S7
GLOW
PLUG
BUTTON
223A
200B
201A
5H
201
209B
C3
800uf
150vdc
200A
200
ROTOR
15A
CB7
229
229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
210C
BAT
IGN
228
L
ALTERNATOR
R3
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210E
210D
229A
Engine Protection
Light PL1
228
229B
212A
S1
210
210D
210H
210A
S2
START
BUTTON
Battery Charge
Light PL2
210F
210B
209A
209
200N
STARTER
211
S6 MODE SELECTOR SWITCH
214
218
PIPE
CC
CV
3
2
1
A
(LOCATED BELOW
TERMINAL 2)
220
222
TIG
4
R2 ARC CONTROL
CCW
10K
277
279
278
231
GND-R 5K
225
5G
7
1
4
CR1
3
6
9
A B
225B
224A
224B
VOLTS
AMPS
R1 OUTPUT CONT. POT
CCW
10K
77
76 75
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
210G
223A
+
-
12 VOLT
BATTERY
GND-L
GND-M
J74
P74 blk red
FUEL
PUMP
ENGINE
GROUND
GND-J
GND-H
FRAME
GROUND
J73
P73 red
HOLD
COIL blk wht
PULL
COIL
FUEL SOLENOID
D4
+
HOUR METER
224
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
R
232
L3
76A
77A
75A
PCB2 WELD CONTROL PC BOARD
210B
B1
14
13
208B
252 251
23
25
260
261
404
2
4
206S
204S
277
278
279
75
76
Key
77
224B
215
404
5K
210H
200N
B2
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
4
GND-R
B3 B4
8
P43-J43
1 5
PCB3
PULL COIL BD.
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.
P6-J6
Shunt
P54 - J4
Meter
P5 - J5
Meter
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
P3-J3
Sense/
Idler/
PWM
A
G4250
RANGER 305D
G-3
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11121 (G4571)
ELECTRICAL DIAGRAMS
RANGER 305D- KUBOTA - WIRING DIAGRAM
G-3
Twisted
Pair
TWISTED PAIR
W10
W10
206S 204S
SHUNT
50MV=400 AMPS
206B
206A
260
261
3
6
WRAP TWO TURNS
#3 & #6 LEADS IN
DIRECTION SHOWN
THROUGH TOROID
6
3
W9
W8
R4
HEATSINK
302
B3
C10
B2
301
C11
B1
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8 25
23
W5
W4
W6
W11
W5
W6
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W3
W1
W2
W3
S6 MODE SELECTOR SWITCH
214
CV
218
PIPE
2
220
CC
TIG
3
4
222
1
A
(LOCATED BELOW
TERMINAL 2)
VOLTS
AMPS
L6
208B
L1 CHOKE
206B 206C
W7
208
WIRE FEED POWER
WINDING
42 VAC
208A
S5
VOLTMETER
POLARITY
SWITCH
42 41
21
208C
206A
SHOWN IN
POSITIVE (+)
POSITION
42A
CB8
15A
41A
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
STATOR AUX. WINDING
3
6
BOTTOM GND INSIDE LEFTCASEFRONT 5
GND-N
GND-K
GND-E
GND-R
120VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
K
H
E
J
A
I
F
G
D
C
B
31
32
41A
42A
21
77B
76B
75B
4B
2B
GND-A
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77B
76B
75B
2B
4B
GND-B
77A
76A
75A
2A
4A
AMPHENOL 2
31
GND-N
GND. SCREW ON RIGHT
INSIDE CASEFRONT
FRAME GND.
GND-B
7
1
1
2
1
6
5
4 1
1
8 6
5
10
8
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
12 9 16
ELECTRICAL SYMBOLS PER E1537
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
GND-A
TERMINALS
GND-G
L4
LINE
GND-D
GND-C
3E
WHITE
TERM.
FIELD WINDING R2 ARC CONTROL
CCW
277
278
279
R1 OUTPUT CONT. POT
CCW
77
76 75
HOT
J102
5N
TOP GND. SCREW ON
INSIDE LEFT CASE FRONT
5
5K
5M
5H
5A
5C
FRAME GND.
5B 5G
32
CB1
WHITE
20A
HOT
J101
CB2
6B
WHITE
J100
120/240V
6F
5C
BLACK
WHITE
BLACK
CB5
50A
3E
CB6
50A
3A
3
6
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
4A
4
2
2A
3A
6B
5C
GND SCREW ON
FAN BAFFLE.
GND-K
GND-J
GND-R 5K
5G
224A
224B
+
HOUR METER
7 9
200B
R3
200N
FUEL GAUGE
5M
D3
201A
201
C3
800uf
150vdc
200A
200
4 1
J52
P52
210J
230
5L
5L
230
5H
TO SLIP RING NEAREST
TO THE LAMINATION
S7
GLOW
PLUG
BUTTON
209B
ROTOR
15A
CB7
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210D
229A
210E
Engine Protection
Light PL1
212A
S1
210D
210H
210J
210
229B
210A
S2
START
BUTTON
223A
223
210C
229
229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
BAT
IGN
L
ALTERNATOR
209A
209
STARTER
211
GND-J
FUEL SENDER
210B
231
225
4
1
7
CR1
A B
6
3
9
210E
210G
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
224
223A
225B
D4
GND-H
-
+
12 VOLT
BATTERY
GND-L
ENGINE
GROUND
GND-M
J74
P74 blk red
FUEL
PUMP
J73
P73 red
HOLD
COIL blk wht
PULL
COIL
FUEL SOLENOID
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
L7
L8
L3
206S
204S
M10
M5
M9
M5
M4
P6-J6
Shunt
P4 - J4
Meter
P5 - J5
Meter
277
278
279
75
76
Key
77
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
224B
215
404
5K
210H
200N
L5
76A
77A
75A
L2
14
13
208B
252 251
260
261
23
25
4
2
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
P3-J3
Sense/
Idler/
PWM
PCB2 WELD CONTROL PC BOARD
232
210B
B1
404
B2
4
1
B3
GND-R
B4
8
P43-J43
5
PCB3
PULL COIL BD.
R
CLEVELAND, OHIO U.S.A.
C
G4571
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.
S
RANGER 305D
G-4
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11188, 11275 (G4571-1)
ELECTRICAL DIAGRAMS
RANGER 305D- KUBOTA - WIRING DIAGRAM
G-4
Twisted
Pair
TWISTED PAIR
R4
W10
260
261
302
HEATSINK
C10
301
C11
B1
206S 204S
206B
206A
L6
208B
L1 CHOKE
W7
206B
WIRE FEED POWER
WINDING
42
42 VAC
41
208
208A
208C
S5
VOLTMETER
POLARITY
SWITCH
21
206A
SHOWN IN
POSITIVE (+)
POSITION
42A 41A
206C
6 WRAP TWO TURNS
#3 & #6 LEADS IN
3
THROUGH TOROID
6
3
W9
W8
B3
B6
13
C9
B2
14
B5
PCB 1
C8
B4
STATOR AUX. WINDING
3
BOTTOM GND INSIDE LEFTCASEFRONT
5
6
GND-N GND-E
GND-K
GND-R
W4
W6
25
23
W5
W11
W10
W5
W6
D1 - THREE PHASE BRIDGE RECTIFIER
W3
W1
W2
FIELD WINDING
W3
S6 MODE SELECTOR SWITCH
214
218
220
222
PIPE
CC
CV
TIG
3
2
4
1
A (LOCATED BELOW
TERMINAL 2)
206C
5N
208C
7
1
1
2
120VAC
42VAC
WORK
REMOTE
CONTACTOR
GROUND
E
F
K
H
I
J
A
G
D
C
B
AMPHENOL 1
CONTACTOR
GROUND
C
D
A
B
E
F
AMPHENOL 2
1 4
6
5
1
8
31
32
41A
42A
21
77B
76B
75B
4B
2B
GND-A
77B
76B
75B
2B
77A
76A
75A
4B
GND-B
2A
4A
1
6
12 9
GND-N
INSIDE CASEFRONT
FRAME GND.
GND-B
GND-A
5
10
8
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
L2, L3: RF CHOKES
16
31
GND-G
GND-C
L4
GND-D
LINE
TERMINALS
3E
WHITE
TERM.
HOT
J102
TOP GND.SCREW ON
INSIDE LEFTCASE FRONT
5N
5
5K
5M
5H
FRAME GND.
5A
5B
5C
5G
32
20A
CB1
WHITE
HOT
J101
20A
6B
CB2
WHITE
120/240V
6F
5C
BLACK
BLACK
WHITE
N.A.
3E
CB5 50A
3A
3
6B
6
3A
S3
2
2A
6B
5C
GND SCREW ON
FAN BAFFLE.
GND-K
7
D3
9
200B
201A
5H
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
GND-J
223
PLUG
BUTTON
223A
201
209B
ROTOR
229 229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
200A 200
210C
BAT
IGN
L
ALTERNATOR
R3
209A
209
200N
FUEL GAUGE
4
1
J52
P52
210J
230
5L
RUN POS.)
212
210D
229A
210E
Engine Protection
Light PL1
SWITCH
(SHOWN IN
212A
S1
210D
210J
210
210H
229B
210A
STARTER
211
GND-J
-
+
GND-H
5L
230
5M
FUEL SENDER
210B
GND-L
FRAME
GROUND
231
R2
210F
277
278
279
GND-R 5K
223A
5G
D4
225B
224A
224B
J73
P73 red blk wht
HOLD
COIL
PULL
COIL
FUEL SOLENOID
R1
VOLTS
AMPS
77
76 75
+
HOUR METER
IDLER CONTROL
251
S4
252
4
224C
CR1
1 3
A
7 9
B
6 210F
210G
224
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
IDENTIFIED AS CB5 & CB6.
L7
L8
L3
M9
M9
M10
M4
P6-J6
Shunt
P4 - J4
Meter
P5 - J5
Meter
279
Key
77
224B
215
404
5K
210H
200N
L5
76A
77A
75A
L2
14
13
208B
252 251
2
4
214
P7 - J7
Output &
Arc Cont.
Mode
Select
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
P3-J3
Sense/
Idler/ PWM
PCB2 WELD CONTROL PC BOARD
232
210B
B1
404
B2
4
1
B3
GND-R
B4
5
8
P43-J43
PCB3
PULL COIL BD.
R
B
G4571-1
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
G-5
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11027 (G4226)
ELECTRICAL DIAGRAMS
RANGER 305D CE KUBOTA WIRING DIAGRAM - UK
G-5
260
261 Twisted
Pair
W10
W10
TWISTED PAIR W9
R4
302
HEATSINK
B3
C10
B2
301
C11
B1
W4
W5
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W1
W3
VOLTS
W6
206S 204S
208B
SHUNT
50MV=400 AMPS
206B
206A
L1 CHOKE
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42 VAC
42 41 21
208C
206A
W8
C
B
D
A
WRAP TWO TURNS OF
LEADS A, 3, D, B, & C IN
DIRECTION
SHOWN THROUGH TOROID
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8 25
23
W5
D
A
STATOR AUX.
WINDING GND-E
5 E
W11
B
C
W6
W3
NOTE: STATOR LEAD 3 NOT USED.
TAPE LEAD END AND SECURE.
W2
CB5
15A
42A 41A
SHOWN IN
POSITIVE (+)
POSITION
BOTTOM GND
INSIDE
CASEFRONT
GND-N
GND-E
GND-R
D
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
NOTE: LEADS 31 AND 32 NOT USED.
TAPE LEAD ENDS AND SECURE.
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
K
H
E
F
I
J
A
G
D
C
B
31
32
41A
42A
21
77B
76B
75B
4B
2B
GND-A
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77B
76B
75B
2B
4B
GND-B
77A
76A
75A
2A
4A
AMPHENOL 2
1 1 4 1 5
1
2
6
5
1
8 6 10
8
7 12 9
ELECTRICAL SYMBOLS PER E1537
16
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
GND-K
GND. SCREW ON LEFT
INSIDE CASEFRONT
GND-N
FRAME GND.
GND-B
GND-A
GND-G
GND-D
GND-C
GND-B
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
5
C B A
5B 1C 1B 1A
5D 2C 2B
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
RCDI
30mA
2A
L3
J100
L3
L2
L2
E
L1
5D
L1
4A
4
2
2A
5N
TOP GND. SCREW ON
INSIDE OF CASE FRONT
5K
2C
2B 2A
L3 L2 L1
12
CB2
15A
N A
E
11
J101
5G
CB1
20A
5H
D
E
CB3
15A
J102
9
N A
E
7
CB4
15A
GND SCREW ON
FAN BAFFLE.
GND-K
GND-J
7
STATOR
EXCITATION
WINDING
42 VAC
9
223
D3
S7
GLOW
PLUG
BUTTON
223A
200B
201A
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
5H
201
209B
C3
800uf
150vdc
200A
ROTOR
CB7
15A
229
229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
200
210C
BAT
IGN
228
L
ALTERNATOR
R3
209A
209
200N
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210E
210D
229A
Engine Protection
Light PL1
228
229B
212A
S1
210
210D
210H
STARTER
211
R
S6 MODE SELECTOR SWITCH
CV
214
218
PIPE
2
1
CC 3
A
(LOCATED BELOW
TERMINAL 2)
220
4
TIG
222
R2 ARC CONTROL
CCW
10K
277
279
278
S2
START
BUTTON
210A
Battery Charge
Light PL2
210F
210B
231
GND-R 5K
225
5G
1
4
7
CR1
3
6
9
A B
225B
224A
224B
AMPS
R1 OUTPUT CONT. POT
CCW
10K
77
76 75
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
210G
223A
-
+
12 VOLT
BATTERY
GND-L
GND-M
J74
P74 blk red
FUEL
PUMP
ENGINE
GROUND
GND-H
GND-J FRAME
GROUND
J73
P73 red
HOLD
COIL blk wht
PULL
COIL
FUEL SOLENOID
D4
+
HOUR METER
224
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
CLEVELAND, OHIO U.S.A.
L3
206S
204S
M10
M5
M9
M10
M5
277
278
279
75
76
Key
77
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
224B
215
404
5K
210H
200N
76A
77A
75A
4
2
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
14
13
208B
252 251
23
25
260
261
P3-J3
Sense/
Idler/
PWM
PCB2 WELD CONTROL PC BOARD
232
210B
B1
404
B2
GND-R
B3 B4
4
8
P43-J43
1 5
PCB3
PULL COIL BD.
P6-J6
Shunt
P54 - J4
Meter
P5 - J5
Meter
A
G4226
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
G-6
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11122 (G4572)
ELECTRICAL DIAGRAMS
RANGER 305D CE KUBOTA WIRING DIAGRAM - UK
G-6
260
261 Twisted
Pair
W10
W10
TWISTED PAIR
W9
R4
302
HEATSINK
B3
C10
B2
301
C11
B1
W4
W5
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W1
W3
VOLTS
W6
206S 204S
208B
SHUNT
50MV=400 AMPS
206B
206A
L1 CHOKE
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42 VAC
42 41 21
208C
206A
W8
A
C
B
D
WRAP TWO TURNS OF
LEADS A, 3, D, B, & C IN
DIRECTION
SHOWN THROUGH TOROID
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8 25
23
W5
D
A
STATOR AUX.
WINDING GND-E
5 E
W11
B
C
W6
W3
NOTE: STATOR LEAD 3 NOT USED.
TAPE LEAD END AND SECURE.
W2
CB5
15A
42A 41A
SHOWN IN
POSITIVE (+)
POSITION
BOTTOM GND
INSIDE
CASEFRONT
GND-N
GND-E
GND-R
D
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
NOTE: LEADS 31 AND 32 NOT USED.
TAPE LEAD ENDS AND SECURE.
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
K
H
E
F
G
D
C
B
J
I
A
GND-A
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77B
76B
75B
2B
4B
GND-B
77A
76A
75A
2A
4A
31
32
41A
42A
21
77B
76B
75B
4B
2B
AMPHENOL 2
1 1 4 1 5
7
1
2
6
5
1
8 6 10
8
12 9
ELECTRICAL SYMBOLS PER E1537
16
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
GND-K
GND-N
GND. SCREW ON LEFT
INSIDE CASEFRONT
FRAME GND.
GND-B
GND-A
GND-G
GND-D
GND-C
GND-B
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
5
C B A
5B 1C 1B 1A
5D 2C 2B
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
RCDI
30mA
2A
L3
J100
L3
L2
L2
E
L1
5D
L1
4A
4
2
2A
5N
TOP GND. SCREW ON
INSIDE OF CASE FRONT
5K
5M
5H
5G
2C 2B 2A
L3 L2 L1
12
CB2
15A
N A
E
11
J101
CB1
20A
D
E
CB3
15A
J102
9
N A
E
7
CB4
15A
GND SCREW ON
FAN BAFFLE.
GND-K
GND-J
7
STATOR
EXCITATION
WINDING
42 VAC
9
D3
201A
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
223
S7
GLOW
PLUG
BUTTON
223A
200B
5H
201
209B
C3
800uf
150vdc
200A
200
ROTOR
CB7
15A
229
229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
210C
BAT
IGN
L
ALTERNATOR
R3
Engine Protection
Light PL1 210E
5L
230
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210D 229B
229A
212A
S1
210D
210H
210J 210 210A
S2
START
BUTTON
209A
209
200N
FUEL GUAGE
4
1
J52
P52
210J
230
5L
STARTER
211
S6 MODE SELECTOR SWITCH
CV
214
218
PIPE
CC 3
2
1
A
(LOCATED BELOW
TERMINAL 2)
220
222
TIG
4
R2 ARC CONTROL
CCW
10K
277
279
278
210B
5M
FUEL SENDER
231
GND-R 5K
225
5G
1
4
7
210E
CR1
3
6
9
A B
225B
224A
224B
AMPS
R1 OUTPUT CONT. POT
CCW
10K
77
76 75
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
210G
223A
+
12 VOLT
BATTERY
-
GND-L
GND-M
J74
P74 blk red
FUEL
PUMP
ENGINE
GROUND
GND-H
GND-J FRAME
GROUND
J73
P73 red
HOLD
COIL blk wht
PULL
COIL
FUEL SOLENOID
D4
+
HOUR METER
224
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
R
CLEVELAND, OHIO U.S.A.
L3
206S
204S
277
278
279
75
76
Key
77
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
224B
215
404
5K
210H
200N
76A
77A
75A
4
2
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
14
13
208B
252 251
23
25
260
261
P3-J3
Sense/
Idler/
PWM
PCB2 WELD CONTROL PC BOARD
232
210B
B1
404
B2
GND-R
B3 B4
4 8
P43-J43
1 5
PCB3
PULL COIL BD.
P6-J6
Shunt
P54 - J4
Meter
P5 - J5
Meter
A.01
G4572
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
G-7
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11189, 11314 (G4572-1)
ELECTRICAL DIAGRAMS G-7
RANGER 305D CE KUBOTA WIRING DIAGRAM - UK
260
261 Twisted
Pair
TWISTED PAIR
W10
206S 204S
W10
SHUNT
50MV=400 AMPS
206B
206A
W9
W8
R4
302
HEATSINK
B3
C10
B2
301
C11
B1
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8 25
23
W5
W4
W6
W11
W5
W6
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W1
W2
W3
S6 MODE SELECTOR SWITCH
CV
1
218
PIPE
2
220
CC
TIG
3
4
222
A
(LOCATED BELOW
TERMINAL 2)
VOLTS
AMPS
L6
208B
L1 CHOKE
W3
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42 VAC
42 41 21
208C
206A
CB5
15A
42A 41A SHOWN IN
POSITIVE (+)
POSITION
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
WRAP TWO TURNS OF
LEADS A, 3, D, B, & C IN
DIRECTION
SHOWN THROUGH TOROID
BOTTOM GND
INSIDE LEFT
CASEFRONT
GND-N
GND-E
GND-R
GND-K
C
B
D
A
5
NOTE: LEADS 31 AND 32 NOT USED.
TAPE LEAD ENDS AND SECURE.
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
J
A
I
K
H
E
F
G
D
C
B
75B
4B
2B
GND-A
31
32
41A
42A
21
77B
76B
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77A
77B
76B
75B
2B
4B
GND-B
76A
75A
2A
4A
AMPHENOL 2
D C B A
GND-N
GND. SCREW ON RIGHT
INSIDE CASEFRONT
5B 1C 1B
FRAME GND.
GND-A
GND-B
GND-G
GND-D
GND-C
5D
5F 2C 2B
1A
RCDI
30mA
2A
L3
7
1
2
1 1
5
1
4 1
8 6
5
10
8
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
6
12 9 16
ELECTRICAL SYMBOLS PER E1537
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
L4
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
2
2A
L2
J100
N
L3 L2
E L1
5D
4A
4
D
C
NOTE: STATOR LEAD 3 NOT USED.
TAPE LEAD END AND SECURE.
R2 ARC CONTROL
CCW
277
278
279
R1 OUTPUT CONT. POT
CCW
77
76 75
A
STATOR AUX.
WINDING GND-E
5 E
5N
TOP GND. SCREW ON
INSIDE LEFT CASE FRONT
5K
5M
5H
5G
2C
L1
L3
12
2B
L2
B
2A
L1
CB2
15A
N A
E
11
J101
CB1
20A
D
CB3
15A
J102
9
N A
E
7
E
CB4
15A
GND SCREW ON
FAN BAFFLE.
5G
GND-K
7
STATOR
EXCITATION
WINDING
42 VAC
9
D3
200B
5H
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
S7
GLOW
PLUG
BUTTON
201A
201
C3
800uf
150vdc
200A
223A
ROTOR
209B
CB7
15A
R3
200N
FUEL GAUGE
5M
200
4
1
J52
P52
210J
230
5L
5L
230
Engine Protection
Light PL1 210E
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210D
229A
212A
S1
229B
210D
210H
210J 210
210A
S2
START
BUTTON
FUEL SENDER 210F
210B
223A
211
223
210C
231
GND-R 5K
224A
210F
224C
7
1
4
A
CR1
B
3
6
9
225B
D4
GND-J OIL
PRES
SW
229
H2O
TEMP
SW
229A
GLOW
PLUGS ENGINE COMPONENTS
BAT
IGN
L
ALTERNATOR
209A
209
STARTER
GND-J
GND-H
-
+
12 VOLT
BATTERY
ENGINE
GROUND
GND-L
FRAME
GROUND
J73
P73 red blk wht
HOLD
COIL
PULL
COIL
+
HOUR METER
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
210G
FUEL SOLENOID
J72
P72
224
1
215
210A
HOLD
COIL
2 3 4 red blk wht
PULL
COIL
IDLE SOLENOID
R
CLEVELAND, OHIO U.S.A.
L7
L8
L3
206S
204S
M10
M5
M9
M10
M5
277
278
279
75
76
Key
77
224B
215
404
5K
210H
200N
L5
76A
77A
75A
L2
14
13
208B
252 251
23
25
260
261
4
2
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
P3-J3
Sense/
Idler/
PWM
232
PCB2 WELD CONTROL PC BOARD
210B
B1
GND-R
404
B2
4
B3
1
8
B4
P43-J43
5
PCB3
PULL COIL BD.
P6-J6
Shunt
P4 - J4
Meter
P5 - J5
Meter
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
A
G4572-1
PRINT TO 11 X 17
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
G-8
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11039 (G4409)
ELECTRICAL DIAGRAMS
RANGER 305D CE KUBOTA - WIRING DIAGRAM - EUROPE
G-8
260
261 Twisted
Pair
W10
W10
TWISTED PAIR W9
R4
302
HEATSINK
B3
C10
B2
301
C11
B1
W4
W5
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W1
W3
VOLTS
W6
206S 204S
208B
SHUNT
50MV=400 AMPS
206B
206A
L1 CHOKE
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42 VAC
42 41 21
208C
206A
W8
A
C
B
WRAP TWO TURNS OF
LEADS A, 3, D, B, & C IN
DIRECTION
SHOWN THROUGH TOROID
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8 25
23
W5
D
A
STATOR AUX.
WINDING GND-E
5 E
W11
C
B
W6
W3
NOTE: STATOR LEADS D AND E NOT USED.
TAPE LEAD ENDS AND SECURE.
W2
CB5
15A
42A 41A
SHOWN IN
POSITIVE (+)
POSITION
BOTTOM GND
INSIDE
CASEFRONT
GND-N
GND-E
GND-R
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
NOTE: LEADS 31 AND 32 NOT USED.
TAPE LEAD ENDS AND SECURE.
GND-K
5
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
K
H
E
F
J
A
I
G
D
C
B
GND-A
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77B
76B
75B
2B
4B
GND-B
77A
76A
75A
2A
4A
31
32
41A
42A
21
77B
76B
75B
4B
2B
AMPHENOL 2
1 1 4 1 5
1
2
6
5
1
8 6 10
8
7 12 9
ELECTRICAL SYMBOLS PER E1537
16
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
C B A
GND. SCREW ON LEFT
INSIDE CASEFRONT
GND-N
FRAME GND.
5B 1C 1B
GND-B
GND-A
GND-G
GND-D
GND-C
5E 5D 2C 2B
1A
RCDI
30mA
2A
GND-B
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
L3
J100
L3
L2
L2
E
L1
5D
L1
4A
4
2
2A
5N
TOP GND. SCREW ON
INSIDE OF CASE FRONT
5K
5H
2C
2B 2A
L3 L2 L1
12
CB2
15A
11
N A
E
J101
CB1
20A
5E
5G
10
J102
N A
E
8
CB4
15A
GND SCREW ON
FAN BAFFLE.
GND-K
GND-J
7
STATOR
EXCITATION
WINDING
42 VAC
9
223
D3
S7
GLOW
PLUG
BUTTON
223A
200B
201A
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
5H
201
209B
C3
800uf
150vdc
200A
ROTOR
CB7
15A
229
229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
200
210C
BAT
IGN
228
L
ALTERNATOR
R3
209A
209
200N
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210E
210D
229A
Engine Protection
Light PL1
228
229B
212A
S1
210
210D
210H
STARTER
211
R
S6 MODE SELECTOR SWITCH
CV
214
218
PIPE
2
1
CC 3
A
(LOCATED BELOW
TERMINAL 2)
220
4
TIG
222
R2 ARC CONTROL
CCW
10K
277
279
278
210A
Battery Charge
Light PL2
210F
S2
START
BUTTON
210B
231
GND-R 5K
225
5G
7
1
4
CR1
3
6
9
A B
225B
224A
224B
AMPS
R1 OUTPUT CONT. POT
CCW
10K
77
76 75
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
210G
223A
+
12 VOLT
BATTERY
-
GND-L
GND-M
J74
P74 blk red
FUEL
PUMP
ENGINE
GROUND
GND-H
GND-J FRAME
GROUND
J73
P73 red
HOLD
COIL blk wht
PULL
COIL
FUEL SOLENOID
D4
+
HOUR METER
224
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
CLEVELAND, OHIO U.S.A.
L3
206S
204S
M10
M5
M9
M10
M5
277
278
279
75
76
Key
77
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
224B
215
404
5K
210H
200N
76A
77A
75A
2
4
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
14
13
208B
252 251
23
25
260
261
P3-J3
Sense/
Idler/
PWM
PCB2 WELD CONTROL PC BOARD
232
210B
B1
404
B2
4
GND-R
B3 B4
8
1 5
P43-J43
PCB3
PULL COIL BD.
P6-J6
Shunt
P54 - J4
Meter
P5 - J5
Meter
A
G4409
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
G-9
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11123 (G4573)
ELECTRICAL DIAGRAMS G-9
RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE
260
261 Twisted
Pair
TWISTED PAIR
W10
206S 204S
W10
SHUNT
50MV=400 AMPS
206B
206A
W9
W8
R4
302
HEATSINK
B3
C10
B2
301
C11
B1
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8
W6
25
23
W5
W4
W11
W5
W6
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W1
W2
W3
S6 MODE SELECTOR SWITCH
CV
1
218
PIPE
2
220
CC
TIG
3
4
222
A
(LOCATED BELOW
TERMINAL 2)
VOLTS
AMPS
L6
208B
L1 CHOKE
W3
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42
42 VAC
41 21
208C
206A
CB5
15A
42A
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
41A SHOWN IN
POSITIVE (+)
POSITION
WRAP TWO TURNS OF
LEADS A, 3, D, B, & C IN
DIRECTION
SHOWN THROUGH TOROID
BOTTOM GND
INSIDE LEFT
CASEFRONT
GND-N
GND-E
GND-R
GND-K
A
C
B
5
D
A
STATOR AUX.
WINDING GND-E
C B A
NOTE: LEADS 31 AND 32 NOT USED.
TAPE LEAD ENDS AND SECURE.
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
J
I
A
K
H
E
F
G
D
C
B
31
32
41A
42A
21
77B
76B
75B
4B
2B
GND-A
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77A
77B
76B
75B
2B
4B
GND-B
76A
75A
2A
4A
GND-N
GND. SCREW ON RIGHT
INSIDE CASEFRONT
FRAME GND.
GND-A
GND-B
GND-G
GND-D
GND-C
5B 1C 1B
5E
5D
5F 2C 2B
1A
L3
RCDI
30mA
2A
AMPHENOL 2
7
1
1
2
1 4 1 5
10
8
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=W HITE
G=GREEN (W/YELLOW STRIPE)
5
1
8 6
6
12 9 16
ELECTRICAL SYMBOLS PER E1537
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
L4
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
2
2A
L2
J100
N
L3 L2
E L1
5D
4A
4
C
NOTE: STATOR LEAD 3 NOT USED.
TAPE LEAD END AND SECURE.
R2 ARC CONTROL
CCW
277
278
279
R1 OUTPUT CONT. POT
CCW
77
76 75
5 E
B
5N
TOP GND. SCREW ON
INSIDE LEFT CASE FRONT
5K
5H
5G
5M
2C
L1
L3
12
2B
L2
2A
L1
CB2
15A
N A
E
11
J101
5E
CB1
20A
10
J102
N A
E
8
CB4
15A
GND SCREW ON
FAN BAFFLE.
GND-K
5G
7
STATOR
EXCITATION
WINDING
42 VAC
9 R3
200N
FUEL GAUGE
5M
GND-R 5K
223
D3
5H
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
S7
GLOW
PLUG
BUTTON
ROTOR
209B
CB7
15A
223A
200B
201A
201
C3
800uf
150vdc
200A
210C
200
4
1
J52
P52
210J
230
5L
5L
230
Engine Protection
Light PL1 210E
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210D
229A
212A
S1
229B
210D
210H
210J 210
210A
S2
START
BUTTON
FUEL SENDER
210B
223A
225
211
231
1
4
7
210E
CR1
3
6
9
A
225B
B
D4
209A
209
GND-J
229
229A
OIL
PRES
SW
H2O
TEMP
SW
GLOW
PLUGS ENGINE COMPONENTS
BAT
IGN
L
ALTERNATOR STARTER
GND-J
GND-H
+
-
12 VOLT
BATTERY
GND-L
ENGINE
GROUND
GND-M
J74
P74 blk red
FUEL
PUMP
J73
P73 red
HOLD
COIL blk wht
PULL
COIL
FRAME
GROUND
210G
FUEL SOLENOID
+
HOUR METER
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
224
215
210A
J72
P72
1 2 3 4 red blk wht
HOLD
COIL
PULL
COIL
IDLE SOLENOID
R
CLEVELAND, OHIO U.S.A.
L7
L8
L3
206S
204S
M10
M5
M9
M10
M5
PCB3
PULL COIL BD.
P6-J6
Shunt
P4 - J4
Meter
P5 - J5
Meter
277
278
279
75
76
Key
77
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
224B
215
404
5K
210H
200N
L5
76A
77A
75A
L2
14
13
208B
252 251
23
25
260
261
4
2
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
P3-J3
Sense/
Idler/
PWM
232
PCB2 WELD CONTROL PC BOARD
210B
B1 B2
GND-R
4
B3
404
1
8
B4
P43-J43
5
A
G4573
PRINT TO 11 X 17
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
G-10
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11190, 11315 (G4573-1)
ELECTRICAL DIAGRAMS G-10
RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE
260
261 Twisted
Pair
TWISTED PAIR
W10
206S 204S
W10
SHUNT
50MV=400 AMPS
206B
206A
W9
W8
R4
302
HEATSINK
B3
C10
B2
301
C11
B1
B6
13
300 AMP
MODULE
14
B5
C9 C8
PCB 1
B4
B7
B8 25
23
W5
W4
W6
W11
W5
W6
D1 - THREE PHASE BRIDGE RECTIFIER
STATOR
WELD
WINDINGS
W1
W2
W3
S6 MODE SELECTOR SWITCH
CV
1
218
PIPE
2
220
CC
TIG
3
4
222
A
(LOCATED BELOW
TERMINAL 2)
VOLTS
AMPS
L6
208B
L1 CHOKE
W3
206B 206C
W7
208
WIRE FEED POWER
WINDING
208A
S5
VOLTMETER
POLARITY
SWITCH
42
42 VAC
41 21
208C
206A
CB5
15A
42A 41A SHOWN IN
POSITIVE (+)
POSITION
BYPASS
FILTER
ASSEMBLY
206C
5N
208C
A
C
B
WRAP TWO TURNS OF
LEADS A, 3, D, B, & C IN
DIRECTION
SHOWN THROUGH TOROID
BOTTOM GND
INSIDE LEFT
CASEFRONT
GND-N
GND-E
GND-R
GND-K
5
C B A
NOTE: LEADS 31 AND 32 NOT USED.
TAPE LEAD ENDS AND SECURE.
115VAC
42VAC
WORK
REMOTE
CONTROL
CONTACTOR
GROUND
J
A
I
K
H
E
F
G
D
C
B
75B
4B
2B
GND-A
31
32
41A
42A
21
77B
76B
AMPHENOL 1
REMOTE
CONTROL
CONTACTOR
GROUND
A
B
C
D
E
F
77A
77B
76B
75B
2B
4B
GND-B
76A
75A
2A
4A
GND-N
GND. SCREW ON RIGHT
INSIDE CASEFRONT
5B 1C 1B
FRAME GND.
GND-A
GND-B
GND-G
GND-D
GND-C
5E
5D
5F 2C 2B
1A
L3
RCDI
30mA
2A
AMPHENOL 2
7
1
1
2
1 4 1 5
10
8
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=W HITE
G=GREEN (W/YELLOW STRIPE)
5
1
8 6
6
12 9 16
ELECTRICAL SYMBOLS PER E1537
CONNECTORS VIEWED FROM INSERTION END
L2, L3: RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
L4
CONTACTOR
CONTROL
S3
SHOWN IN
"WELDING ON"
POSITION
L2
J100
N
L3 L2
E L1
5D
4A
4
2
2A
D
C
NOTE: STATOR LEAD 3 NOT USED.
TAPE LEAD END AND SECURE.
R2 ARC CONTROL
CCW
277
278
279
R1 OUTPUT CONT. POT
CCW
77
76 75
A
STATOR AUX.
WINDING GND-E
5 E
2C
L1
L3
12
2B
L2
B
5N
TOP GND. SCREW ON
INSIDE LEFT CASE FRONT
5K
5H
5G
5M
2A
L1
CB2
15A
N A
E
11
J101
5E
CB1
20A
10
J102
N A
E
8
CB4
15A
GND SCREW ON
FAN BAFFLE.
5G
GND-K
7
STATOR
EXCITATION
WINDING
42 VAC
9
D3
5H
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
S7
GLOW
PLUG
BUTTON
200B
201A
201
C3
800uf
150vdc
200A
223A
ROTOR
209B
CB7
15A
R3
200N
FUEL GAUGE
5M
200
4
1
J52
P52
210J
230
5L
5L
230
Engine Protection
Light PL1 210E
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
212
210D
229A
212A
S1
229B
210D
210H
210J 210
210A
S2
START
BUTTON
FUEL SENDER 210F
210B
223A
211
223
210C
231
GND-R 5K
224A
210F
224C
1
4
7
A
CR1
B
3
6
9
225B
D4
GND-J OIL
PRES
SW
229
H2O
TEMP
SW
229A
GLOW
PLUGS ENGINE COMPONENTS
BAT
IGN
L
ALTERNATOR
209A
209
STARTER
GND-J
GND-H
+
12 VOLT
BATTERY
-
GND-L
ENGINE
GROUND
FRAME
GROUND
J73
P73 red blk wht
HOLD
COIL
PULL
COIL
224A
+
HOUR METER
IDLER CONTROL
251
S4
252
SHOWN IN
"AUTO" POSITION
210G
FUEL SOLENOID
J72
P72
224
1
215
210A
HOLD
COIL
2 3 4 red blk wht
PULL
COIL
IDLE SOLENOID
R
CLEVELAND, OHIO U.S.A.
L7
L8
L3
206S
204S
M10
M5
M9
M10
M5
PCB3
PULL COIL BD.
P6-J6
Shunt
P4 - J4
Meter
P5 - J5
Meter
277
278
279
75
76
Key
77
222
220
218
214
P7 - J7
Output &
Arc Cont.
Mode
Select
224B
215
404
5K
210H
200N
L5
76A
77A
75A
L2
14
13
208B
252 251
23
25
260
261
4
2
P2 - J2
Engine &
Battery
Function
Key
305
P1 - J1
Amphenol,
Model
Select,
Hot Start
P3-J3
Sense/
Idler/
PWM
232
PCB2 WELD CONTROL PC BOARD
210B
B1 B2
GND-R
4
B3
404
1
8
B4
P43-J43
5
A
G4573-1
PRINT TO 11 X 17
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
G-11
SCHEMATIC - ENTIRE MACHINE - CODE 10926 (L11946) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
46 L119
ENGINEERING CONTROLLED
MANUFACTURER:
No
POSITIVE
OUTPUT
TERMINAL
Located on back of output panel between terminals
206B
BY-PASS
PC BOARD
206C
208C
206A
208
SHUNT
21
208A
Shunt on back of positive output terminal
50MV=400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
L1 CHOKE
Choke is beneath bearing end of generator on support.
TWISTED
PAIR
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
B3
B6
B7 B8
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
Located on front of fan baffle near top of machine.
ARC
CONTROL 10K
R2
279 (J7-6)
278 (J7-7)
WELD CONTROL
PC BOARD
P/N G4107-1
25 (J3-9)
Control board common is at welder positive output and shunt
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
77B
76B
75B
2B
4B
GND-B
CHANGE DETAIL: RELEASED FROM "X"
R4 is located on front of fan baffle near top of machine
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
(J4-1 to 10)
115VAC
42VAC
WORK
CONTACTOR
GROUND
E
F
K
H
I
J
A
G
D
C
B
AMPHENOL
(J5-1 to 10)
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
+COM
B2
GATE SIGNAL
(J2-1) 200N
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-12) 305
4B
2B
B5 10,000uF x4
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
C
IGBT (8)
E
TWISTED
PAIR
23 (J3-10)
(J2-5) 215
(J1-4) 2
(J1-3) 4
(J1-7) 305
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
77B
76B
75B
B1
B4
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
-INPUT
Chopper is mounted on the back side of fan baffle near top of machine.
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
R3 25 OHM
R3 located on front of fan baffle on left side near bottom of machine
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
CV
PIPE
TIG
CC
Swich closed for high idle.
IDLER SWITCH
2A
(TO AMPHENOL)
WELD TERM. SW.
4A
(TO AMPHENOL)
MODE
SWITCH
+12 to 14V @ NORMAL OIL PRES. (INPUT)
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
INPUT TO
AMPHENOL
Battery charge lamp will be on whenever RUN/STOP switch is in RUN position and alternator is not charging
209
YELLOW
BATTERY
CHARGING
LIGHT
GLOWPLUG
SWITCH S7
15A BATTERY
209
PL2
228
L
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
223
BAT
IGN
W3
GLOWPLUGS
START BUTTON
SWITCH S2
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
+
S1
TO AUX.
OUTLETS
AND
AMPHENOLS
211
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
W1
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W2
240 V AC
120 V AC
120 V AC
42 VOLT AC
WIRE FEEDER
POWER
RUN-STOP SWITCH
(SHOWN IN RUN)
210
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
3
5
GND E
41
6
42
210
WHITE FUEL RED
SOLENOID
TWO POLE 3600 RPM ALTERNATOR
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
ENGINE
PROTECTION
RELAY
9
D4
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
3
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
9
7
201
5H
C3 and D3 located on rear of fan baffle on left side of machine.
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
B
CR1
A
ELECTRIC
FUEL
PUMP
PL1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
229
D
3
224
+
YELLOW
ENGINE
PROTECTION
LIGHT
+
Relay CR1 and D4 located on fron baffle on right side of machine.
232
IDLE SOLENOID
ENEGIZED FOR
LOW IDLE
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE 11 OHMS
HOUR METER
+15V @ LOW IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N L11768-1
Located next to control board.
RED
215
B2
B4
B1
PROPRIETARY & CONFIDENTIAL:
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
BAM
BAM
-
REFERENCE:
L11943
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D
MACHINE SCHEMATIC
2/5/03
PROJECT
NUMBER:
CRM33549
DOCUMENT
NUMBER:
L11946
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-11
RANGER 305D
G-12
SCHEMATIC - ENTIRE MACHINE - CODE 10926 (L11946) PAGE 2 OF 2
6 L1194
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: RELEASED FROM "X"
ELECTRICAL DIAGRAMS
+15V
TRANSFORMER
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
J3-3
J3-7
J3-14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+15V
THERMAL LAMP
THERMOSTAT(IF USED)
J3-5
J3-1
+15V
+ STUD
THERMAL SENSE (if used)
+15V
+ STUD
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8 MACHINE
J1-13
J1-13
J1-13
J1-13
RANGER 250 G&D
RANGER 305 G&D
VANTAGE 500
VANTAGE 575
AIR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MACHINE /
MODE
LOGIC
(CPU)
BLINK (PULLED LOW AND HIGH
DECIMAL POINT)
+15V
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
4
TIG
3
CC
1
CV
2
PIPE
J7-16
J7-15
J7-14
J7-13
J7-12
J7-11
J7-9
+ STUD
TIG MODE
PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
N/A
N/A
CV MODE
BLINK (PULLED LOW AND HIGH
DECIMAL POINT)
SELECT CONTROL POINT
+ STUD
-
+
SHUNT
+
(206S)
50mV = 400 AMPS
(204S)
- STUD
-
(208B)
J7-10
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3-15
47.5 ohms
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
+5V +5V
+ STUD
+ STUD
ARC CONTROL 10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRCUITRY
+ STUD
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J3-6
(253)
J3-13
(252)
SILVER
GOLD
THERMAL
PROTECTION
INDICATOR
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
VOLTMETER
DISPLAY
J5-9
J5-10
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CURRENT FEEDBACK
CONTROL POINT
REGULATING
AMPLIFIER
+10V
OUTPUT
CONTROL
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1-10
+ STUD
+ STUD
TIG MODE +10V
ALL OTHER MODES
LOCAL
PRESET
REMOTE
+ STUD + STUD
OCV
TOUCH START
VARIABLE PINCH
PIPE ARC FORCE
VARIABLE ARC FORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD
+5V
+3.3V
CURRENT
LIMITS,
AVERAGE,
ABSOLUTE,
& FOLDBACK
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
FRAME
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
DIODE ONLY ON -E
VERSION AND ABOVE
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
4
1
2
3
FRAME
TO IDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TO FRAME FOR HIGH IDLE
+ STUD
FRAME
RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
PULL COIL
BOARD
RED
IDLE
SOLENOID
HOLD
COIL
BLK
WHT
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN
J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ -
NEGATIVE
BRUSH
FRAME
ROTOR
+15V COM
J2-7
-
BATTERY NEGATIVE
J2-3
V-BATTERY
FRAME
VREF
-
+
FRAME
J2-2
CHARGE
LAMP
J2-11
+15V when the battery charge light is "OFF"
(Machine running, alternator charging battery, +1.5V when battery charge light is seconds when machine is turned off)
PWM
CHOPPER
CONTROL
CIRCUIT
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWM COMMON
#1
CHOPPER
BOARD
(ALL MACHINES)
#2
CHOPPER
BOARD
(VANTAGE ONLY)
+ STUD
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
O-ORANGE
R-RED
U-BLUE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2 6
7 12
LATCH
VIEW OF CONNECTOR ON PC BOARD
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
BAM
BAM
-
REFERENCE:
L11943
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D
MACHINE SCHEMATIC
2/5/03
PROJECT
NUMBER:
CRM33549
DOCUMENT
NUMBER:
L11946
2
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-12
RANGER 305D
G-13
SCHEMATIC - ENTIRE MACHINE - CODE 11121 (L12212) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
12 L122
ENGINEERING CONTROLLED
M ANUFACTURER:
No
CHANGE DETAIL: RELEASED "A.02" FROM "X"
POSITIVE
OUTPUT
TERMINAL
Located on back of output panel between terminals
206B
BY-PASS
PC BOARD
206C
208C
206A
208
SH UNT
Shunt on back of positive output terminal
50MV= 400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
58
12
L6
L1 CHOKE
Choke is beneath bearing end of generator on support.
2 TURNS
FERRITE
L3
TWISTED
PAIR
Control Board senses Weld Output from Current Feedback Shunt to activate idler.
R4 is located on front of fan baffle near top of machine
THRU
FERRITE
L5
Power Supply to Control
Board
TWISTED
PAIR
R4
50 OHM
100 W
-OUTPUT
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
GROUND
C
D
A
B
E
F
AMPHENOL
ARC
CONTROL 10K
R2
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
77B
76B
75B
2B
4B
GND-B
279 (J7-6)
278 (J7-7)
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
CHOPPER PC BOARD
L11845-1
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
(J4-1 to 10)
E
F
K
H
I
J
A
G
D
C
B
AMPHENOL
B3
B6
B7
+COM
B2 B5
10,000uF x4
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
C
IGBT (8)
B8
25 (J3-9)
(J5-1 to 10)
E
GATE SIGNAL
TWISTED
PAIR
23 (J3-10)
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
L8
All leads
1 time thru ferrite
L7
All leads
1 time thru ferrite
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
115VAC
42VAC
WORK
CONTACTOR
GROUND
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
4B
2B
77B
76B
75B
B1
B4
0 V
15 V
15 V
L2
0 V
CV
PIPE
TIG
CC
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
Chopper is mounted on the back side of fan baffle near top of machine. Requires added baffle for cooling air flow.
-INPUT
L4
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
2A
MODE
SWITCH
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
FUEL SENDER
R3 25 OHM
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
Swich closed for high
2 TURNS THRU FERRITE
(TO AMPHENOL)
WELD TERM. SW.
4A
(TO AMPHENOL)
+12 to 14V @ NORMAL OIL PRES. (INPUT)
209
INPUT TO
AMPHENOL
4 1
GLOWPLUG
SWITCH S7
START BUTTON
SWITCH S2
L
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
R3 located on front of fan baffle on left side near bottom of machine
BAT
223
15A BATTERY
209
IGN
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
W3
GLOWPLUGS
+
S1
TO AUX.
12 VOLT
BATTERY
FRAME
GROUND
W1
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
OUTLETS
AND
W2
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
211
120 V AC
240 V AC
120 V AC
RUN-STOP SWITCH
(SHOWN IN RUN)
42 VOLT AC
WIRE FEEDER
POWER
210
3
5
GND E
41
6
42
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
210
TWO POLE 3600 RPM ALTERNATOR
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
ENGINE
PROTECTION
RELAY
9
D4
J73-4
P73-4
WHITE FUEL RED
SOLENOID
J73-2
225
P73-2
P73-3
HOLD
11 OHMS
BLACK
FUEL
SOLENOID
J73-3 AND FUEL
PUMP
ENERGIZED
FOR RUN
3
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
J74
201
5H
REVOLVING FIELD
APPROX. 5 OHMS @ 75F
9
7
B
CR1
A
P74
ELECTRIC
FUEL
PUMP
P74
J74
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
YELLOW
ENGINE
PROTECTION
LIGHT
PL
1
229
224
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
P72-3
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE
HOLD
P72-4
11 OHMS
P72-2
J72-4 J72-2
232
RED
215
HOUR METER
+15V @ LOW
IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
L11768-1
Located next to control board.
B2
B4
B1
240-265 OHMS EMPTY
20-35 OHMS FULL
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
DEO
BAM
-
REFERENCE:
L11946
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF APPROVAL
DATE:
RANGER 305D
MACHINE SCHEMATIC
12/11/2003
PROJECT
NUMBER:
CRM35573
DOCUMENT
NUMBER:
1 2
DOCUMENT
REVISION:
L12212 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-13
RANGER 305D
G-14
SCHEMATIC - ENTIRE MACHINE - CODE 11121 (L12212) PAGE 2 OF 2
12 L122
ENGINEERING CONTROLLED
M ANUFACTURER: No
CHANGE DETAIL: RELEASED "A.02" FROM "X"
ELECTRICAL DIAGRAMS
+15V
TRANSFORMER
J3-3
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
J3-7
J3- 14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
AUXILLARY
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+ STUD
+ STUD +
-
SHUNT
- STUD
+
4
TIG
3
CC
1
CV
2
PIPE
(206S)
50mV = 400 AMPS
(204S)
-
(208B)
+15V
MACHINE /
MODE
LOGIC
(CPU)
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
J1-13
J1-13
J1-13
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8
J1-13
M ACHINE
RANGER 250 G&D
RANGER 305 G&D
V ANTA GE 500
V ANTA GE 575
A IR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
BLINK (PULLED LOW AND HIGH
INLOOKBACK TO FLASH
DECIMAL POINT)
+15V
J7-16
J7-15
+ STUD
TIG MODE
J7-14 PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
J7- 13 BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
J7- 12
N/A
J7- 11
N/A
J7-9 CV MODE
J7- 10 ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3- 15
47.5 ohm s
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
+
x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
SELECT CONTROL POINT
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON/ OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
+5V +5V
+ STUD
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRC UI TRY
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
(77)
(76)
(75)
J7-1
J7-4
J7-5
+ STUD TIG M ODE +10V
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
REMOTE
CONTROL
10K
POT
(77B)
J1-11
(76B)
J1-14
(75B)
J1- 10
ALL OTHER MODES
+ STUD
+ STUD + STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
VOLTMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CONTROL POINT
REG ULATING
AMPLIFIER
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
+5V
+3.3V
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
DIODE ONLY ON -E
FRAME
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
1
2
3
4
FRAME
TO IDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TO FRAME FOR HIGH IDLE
FRAME
+ STUD RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
BOARD
WHT
RED
IDLE
SOLENOID
HOLD
COIL
BLK
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ -
NEGATIVE
BRUSH
FRAME
ROTOR
PW M
CHOPPER
CONTROL
CIRCUIT
+
BATTERY POSITIVE
J2-7
J2-3
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
V-BATTERY
FRAME
#1
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWMCOMMON
BOARD
(ALL MACHINES)
#2
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
1 2
7
6
1 2
LATCH
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
DEO
BAM
-
REFERENCE:
L11946
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
12/11/2003
RANGER 305D
MACHINE SCHEMATIC
PROJECT
NUMBER:
L12212
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-14
RANGER 305D
G-15
SCHEMATIC - ENTIRE MACHINE - CODES 11188, 11275 (L12212-1) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
-1 212 L12
ENGINEERING CONTROLLED
M ANUFACTURER: No
POSITIVE
OUTPUT
TERMINAL
206B
CHANGE DETAIL: NEW
Shunt on back of positive
SH UNT output terminal
50MV= 400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
R4 is located on front of fan baffle near top of machine
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
L6
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
2 TURNS
THRU FERRITE
THRU
FERRITE
L3
TWISTED
PAIR
Control Board senses Weld Output from Current Feedback Shunt to activate idler.
THRU
FERRITE
L5
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
ARC
CONTROL 10K
R2
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
77B
76B
75B
2B
4B
GND-B
279 (J7-6)
278 (J7-7)
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
E
TWISTED
PAIR
(J2-5) 215
(J1-4) 2
(J1-3) 4
(J1-7) 305
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
42VAC
WORK
GROUND
B3
B6
B7
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
B8
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
(J4-1 to 10)
L8
115VAC
CONTACTOR
All leads
1 time thru ferrite
E
F
K
H
I
J
A
G
D
C
B
AMPHENOL
(J5-1 to 10)
L7
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
L11845-1
+COM
B2
4B
2B
B5
C
IGBT (8)
23 (J3-10)
All leads
1 time thru ferrite
77B
76B
75B
10,000uF x4
GATE SIGNAL
(J2-1) 200N
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-12) 305
B1
B4
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
Chopper is mounted on the back side of fan baffle near top of machine. Requires added baffle for cooling air flow.
-INPUT
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
R3 25 OHM
R3 located on front of fan baffle on left side near bottom of machine
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
L2
CV
PIPE
TIG
CC
D1 - THREE PHASE BRIDGE RECTIFIER
Swich closed for high
IDLER SWITCH
2 TURNS THRU FERRITE
2A
(TO AMPHENOL)
WELD TERM. SW.
4A
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
(TO AMPHENOL)
MODE
SWITCH
+12 to 14V @ NORMAL OIL PRES. (INPUT)
L4
FUEL SENDER
4
15A BATTERY
CIRCUIT BREAKER
209
209
INPUT TO
AMPHENOL
FUEL
GAUGE
1
GLOWPLUG
SWITCH S7
START BUTTON
SWITCH S2
L
Rectifier mounted to generator support above output choke.
BAT
223
IGN
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
W3
GLOWPLUGS
+
S1
211
TO AUX.
W1
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W2
OUTLETS
AND
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
240 V AC
120 V AC
120 V AC
42 VOLT AC
WIRE FEEDER
POWER
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
5
GND E
41
42
3
6
P73-3
J73-3
210
TWO POLE 3600 RPM ALTERNATOR
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
ENGINE
PROTECTION
RELAY
7
1
D4
J73-4 J73-2
225
P73-4
WHITE FUEL RED
SOLENOID
P73-2
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
9
3
9
7
201
5H
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
B
CR1
A
YELLOW
ENGINE
PROTECTION
LIGHT
PL
1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
P72-3
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE
HOLD
P72-4 P72-2
J72-4 J72-2
232
RED
215
HOUR METER
+15V @ LOW
IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N
L11768-1
Located next to control board.
B2
B4
B1
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
MAP
BAM
-
REFERENCE:
L12212
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D
MACHINE SCHEMATIC
07/15/2004
PROJECT
NUMBER:
CRM35578
DOCUMENT
NUMBER:
1 2
DOCUMENT
REVISION:
L12212-1 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-15
RANGER 305D
G-16
SCHEMATIC - ENTIRE MACHINE - CODES 11188, 11275 (L12212-1) PAGE 2 OF 2
ELECTRICAL DIAGRAMS
-1 212 L12
ENGINEERING CONTROLLED
M ANUFACTURER: No
CHANGE DETAIL: NEW
+15V
TRANSFORMER
J3-3
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
J3-7
J3- 14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
AUXILLARY
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+ STUD
+ STUD
+
-
SHUNT
- STUD
+
4
TIG
3
CC
1
CV
2
PIPE
(206S)
50mV = 400 AMPS
(204S)
-
(208B)
+15V
MACHINE /
MODE
LOGIC
(CPU)
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
J1-13
J1-13
J1-13
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8
J1-13
M ACHINE
RANGER 250 G&D
RANGER 305 G&D
V ANTA GE 500
V ANTA GE 575
A IR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
J7-16
+ STUD
J7-15
TIG MODE
J7-14 PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
J7- 13 BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
J7- 12
N/A
J7- 11 N/A
J7-9
CV MODE
J7- 10
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3- 15
47.5 ohm s
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
SELECT CONTROL POINT
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
+5V +5V
+ STUD
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRC UI TRY
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1- 10
+ STUD TIG M ODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD + STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
VOLTMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CONTROL POINT
REG ULATING
AMPLIFIER
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
+5V
+3.3V
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
DIODE ONLY ON -E
FRAME
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
1
2
3
4
FRAME
TOIDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TOFRAME FOR HIGH IDLE
FRAME
+ STUD RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
BOARD
WHT
RED
IDLE
SOLENOID
HOLD
COIL
BLK
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ NEGATIVE
BRUSH
FRAME
ROTOR
PW M
CHOPPER
CONTROL
CIRCUIT
+
BATTERY POSITIVE
J2-7
-
J2-3
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
V-BATTERY
FRAME
#1
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWMCOMMON
BOARD
(ALL MACHINES)
#2
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
1 2
7
6
1 2
LATCH
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
MAP
BAM
-
REFERENCE:
L12212
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
07/15/2004
RANGER 305D
MACHINE SCHEMATIC
PROJECT
NUMBER:
L12212-1
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-16
RANGER 305D
G-17
SCHEMATIC - ENTIRE MACHINE - CODE 11027 (L12039) PAGE 1 OF 2
9
ELECTRICAL DIAGRAMS
L1203
ENGINEERING CONTROLLED
MANUFACTURER:
No
SHUNT
CHANGE DETAIL:
Shunt on back of positive output terminal POSITIVE
OUTPUT
TERMINAL
206B
50MV=400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
TWISTED
PAIR
RELEASED FROM "X"
R4 is located on front of fan baffle near top of machine
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
ARC
CONTROL 10K
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
77B
76B
75B
2B
4B
GND-B
R2
279 (J7-6)
278 (J7-7)
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
42VAC
WORK
GROUND
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
B8
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
(J4-1 to 10)
CONTACTOR
E
F
K
H
G
D
C
B
J
I
A
AMPHENOL
B3
B6
B7
(J5-1 to 10)
+COM
B2 B5
C
IGBT (8)
E
23 (J3-10)
10,000uF x4
GATE SIGNAL
TWISTED
PAIR
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
21
77A
76A
75A
4A
31
32
41A
42A
2A
GND-A
NO CONNECTION
4B
2B
77B
76B
75B
B1
B4
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
-INPUT
Chopper is mounted on the back side of fan baffle near top of machine.
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
2A
4A
MODE
SWITCH
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
R3 located on front of fan baffle on left side near bottom of machine
R3 25 OHM
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
CV
PIPE
TIG
CC
Swich closed for high idle.
IDLER SWITCH
(TO AMPHENOL)
WELD TERM. SW.
(TO AMPHENOL)
+12 to 14V @ NORMAL OIL PRES. (INPUT)
INPUT TO
AMPHENOL
Battery charge lamp will be on whenever RUN/STOP switch is in RUN position and alternator is not charging
223
GLOWPLUGS
15A BATTERY
CIRCUIT BREAKER
209
209
YELLOW
BATTERY
CHARGING
LIGHT
GLOWPLUG
SWITCH S7
PL2
228
START BUTTON
SWITCH S2
L
BAT
IGN
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
TO AUX.
OUTLETS
AND
AMPHENOLS
+
S1
211
C
D
A
5
E
B
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W1
W2
W3
42 VOLT AC
WIRE FEEDER
POWER
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
B-5 230 VAC, 1 PH.
C-5
D-E 115 VAC, 1 PH.
CENTER-TAP
EARTH
41
42
210
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
WHITE FUEL RED
SOLENOID
TWO POLE 3600 RPM ALTERNATOR
ENGINE
PROTECTION
RELAY
9
D4
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
3
9
7
201
5H
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
B
CR1
A
ELECTRIC
FUEL
PUMP
YELLOW
ENGINE
PROTECTION
LIGHT
PL1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
HOUR METER
+15V @ LOW IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
IDLE SOLENOID
ENEGIZED FOR
LOW IDLE
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE 11 OHMS
232
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N L11768-1
Located next to control board.
RED
215
B2
B4
B1
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
MAP
BAM
-
REFERENCE:
L11946
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
6/20/03 PROJECT
NUMBER:
CRM33673
DOCUMENT
NUMBER:
L12039
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-17
RANGER 305D
G-18
SCHEMATIC - ENTIRE MACHINE - CODE 11027 (L12039) PAGE 2 OF 2
9 L1203
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: RELEASED FROM "X"
ELECTRICAL DIAGRAMS
+15V
TRANSFORMER
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
J3-3
J3-7
J3-14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+15V
THERMAL LAMP
THERMOSTAT(IF USED)
J3-5
J3-1
+15V
+ STUD
THERMAL SENSE (if used)
+15V
+ STUD
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8 MACHINE
J1-13
J1-13
J1-13
J1-13
RANGER 250 G&D
RANGER 305 G&D
VANTAGE 500
VANTAGE 575
AIR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
+ STUD
MACHINE /
MODE
LOGIC
(CPU)
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
4
TIG
3
CC
1
CV
2
PIPE
J7-16
J7-15
J7-14
J7-13
J7-12
J7-11
J7-9
+ STUD
TIG MODE
PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
N/A
N/A
CV MODE
BLINK (PULLED LOW AND HIGH
DECIMAL POINT)
SELECT CONTROL POINT
+ STUD
-
+
SHUNT
+
(206S)
50mV = 400 AMPS
(204S)
- STUD
-
(208B)
J7-10
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3-15
47.5 ohms
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
+5V +5V
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRCUITRY
+ STUD
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J3-6
(253)
J3-13
(252)
SILVER
GOLD
THERMAL
PROTECTION
INDICATOR
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
VOLTMETER
DISPLAY
J5-9
J5-10
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CURRENT FEEDBACK
CONTROL POINT
REGULATING
AMPLIFIER
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1-10
+ STUD
+ STUD
TIG MODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIABLE PINCH
PIPE ARC FORCE
VARIABLE ARC FORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD
+5V
CURRENT
LIMITS,
AVERAGE,
ABSOLUTE,
& FOLDBACK
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
FRAME
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
DIODE ONLY ON -E
VERSION AND ABOVE
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
4
1
2
3
FRAME
TO IDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TO FRAME FOR HIGH IDLE
+ STUD
FRAME
RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
PULL COIL
BOARD
BLK
WHT
RED
IDLE
SOLENOID
STARTER BUTTON
J2-8
FUEL SHUTDOWN
J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ -
NEGATIVE
BRUSH
FRAME
ROTOR
+15V COM
J2-7
-
BATTERY NEGATIVE J2-3
V-BATTERY
FRAME
VREF
-
+
J2-2
J2-11
CHARGE
LAMP
(Machine running, alternator charging battery, +1.5V when battery charge light is
FRAME
PWM
CHOPPER
CONTROL
CIRCUIT
+3.3V
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWM COMMON
#1
CHOPPER
BOARD
(ALL MACHINES)
#2
CHOPPER
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2 6
7 12
LATCH
VIEW OF CONNECTOR ON PC BOARD
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
MAP
BAM
-
REFERENCE:
L11946
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
6/20/03 PROJECT
NUMBER:
CRM33673
DOCUMENT
NUMBER:
L12039
2
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-18
RANGER 305D
G-19
SCHEMATIC - ENTIRE MACHINE - CODE 11122 (L12213) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
13 L122
ENGINEERING CONTROLLED
M ANUFACTURER: No
POSITIVE
OUTPUT
TERMINAL
206B
CHANGE DETAIL: RELEASED "A.02" FROM "X"
Shunt on back of positive
SH UNT output terminal
50MV= 400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
R4 is located on front of fan baffle near top of machine
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
L6
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
2 TURNS
THRU FERRITE
THRU
FERRITE
L3
TWISTED
PAIR
Control Board senses Weld Output from Current Feedback Shunt to activate idler.
THRU
FERRITE
L5
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
GROUND
C
D
A
B
E
F
AMPHENOL
ARC
CONTROL 10K
77B
76B
75B
2B
4B
GND-B
R2
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
279 (J7-6)
278 (J7-7)
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
42VAC
WORK
CONTACTOR
GROUND
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
(J4-1 to 10)
L8
All leads
1 time thru ferrite
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
E
F
K
H
G
D
C
B
J
I
A
AMPHENOL
B3
B6
B7
(J5-1 to 10)
L7
B8
L11845-1
+COM
B2 B5
C
IGBT (8)
All leads
1 time thru ferrite
E
23 (J3-10)
10,000uF x4
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
GATE SIGNAL
TWISTED
PAIR
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
NO CONNECTION
4B
2B
77B
76B
75B
B1
B4
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
Chopper is mounted on the back side of fan baffle near top of machine. Requires added baffle for cooling air flow.
-INPUT
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
R3 located on front of fan baffle on left side near bottom of machine
R3 25 OHM
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
L2
CV
PIPE
TIG
CC
Swich closed for high
IDLER SWITCH
2A
2 TURNS THRU
(TO AMPHENOL)
WELD TERM. SW.
4A
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
FUEL SENDER
(TO AMPHENOL)
MODE
SWITCH
+12 to 14V @ NORMAL OIL PRES. (INPUT)
L4
INPUT TO
AMPHENOL
4
15A BATTERY
CIRCUIT BREAKER
209
209
FUEL
GAUGE
1
D1 - THREE PHASE BRIDGE RECTIFIER
GLOWPLUG
SWITCH S7
START BUTTON
SWITCH S2
L
Rectifier mounted to generator support above output choke.
BAT
223
IGN
TO AUX.
OUTLETS
AND
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
GLOWPLUGS
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
+
S1
211
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
C
D
A
5
E
B
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W1
W2
W3
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
B-5 230 VAC, 1 PH.
C-5
D-E 115 VAC, 1 PH.
CENTER-TAP
EARTH
41
42 VOLT AC
WIRE FEEDER
POWER
42
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
210
TWO POLE 3600 RPM ALTERNATOR
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
ENGINE
PROTECTION
RELAY
9
J73-4 J73-2
P73-4
WHITE FUEL RED
SOLENOID
P73-2
P73-3
J73-3
D4
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
3
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
9
7
CR1
A
J74
P74
ELECTRIC
FUEL
PUMP
P74
J74
201
5H
B
YELLOW
ENGINE
PROTECTION
LIGHT
PL
1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
P72-3
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE
HOLD
P72-4 P72-2
J72-4 J72-2
232
RED
215
HOUR METER
+15V @ LOW
IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N
L11768-1
Located next to control board.
B2
B4
B1
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
DEO
BAM
-
REFERENCE:
L12039
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
12/11/2003
PROJECT
NUMBER:
CRM35573
DOCUMENT
NUMBER:
1 2
DOCUMENT
REVISION:
L12213 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-19
RANGER 305D
G-20
SCHEMATIC - ENTIRE MACHINE - CODE 11122 (L12213) PAGE 2 OF 2
13 L122
ENGINEERING CONTROLLED
M ANUFACTURER: No
CHANGE DETAIL: RELEASED "A.02" FROM "X"
ELECTRICAL DIAGRAMS
+15V
TRANSFORMER
J3-3
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
J3-7
J3- 14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
AUXILLARY
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+ STUD
+ STUD
+
-
SHUNT
- STUD
+
4
TIG
3
CC
1
CV
2
PIPE
(206S)
50mV = 400 AMPS
(204S)
-
(208B)
+15V
MACHINE /
MODE
LOGIC
(CPU)
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
J1-13
J1-13
J1-13
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8
J1-13
M ACHINE
RANGER 250 G&D
RANGER 305 G&D
V ANTA GE 500
V ANTA GE 575
A IR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
J7-16
+ STUD
J7-15
TIG MODE
J7-14 PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
J7- 13 BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
J7- 12
N/A
J7- 11 N/A
J7-9
CV MODE
J7- 10
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3- 15
47.5 ohm s
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
SELECT CONTROL POINT
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
+5V +5V
+ STUD
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRC UI TRY
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1- 10
+ STUD TIG M ODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD + STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
VOLTMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CONTROL POINT
REG ULATING
AMPLIFIER
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
+5V
+3.3V
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
DIODE ONLY ON -E
FRAME
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
1
2
3
4
FRAME
TOIDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TOFRAME FOR HIGH IDLE
FRAME
+ STUD RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
BOARD
WHT
RED
IDLE
SOLENOID
HOLD
COIL
BLK
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ NEGATIVE
BRUSH
FRAME
ROTOR
PW M
CHOPPER
CONTROL
CIRCUIT
+
BATTERY POSITIVE
J2-7
-
J2-3
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
V-BATTERY
FRAME
#1
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWMCOMMON
BOARD
(ALL MACHINES)
#2
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
1 2
7
6
1 2
LATCH
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
DEO
BAM
-
REFERENCE:
L12039
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
12/11/2003
PROJECT
NUMBER:
L12213
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-20
RANGER 305D
G-21
SCHEMATIC - ENTIRE MACHINE - CODES 11189, 11314 (L12213-1) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
-1 213 L12
ENGINEERING CONTROLLED
M ANUFACTURER: No
POSITIVE
OUTPUT
TERMINAL
206B
CHANGE DETAIL: NEW
Shunt on back of positive
SH UNT output terminal
50MV= 400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
R4 is located on front of fan baffle near top of machine
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
L6
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
2 TURNS
THRU FERRITE
THRU
FERRITE
L3
TWISTED
PAIR
Control Board senses Weld Output from Current Feedback Shunt to activate idler.
THRU
FERRITE
L5
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
ARC
CONTROL 10K
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
77B
76B
75B
2B
4B
GND-B
R2
279 (J7-6)
278 (J7-7)
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
L8
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
42VAC
WORK
(J4-1 to 10)
CONTACTOR
GROUND
B3
B6
B7
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
B8
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
All leads
1 time thru ferrite
E
F
K
H
G
D
C
B
J
I
A
AMPHENOL
(J5-1 to 10)
L7
L11845-1
+COM
B2 B5
C
IGBT (8)
E
23 (J3-10)
All leads
1 time thru ferrite
10,000uF x4
GATE SIGNAL
TWISTED
PAIR
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
NO CONNECTION
4B
2B
77B
76B
75B
B1
B4
0 V
15 V
15 V
0 V
L2
CV
PIPE
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
TIG
CC
Chopper is mounted on the back side of fan baffle near top of machine. Requires added baffle for cooling air flow.
-INPUT
ROTOR FLASHING
L4
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
WELD TERM. SW.
4A
MODE
SWITCH
+12 to 14V @ NORMAL OIL PRES. (INPUT)
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
FUEL SENDER
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
R3 located on front of fan baffle on left side near bottom of machine
R3 25 OHM
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
Swich closed for high
IDLER SWITCH
2A
2 TURNS THRU
(TO AMPHENOL)
(TO AMPHENOL)
INPUT TO
AMPHENOL
4
FUEL
GAUGE
1
GLOWPLUG
SWITCH S7
223
GLOWPLUGS
15A BATTERY
CIRCUIT BREAKER
209
209
210
START BUTTON
SWITCH S2
L
BAT
IGN
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
TO AUX.
OUTLETS
AND
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
+
S1
211
C
D
A
5
E
B
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W1
W2
W3
42 VOLT AC
WIRE FEEDER
POWER
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
B-5 230 VAC, 1 PH.
C-5
D-E 115 VAC, 1 PH.
CENTER-TAP
EARTH
41
42
P73-3
J73-3
210
TWO POLE 3600 RPM ALTERNATOR
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
ENGINE
PROTECTION
RELAY
7
J73-4 J73-2
P73-4
WHITE FUEL RED
SOLENOID
P73-2
1
D4
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
9
3
9
7
201
5H
B
CR1
A
YELLOW
ENGINE
PROTECTION
LIGHT
PL
1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
Relay CR1 and D4 located on fron baffle on right side of machine.
P72-3
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE
HOLD
P72-4 P72-2
J72-4 J72-2
232
RED
215
HOUR METER
+15V @ LOW
IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N
L11768-1
Located next to control board.
B2
B4
B1
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
MAP
BAM
-
REFERENCE:
L12213
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
07/15/2004
PROJECT
NUMBER:
CRM35578
DOCUMENT
NUMBER:
1 2
DOCUMENT
REVISION:
L12213-1 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-21
RANGER 305D
G-22
SCHEMATIC - ENTIRE MACHINE - CODES 11189, 11314 (L12213-1) PAGE 2 OF 2
ELECTRICAL DIAGRAMS
-1 213 L12
ENGINEERING CONTROLLED
M ANUFACTURER: No
CHANGE DETAIL: NEW
+15V
TRANSFORMER
J3-3
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
J3-7
J3- 14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
AUXILLARY
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+ STUD
+ STUD
+
-
SHUNT
- STUD
+
4
TIG
3
CC
1
CV
2
PIPE
(206S)
50mV = 400 AMPS
(204S)
-
(208B)
+15V
MACHINE /
MODE
LOGIC
(CPU)
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
J1-13
J1-13
J1-13
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8
J1-13
M ACHINE
RANGER 250 G&D
RANGER 305 G&D
V ANTA GE 500
V ANTA GE 575
A IR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
J7-16
+ STUD
J7-15
TIG MODE
J7-14 PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
J7- 13 BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
J7- 12
N/A
J7- 11 N/A
J7-9
CV MODE
J7- 10
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3- 15
47.5 ohm s
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
SELECT CONTROL POINT
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
+5V +5V
+ STUD
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRC UI TRY
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1- 10
+ STUD TIG M ODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD + STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
VOLTMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CONTROL POINT
REG ULATING
AMPLIFIER
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
+5V
+3.3V
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
DIODE ONLY ON -E
FRAME
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
1
2
3
4
FRAME
TOIDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TOFRAME FOR HIGH IDLE
FRAME
+ STUD RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
BOARD
WHT
RED
IDLE
SOLENOID
HOLD
COIL
BLK
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ NEGATIVE
BRUSH
FRAME
ROTOR
PW M
CHOPPER
CONTROL
CIRCUIT
+
BATTERY POSITIVE
J2-7
-
J2-3
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
V-BATTERY
FRAME
#1
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWMCOMMON
BOARD
(ALL MACHINES)
#2
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
1 2
7
6
1 2
LATCH
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
MAP
BAM
-
REFERENCE:
L12213
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
07/15/2004
PROJECT
NUMBER:
L12213-1
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-22
RANGER 305D
G-23
SCHEMATIC - ENTIRE MACHINE - CODE 11039 (L12038) PAGE 1 OF 2
9
ELECTRICAL DIAGRAMS
L1203
ENGINEERING CONTROLLED
MANUFACTURER:
No
SHUNT
CHANGE DETAIL:
Shunt on back of positive output terminal POSITIVE
OUTPUT
TERMINAL
206B
50MV=400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
TWISTED
PAIR
RELEASED FROM "X"
R4 is located on front of fan baffle near top of machine
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
ARC
CONTROL 10K
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
77B
76B
75B
2B
4B
GND-B
R2
279 (J7-6)
278 (J7-7)
277 (J7-8)
260A (J3-4)
261A (J3-3)
5K (J2-3)
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
42VAC
WORK
GROUND
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
B8
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
(J4-1 to 10)
CONTACTOR
E
F
K
H
G
D
C
B
J
I
A
AMPHENOL
B3
B6
B7
(J5-1 to 10)
+COM
B2 B5
C
IGBT (8)
E
23 (J3-10)
10,000uF x4
GATE SIGNAL
TWISTED
PAIR
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
21
77A
76A
75A
4A
31
32
41A
42A
2A
GND-A
NO CONNECTION
4B
2B
77B
76B
75B
B1
B4
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
-INPUT
Chopper is mounted on the back side of fan baffle near top of machine.
PWM Signal to Chopper
15 volt @ 20 kHz
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
2A
4A
MODE
SWITCH
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
R3 located on front of fan baffle on left side near bottom of machine
R3 25 OHM
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
CV
PIPE
TIG
CC
Swich closed for high idle.
IDLER SWITCH
(TO AMPHENOL)
WELD TERM. SW.
(TO AMPHENOL)
+12 to 14V @ NORMAL OIL PRES. (INPUT)
INPUT TO
AMPHENOL
Battery charge lamp will be on whenever RUN/STOP switch is in RUN position and alternator is not charging
223
GLOWPLUGS
15A BATTERY
CIRCUIT BREAKER
209
209
YELLOW
BATTERY
CHARGING
LIGHT
GLOWPLUG
SWITCH S7
PL2
228
START BUTTON
SWITCH S2
L
BAT
IGN
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
TO AUX.
OUTLETS
AND
AMPHENOLS
+
S1
211
C
D
A
5
E
B
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W1
W2
W3
42 VOLT AC
WIRE FEEDER
POWER
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
B-5 230 VAC, 1 PH.
C-5
D-E 115 VAC, 1 PH.
CENTER-TAP
EARTH
41
42
210
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
WHITE FUEL RED
SOLENOID
TWO POLE 3600 RPM ALTERNATOR
ENGINE
PROTECTION
RELAY
9
D4
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
3
9
7
201
5H
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
B
CR1
A
ELECTRIC
FUEL
PUMP
YELLOW
ENGINE
PROTECTION
LIGHT
PL1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
HOUR METER
+15V @ LOW IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
IDLE SOLENOID
ENEGIZED FOR
LOW IDLE
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE 11 OHMS
232
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N L11768-1
Located next to control board.
RED
215
B2
B4
B1
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
MAP
BAM
-
REFERENCE:
L11946
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
6/20/03 PROJECT
NUMBER:
CRM33673
DOCUMENT
NUMBER:
L12039
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-23
RANGER 305D
G-24
SCHEMATIC - ENTIRE MACHINE - CODE 11039 (L12038) PAGE 2 OF 2
9 L1203
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: RELEASED FROM "X"
ELECTRICAL DIAGRAMS
+15V
TRANSFORMER
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
J3-3
J3-7
J3-14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+15V
THERMAL LAMP
THERMOSTAT(IF USED)
J3-5
J3-1
+15V
+ STUD
THERMAL SENSE (if used)
+15V
+ STUD
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8 MACHINE
J1-13
J1-13
J1-13
J1-13
RANGER 250 G&D
RANGER 305 G&D
VANTAGE 500
VANTAGE 575
AIR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
+ STUD
MACHINE /
MODE
LOGIC
(CPU)
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
4
TIG
3
CC
1
CV
2
PIPE
J7-16
J7-15
J7-14
J7-13
J7-12
J7-11
J7-9
+ STUD
TIG MODE
PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
N/A
N/A
CV MODE
BLINK (PULLED LOW AND HIGH
DECIMAL POINT)
SELECT CONTROL POINT
+ STUD
-
+
SHUNT
+
(206S)
50mV = 400 AMPS
(204S)
- STUD
-
(208B)
J7-10
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3-15
47.5 ohms
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
+5V +5V
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRCUITRY
+ STUD
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J3-6
(253)
J3-13
(252)
SILVER
GOLD
THERMAL
PROTECTION
INDICATOR
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
VOLTMETER
DISPLAY
J5-9
J5-10
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CURRENT FEEDBACK
CONTROL POINT
REGULATING
AMPLIFIER
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1-10
+ STUD
+ STUD
TIG MODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIABLE PINCH
PIPE ARC FORCE
VARIABLE ARC FORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD
+5V
CURRENT
LIMITS,
AVERAGE,
ABSOLUTE,
& FOLDBACK
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
FRAME
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
DIODE ONLY ON -E
VERSION AND ABOVE
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
4
1
2
3
FRAME
TO IDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TO FRAME FOR HIGH IDLE
+ STUD
FRAME
RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
PULL COIL
BOARD
BLK
WHT
RED
IDLE
SOLENOID
STARTER BUTTON
J2-8
FUEL SHUTDOWN
J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ -
NEGATIVE
BRUSH
FRAME
ROTOR
+15V COM
J2-7
-
BATTERY NEGATIVE J2-3
V-BATTERY
FRAME
VREF
-
+
J2-2
J2-11
CHARGE
LAMP
(Machine running, alternator charging battery, +1.5V when battery charge light is
FRAME
PWM
CHOPPER
CONTROL
CIRCUIT
+3.3V
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWM COMMON
#1
CHOPPER
BOARD
(ALL MACHINES)
#2
CHOPPER
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2 6
7 12
LATCH
VIEW OF CONNECTOR ON PC BOARD
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPROVED:
MAP
BAM
-
REFERENCE:
L11946
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (UK)
MACHINE SCHEMATIC
6/20/03 PROJECT
NUMBER:
CRM33673
DOCUMENT
NUMBER:
L12039
2
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-24
RANGER 305D
G-25
SCHEMATIC - ENTIRE MACHINE - CODE 11123 (L12214) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
14 L122
ENGINEERING CONTROLLED
M ANUFACTURER: No
POSITIVE
OUTPUT
TERMINAL
206B
CHANGE DETAIL: RELEASED "A.02" FROM "X"
Shunt on back of positive
SH UNT output terminal
50MV= 400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
R4 is located on front of fan baffle near top of machine
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
L6
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
2 TURNS
THRU FERRITE
THRU
FERRITE
L3
TWISTED
PAIR
Control Board senses Weld Output from Current Feedback Shunt to activate idler.
THRU
FERRITE
L5
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
ARC
CONTROL 10K
R2
279 (J7-6)
278 (J7-7)
277 (J7-8)
B3
B6
B7
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
B8
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
L11845-1
+COM
B2 B5
C
IGBT (8)
E
GATE SIGNAL
TWISTED
PAIR
23 (J3-10)
10,000uF x4
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
B1
B4
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
R3 located on front of fan baffle on left side near bottom of machine
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
L2
CV
PIPE
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
TIG
CC
Chopper is mounted on the back side of fan baffle near top of machine. Requires added baffle for cooling air flow.
-INPUT
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
R3 25 OHM
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
Swich closed for high
IDLER SWITCH
2 TURNS THRU FERRITE
2A
(TO AMPHENOL)
WELD TERM. SW.
4A
(TO AMPHENOL)
MODE
SWITCH
TO AUX.
OUTLETS
AND
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
C
A
5
B
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W1
W2
W3
A-B-C 400 VAC, 3 PH.
A-5
B-5 230 VAC, 1 PH.
C-5
42 VOLT AC
WIRE FEEDER
POWER
41
42
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
77B
76B
75B
2B
4B
GND-B
260A (J3-4)
261A (J3-3)
5K (J2-3)
(J4-1 to 10)
L8
All leads
1 time thru ferrite
(J5-1 to 10)
L7
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
All leads
1 time thru ferrite
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
42VAC
WORK
CONTACTOR
GROUND
E
F
K
H
G
D
C
B
J
I
A
AMPHENOL
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
NO CONNECTION
4B
2B
77B
76B
75B
+12 to 14V @ NORMAL OIL PRES. (INPUT)
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
L4
FUEL SENDER
INPUT TO
AMPHENOL
4 1
GLOWPLUG
SWITCH S7
223
GLOWPLUGS
15A BATTERY
CIRCUIT BREAKER
209
209
210
START BUTTON
SWITCH S2
L
BAT
IGN
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
+
S1
211
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
210
TWO POLE 3600 RPM ALTERNATOR
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
ENGINE
PROTECTION
RELAY
9
J73-4 J73-2
P73-4
WHITE FUEL RED
SOLENOID
P73-2
P73-3
J73-3
D4
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
3
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
9
7
CR1
A
J74
P74
ELECTRIC
FUEL
PUMP
P74
J74
201
5H
B
YELLOW
ENGINE
PROTECTION
LIGHT
PL
1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
P72-3
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE
HOLD
P72-4 P72-2
J72-4 J72-2
232
RED
215
HOUR METER
+15V @ LOW
IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N
L11768-1
Located next to control board.
B2
B4
B1
240-265 OHMS EMPTY
20-35 OHMS FULL
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
DEO
BAM
-
REFERENCE:
L12038
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (EUROPE)
MACHINE SCHEMATIC
12/11/2003
PROJECT
NUMBER:
CRM35573
DOCUMENT
NUMBER:
1 2
DOCUMENT
REVISION:
L12214 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-25
RANGER 305D
G-26
SCHEMATIC - ENTIRE MACHINE - CODE 11123 (L12214) PAGE 2 OF 2
14 L122
ENGINEERING CONTROLLED
M ANUFACTURER: No
CHANGE DETAIL: RELEASED "A.02" FROM "X"
ELECTRICAL DIAGRAMS
+15V
TRANSFORMER
J3-3
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
J3-7
J3- 14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
AUXILLARY
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+ STUD
+ STUD
+
-
SHUNT
- STUD
+
4
TIG
3
CC
1
CV
2
PIPE
(206S)
50mV = 400 AMPS
(204S)
-
(208B)
+15V
MACHINE /
MODE
LOGIC
(CPU)
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
J1-13
J1-13
J1-13
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8
J1-13
M ACHINE
RANGER 250 G&D
RANGER 305 G&D
V ANTA GE 500
V ANTA GE 575
A IR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
J7-16
+ STUD
J7-15
TIG MODE
J7-14 PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
J7- 13 BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
J7- 12
N/A
J7- 11 N/A
J7-9
CV MODE
J7- 10
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3- 15
47.5 ohm s
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
SELECT CONTROL POINT
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
+5V +5V
+ STUD
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRC UI TRY
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1- 10
+ STUD TIG M ODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD + STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
VOLTMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CONTROL POINT
REG ULATING
AMPLIFIER
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
+5V
+3.3V
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
DIODE ONLY ON -E
FRAME
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
1
2
3
4
FRAME
TOIDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TOFRAME FOR HIGH IDLE
FRAME
+ STUD RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
BOARD
WHT
RED
IDLE
SOLENOID
HOLD
COIL
BLK
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ NEGATIVE
BRUSH
FRAME
ROTOR
PW M
CHOPPER
CONTROL
CIRCUIT
+
BATTERY POSITIVE
J2-7
-
J2-3
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
V-BATTERY
FRAME
#1
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWMCOMMON
BOARD
(ALL MACHINES)
#2
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
1 2
7
6
1 2
LATCH
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
DEO
BAM
-
REFERENCE:
L12038
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
RANGER 305D CE (EUROPE)
MACHINE SCHEMATIC
12/11/2003
PROJECT
NUMBER:
L12214
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-26
RANGER 305D
G-27
SCHEMATIC - ENTIRE MACHINE - CODES 11190, 11315 (L12214-1) PAGE 1 OF 2
ELECTRICAL DIAGRAMS
-1 214 L12
ENGINEERING CONTROLLED
M ANUFACTURER: No
POSITIVE
OUTPUT
TERMINAL
206B
CHANGE DETAIL: NEW
Shunt on back of positive
SH UNT output terminal
50MV= 400 AMPS
206S 204S WELD CURRENT
FEED BACK SIGNAL
R4 is located on front of fan baffle near top of machine
Located on back of output panel between terminals
BY-PASS
PC BOARD
206C
208C
206A
NEGATIVE
OUTPUT
TERMINAL
CC
CV
Open Circuit Volts:
Max Min
58
58
26
12
208
L6
21
208A
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
L1 CHOKE
Choke is beneath bearing end of generator on support.
2 TURNS
THRU FERRITE
THRU
FERRITE
L3
TWISTED
PAIR
Control Board senses Weld Output from Current Feedback Shunt to activate idler.
THRU
FERRITE
L5
R4
50 OHM
100 W
-OUTPUT
Power Supply to Control
Board
TWISTED
PAIR
13 (J3-8) 14 (J3-16)
204S (J6-1)
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
(TO AMPHENOL)
OUTPUT
CONTROL 10K
REMOTE
CONTROL 10K
R1
208B (J3-15)
10 V
77 (J7-1)
0-10 V
76 (J7-4)
0 V
0 V
75 (J7-5)
10 V
-15 V (W/O POT.)
77A (J1-11)
76A (J1-14)
75A (J1-10)
ARC
CONTROL 10K
R2
279 (J7-6)
278 (J7-7)
277 (J7-8)
B3
B6
B7
FLYBACK
DIODES (6)
+
FILTER
CAPACITORS (4)
B8
25 (J3-9)
Control board common is at welder positive output and shunt
WELD CONTROL
PC BOARD
P/N G4107-1
Located on front of fan baffle near top of machine.
L11845-1
+COM
B2 B5
C
IGBT (8)
E
GATE SIGNAL
TWISTED
PAIR
23 (J3-10)
10,000uF x4
(J2-1) 200N
(J2-5) 215
(J2-4) 404
(J3-14) 252
(J3-7) 251
(J1-4) 2
(J1-3) 4
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
B1
B4
Rotor Flashing: +12 volts
@ 0.5 amps until generator builds up then +50 volts @ 0 amps.
ROTOR FLASHING
R3 located on front of fan baffle on left side near bottom of machine
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
+15V @ LOW IDLE TO PULL COIL BOARD
0 V
15 V
15 V
0 V
L2
CV
PIPE
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
TIG
CC
Chopper is mounted on the back side of fan baffle near top of machine. Requires added baffle for cooling air flow.
-INPUT
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
PWM Signal to Chopper
15 volt @ 20 kHz
R3 25 OHM
Rectifier mounted to generator support above output choke.
D1 - THREE PHASE BRIDGE RECTIFIER
Swich closed for high
IDLER SWITCH
2 TURNS THRU FERRITE
2A
(TO AMPHENOL)
WELD TERM. SW.
4A
(TO AMPHENOL)
MODE
SWITCH
TO AUX.
OUTLETS
AND
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
C
A
5
B
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W1
W2
W3
A-B-C 400 VAC, 3 PH.
A-5
B-5 230 VAC, 1 PH.
C-5
42 VOLT AC
WIRE FEEDER
POWER
41
42
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
Located on wiring behind receptacles.
Control board circuits associated with J2 are part of engine electrical system and are common to frame ground (negative battery terminal.
GROUND
C
D
A
B
E
F
AMPHENOL
77B
76B
75B
2B
4B
GND-B
260A (J3-4)
261A (J3-3)
5K (J2-3)
L8
WELD AMMETER WELD VOLTMETER
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and amps for approximately 5 seconds after welding stops.
During this hold display the right most decimal point will blink.
42VAC
WORK
CONTACTOR
GROUND
(J4-1 to 10)
All leads
1 time thru ferrite
E
F
K
H
G
D
C
B
J
I
A
AMPHENOL
(J5-1 to 10)
L7
(J2-9) 224B
(J2-7) 210B
(J1-7) 305
(J1-12) 305
All leads
1 time thru ferrite
31
32
41A
42A
21
77A
76A
75A
4A
2A
GND-A
NO CONNECTION
4B
2B
77B
76B
75B
+12 to 14V @ NORMAL OIL PRES. (INPUT)
+12 to 14V @ RUN (INPUT)
305 I.D. JUMPER (Part of amphenol plug and lead assembly.)
L4
FUEL SENDER
INPUT TO
AMPHENOL
4
209
1
GLOWPLUG
SWITCH S7
L
BAT
223
IGN
GLOWPLUGS
15A BATTERY
CIRCUIT BREAKER
209
209
ALTERNATOR
Battery voltage:
12.6 volts at rest
14 volts engine running
212
210
START BUTTON
SWITCH S2
+
S1
211
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
12 VOLT
BATTERY
FRAME
GROUND
RUN-STOP SWITCH
(SHOWN IN RUN)
210
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
231
STARTER
SOLENOID
STARTER
MOTOR
P73-3
J73-3
210
TWO POLE 3600 RPM ALTERNATOR
C3 and D3 located on rear of fan baffle on left side of machine.
SLIP RINGS
200
200A
50 V DC
C3
800uf
150vdc
D
3
+
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
9
7
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
ENGINE
PROTECTION
RELAY
7
J73-4 J73-2
P73-4
WHITE FUEL RED
SOLENOID
P73-2
1
D4
225
BLACK
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
9
3
201
5H
B
CR1
A
YELLOW
ENGINE
PROTECTION
LIGHT
PL
1
OIL PRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
224
229
P72-3
IDLE BLACK
SOLENOID
PULL
0.2 OHM
WHITE
HOLD
P72-4 P72-2
J72-4 J72-2
232
RED
215
HOUR METER
+15V @ LOW
IDLE
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
+
Relay CR1 and D4 located on fron baffle on right side of machine.
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
404 (J43-8)
TIMER
CIRCUIT
PULL COIL
PC BOARD
P/N
L11768-1
Located next to control board.
B2
B4
B1
240-265 OHMS EMPTY
20-35 OHMS FULL
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
MAP
BAM
-
REFERENCE:
L12214-1
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D CE (EUROPE)
MACHINE SCHEMATIC
07/15/2004
PROJECT
NUMBER:
CRM35578
DOCUMENT
NUMBER:
1 2
DOCUMENT
REVISION:
L12214-1 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-27
RANGER 305D
G-28
SCHEMATIC - ENTIRE MACHINE - CODES 11190, 11315 (L12214-1) PAGE 2 OF 2
ELECTRICAL DIAGRAMS
-1 214 L12
ENGINEERING CONTROLLED
M ANUFACTURER: No
CHANGE DETAIL: NEW
+15V
TRANSFORMER
J3-3
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
AUXILIARY
SENSE
TOROID
(2)
(4)
J3-7
J3- 14
J3-4
J1-4
J1-3
+15V
+ STUD
+15V
AUXILLARY
CURRENT
SENSE
2-4 SENSE
+ STUD
IDLE SWITCH SENSE
+ STUD
+ STUD
+
-
SHUNT
- STUD
+
4
TIG
3
CC
1
CV
2
PIPE
(206S)
50mV = 400 AMPS
(204S)
-
(208B)
+15V
MACHINE /
MODE
LOGIC
(CPU)
IDLE CONTROL
THERMAL SHUTDOWN (if used)
CURRENT LIMITS
REGULATION MODE
MACHINE IDENTITY TABLE:
J1-13
J1-13
J1-13
PINS JUMPERED TO SELECT MACHINE
J1-5 J1-6 J1-7 J1-8
J1-13
M ACHINE
RANGER 250 G&D
RANGER 305 G&D
V ANTA GE 500
V ANTA GE 575
A IR VANTAGE 500
J1-13
J1-12
J1-8
J1-7
J1-6
J1-5
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
A
MACH SEL 1
MACH SEL 2
MACH SEL 3
MACH SEL 4
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+15V
J7-16
+ STUD
J7-15
TIG MODE
J7-14 PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
J7- 13 BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
J7- 12
N/A
J7- 11 N/A
J7-9
CV MODE
J7- 10
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
+15V
J7-2
+ STUD
G4107
(ONLY)
J6-2
J6-1
J3- 15
47.5 ohm s
G4109
(ONLY)
+ STUD
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
-
+ x80
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CURRENT FEEDBACK
SELECT CONTROL POINT
DISPLAY WELD AMPS
PRESET DISPLAY
PRESET
VALUE
VOLTAGE
FEEDBACK
DISPLAY WELD VOLTS
ON / OFF (+5V=ON)
HOLD (+5V=HOLD)
+ STUD
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
+ STUD
+5V +5V
+ STUD
+ STUD
ARC CONTROL
10K
POT
(277)
(278)
(279)
J7-8
J7-7
J7-6
ARC
CONTROL
CIRC UI TRY
+10V
OUTPUT
CONTROL
10K
POT
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE
CONTROL
10K
POT
(77)
(76)
(75)
J7-1
J7-4
J7-5
(77B)
J1-11
(76B)
J1-14
(75B)
J1- 10
+ STUD TIG M ODE +10V
ALL OTHER MODES
LOCAL
REMOTE
PRESET
+ STUD + STUD
OCV
TOUCH START
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
PRESET
FIXED HOT START
+5V
CONTROL
POINT
SELECT
+ STUD
+ STUD + STUD
CONTROL BOARD
POWER FROM
CHOPPER BOARD
+
J3-8
40-100VDC
INPUT
-
J3-16
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
AMMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
VOLTMETER
DISPLAY
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
METER (-) INPUT
FEEDBACK
CONTROL POINT
REG ULATING
AMPLIFIER
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
+5V
+3.3V
+ STUD
IDLE CONTROL
-15V
+15V +15V COM
+15V COM
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
V-BATTERY
+12V Battery Supply to the Idle Hold Solenoid
J2-6
IDLE HOLD COIL
J2-5
DIODE ONLY ON -E
FRAME
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V when not energized. "HIGH IDLE"
1
2
3
4
FRAME
TOIDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
J2-4 J2-12
FOR AUX USE: CONNECT
TOFRAME FOR HIGH IDLE
FRAME
+ STUD RANGER OIL PRESSURE
J2-9
V-BATTERY
V-BATTERY
BOARD
WHT
RED
IDLE
SOLENOID
HOLD
COIL
BLK
PULL
COIL
STARTER BUTTON
J2-8
FUEL SHUTDOWN J2-10
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted the PTC will change to high impedance
PTC
FRAME
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine is not ON. +40V or more when the machine is running.
J2-1
POSITIVE
BRUSH
+ NEGATIVE
BRUSH
FRAME
ROTOR
PW M
CHOPPER
CONTROL
CIRCUIT
+
BATTERY POSITIVE
J2-7
-
J2-3
+ STUD
47.5 ohm
47.5 ohm
47.5 ohm
47.5 ohm
V-BATTERY
FRAME
#1
J3-9
PWM SIGNAL (+12V ON MULTIMETER)
J3-11
PWM SIGNAL (+12V)
J3-10
PWM COMMON
J3-12
PWMCOMMON
BOARD
(ALL MACHINES)
#2
BOARD
(VANTAGE ONLY)
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
1 2
7
6
1 2
LATCH
PROPRIETARY & CONFIDENTIAL:
THIS D OCUME NT C ONTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D F OR ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
ON 3 PLACE DECIMALS IS ± .002
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER:
APPRO VED:
MAP
BAM
-
REFERENCE:
L12214-1
SCALE:
NONE
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE:
RANGER 305D CE (EUROPE)
MACHINE SCHEMATIC
07/15/2004
PROJECT
NUMBER:
L12214-1
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-28
RANGER 305D
G-29
SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 1 OF 5
ELECTRICAL DIAGRAMS G-29
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-30
SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 2 OF 5
ELECTRICAL DIAGRAMS G-30
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-31
SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 3 OF 5
ELECTRICAL DIAGRAMS G-31
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-32
SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 4 OF 5
ELECTRICAL DIAGRAMS G-32
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-33
SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 5 OF 5
ELECTRICAL DIAGRAMS G-33
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-34
PC BOARD ASSEMBLY - WELD CONTROL PC BD - ALL CODES (G4107-1)
ELECTRICAL DIAGRAMS G-34
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 provided 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 machine.
RANGER 305D
G-35
SCHEMATIC - PULL COIL PC BD - ALL CODES (G4117-1)
ELECTRICAL DIAGRAMS G-35
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-36
PC BOARD ASSEMBLY - PULL COIL PC BD - ALL CODES (L11768-1)
ELECTRICAL DIAGRAMS G-36
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 provided 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 machine.
RANGER 305D
G-37
SCHEMATIC - CHOPPER PC BD - ALL CODES (M19792-1)
ELECTRICAL DIAGRAMS G-37
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 305D
G-38 ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CHOPPER PC BD - ALL CODES (L11845-1)
STRP
ED
ON:
NT
ISI
UME
H
AT NIC MU
1
__
REV
DOC
OM
F_
-1 45
_O
.
,C
__
1
NC
ED
,I
AT
AL
IC
OB
PL
GE PA
GL
DU
:
NT
18
BER
UME
L1
LN
BE
NUM
DOC
LY
CO
OT
IN
YN
FL
MA
NO
ND
SIO
.A
EMB
MIS
NC
ER
,I AL
91-E
ASS
349
S
NP
OB
TE IT
GL
WR
LN
CRM
RD
DER
BOA
SS
CO
RE
LIN
WEL
:
T
XP
BY
BER
JEC
KPC
EE
ED
SIN
INE
NUM
PRO
TH
WN
UT
NO
ENG
05
HO
IO
WIT
AT
/20
EAT
2/24
RH
AL
RM
SE
FO
PO
IN
UR
RY
E:
ROV
PPE
DAT
APP
CHO
YP
TA
AN
IE
:
PR
YPE
OR
UF
RO
TT
:
T:
ION
AL
OSIT
ERI
JEC
MEN UIP
DF SE
SP
RU
AIN NT
DISP
MAT
SUB
EQ
SO
CO
TIE
NT
:
-1
AR
NCE
ME
497
LE:
1:2
RP
ERE
CU
SCA
L11
HE
REF
DO
OT
IS
-
BAM
SWB
ATI
TO
TH
ON
L:
RM
TIA
FO
: ED
R: EE
OV
Y: NB
NIN IG
EN
AW
PR
GIN
DR
EN
AP
DES
FID
E
G
EE
E
56
NC
E20
RA
ON
IN
GR
RE
AW DR
&C
02
2
OA
DS
EG
ER
OLE
EP
DT
±.0
±.0
)T
AR
AD
""
ND t
NC
IS
CIF
OF
E(
RA
RY
TA
PE
TH
NC
±.5
ALS
ALS
DS
OLE
ES
RA
TA
LE
HE
SIS
CIM
CIM
GT
CA
RIE
RW
DE
DE
OLE
LIS
GLE
CE
CE
UR
HE
AN
CT
OT
LT
UB
TS
OP
NO
LA
LA
RIA
HP
3P
2P
ALL
TE
FA
SS
WIT
NU
LE
ON
ON
ON
MA
UN
MA
PR
DO
G-38
2 3
R15
R7
D 1
R18
Q1
C14
R2
R16
D Z 1
R1
C3
R31
R13
Q2
R12
D Z 2
C6
R11
R14
C5
R17
D 6
D 5
DZ3
R4
R9
2 D1
R51
C4
R53
R52
D Z 8
R8
R54
Q5
Q4
D 7
R5
D9
C15
C13
C20
C7
C17
R47
1
R49
C22
D 1
R6
C19
R36
R37
C18
R3
S REW DSC ISE REV M7, ITE : IL TA DE GE AN CH D LE OL
No
TR
:
ON
ER
GC
UR CT
RIN
FA
EE
NU
GIN
MA
EN
L11845-1
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 provided 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 machine.
RANGER 305D
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