Main
SVM175-A
Ranger 305D
July, 2007
SERVICE MANUAL
Safety Depends on You
FOR ENGINE powered equipment.
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
FUMES AND GASES can be dangerous.
ii
ARC RAYS can burn.
AUG 06
ELECTRICSHOCKcankill.
FOR ELECTRICALLY powered equipment.
iii
CYLINDER may explode if damaged.
Mar 95
WELDING SPARKS can cause fire or explosion.
PRCAUTIONS DE SRET
iv
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
Mar.93
iv
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
- INSTALLATIONSECTION -
TECHNICAL SPECIFICATIONS -
INPUT - DIESEL ENGINE
RECEPTACLESAND CIRCUIT BREAKERS
RATED OUTPUT @ 104 F (40 C) - WELDER
PHYSICALDIMENSIONS ENGINE
TECHNICAL SPECIFICATIONS -
INPUT - DIESEL ENGINE
RECEPTACLESAND CIRCUIT BREAKERS
RATED OUTPUT @ 40 C (104 F) - WELDER
PHYSICAL DIMENSIONS ENGINE
STORING
STACKING
ANGLE OF OPERATION
LOCATION AND VENTILATION
SAFETYPRECAUTIONS
VEHICLE MOUNTING
HIGH ALTITUDEOPERATION
HIGH TEMPERATURE OPERATION
Cold Weather Starting & Operation:
LIFTING
PRE-OPERATION ENGINE SERVICE
OIL
FUEL
ENGINE COOLING SYSTEM
BATTERYCONNECTION
REMOTE CONTROL
ELECTRICAL OUTPUT CONNECTIONS
MACHINE GROUNDING
Note: Different models appearance may vary slightly.
----------------------------------------------------------- AUXILIARY POWER RECEPTACLES
STANDBY POWER CONNECTIONS
WELDING OUTPUT CABLES
CABLE INSTALLATION TABLEA.1
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
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FIGURE A.2 CONNECTION OF RANGER 305D TO PREMISES WIRING
- OPERATION SECTION -
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DESIGN FEATURES
CONTROL AND SETTINGS
ENGINE CONTROLS (Figure B.1) 1. RUN.STOP SWITCH:
4.
2. GLOW PLUG PUSH BUTTON:
3. START PUSH BUTTON:
ENGINE ALTERNATORTROUBLE LIGHT:
WELDING CONTROLS
9. OUTPUT CONTROL
10. WELD MODE SELECTOR SWITCH:
11. ARC CONTROL
ENGINE OPERATION
BEFORE STARTING THE ENGINE
STARTING THE ENGINE
STOPPING THE ENGINE
DIESELFUEL can cause fire.
BREAK-IN PERIOD
STICK WELDING
TABLE B.2 - TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES
Constant Current (CC-STICK) Welding
TIG WELDING
WIRE WELDING-CV
ARC GOUGING
AUXILIARYPOWER
SIMULTANEOUSWELDING AND AUXILIARY POWER LOADS
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- ACCESSORIES -
OPTIONS / ACCESSORIES
FIELD INSTALLED OPTIONS
TIG WELDING ACCESSORIES
SEMIAUTOMATIC FCAWAND MIG WELDINGACCESSORIES
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
CONNECTION OF THE RANGER 305D TO WIRE FEEDERS USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1)
RANGER 305D ACROSS THE ARC (SEE FIGURE C.2.)
FIGURE C.2 - Ranger 305D/LN-25 ACROSS THE ARC CONNECTION DIAGRAM
+-
RANGER 305D WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE (SEE FIGURE C.3.)
+-
FIGURE C.3 - Ranger 305D/LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM
RANGER 305D ACROSS THE ARC WITH K857 REMOTE CONTROL (SEE FIGURE C.4.)
+-
FIGURE C.4 - Ranger 305D/LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL
CONNECTION OF THE LN-7 TO THE RANGER 305D USING K584 CONTROL CABLE (SEE FIGURE C.5.)
FIGURE C.5 - Ranger 305D/LN-7 WITH 584 CONTROL CABLE CONNECTION DIAGRAM
-
CONNECTION OF THE LN-8 TO THE RANGER 305D USING K595 CONTROL CABLE (SEE FIGURE C.6.)
FIGURE C.6 - Ranger 305D/LN-8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM
+-
CONNECTION OF THE LN-742 TO THE RANGER 305D. (SEE FIGURE C.7.)
FIGURE C.7 - Ranger 305D/LN-742 CONNECTION DIAGRAM
+-
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-MAINTENANCE-
SAFETYPRECAUTIONS
WARNING ROUTINEANDPERIODIC
MAINTENANCE
ENGINEMAINTENANCE
ITEM MAKE AND PARTNUMBER
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D-5 D-5
Service Instructions & Installation Tips
For Engine Air Filter Release the
1
Avoid Dislodging
2
CleanSealing Surface
3
AIRCLEANER
COOLING SYSTEM HOT COOLANT
TIGHTENING THE FAN BELT
FUEL SYSTEM SERVICE
BLEEDING THE FUEL SYSTEM
ENGINEADJUSTMENT
BATTERYMAINTENANCE
OVERSPEED IS HAZARDOUS
CLEANING THE BATTERY
CHECKING THE ELECTROLYTE LEVEL
WELDER / GENERATOR MAINTENANCE
GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE
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Section E-1 Section E-1
ROTOR
-THEORY OF OPERATION SECTION-
FIGURE E.1 RANGER 305D BLOCK LOGIC DIAGRAM
STATOR
+
GENERAL DESCRIPTION
Battery, Engine, Engine Protection, and Charging System.
BATTERY:
Starting the engine:
Engine Idle System Idle Switch Operation:
Idle Solenoid Operation:
Generating Power
Weld Power and Control
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CHOPPER TECHNOLOGY FUNDAMENTALS
E-8
PULSE WIDTH MODULATION:
TROUBLESHOOTING & REPAIR SECTION
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
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POWER OUTPUT PROBLEMS
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MISC. WELD ISSUES
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CASE COVER REMOVALAND REPLACEMENT PROCEDURE
CASE COVER REMOVALAND REPLACEMENT PROCEDURE (continued)
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (continued)
INSULATED GLOVES
INSULATED PLIERS
FUEL SHUTDOWN SOLENOID TEST
FUEL SHUTDOWN SOLENOID TEST (continued)
IDLEIDLE SOLENOIDSOLENOID
SHUTDOWNSHUTDOWN SOLENOIDSOLENOID
FUEL SHUTDOWN SOLENOID TEST (continued)
P73 J73
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ENGINE THROTTLE ADJUSTMENT TEST
STROBE TACH MARK
FAN HUB
ENGINE SPEED CONTROL LEVER
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IDLER SOLENOID TEST
IDLER SOLENOID TEST (continued)
BLACK RED
215
WHITE
P-72 J-72
ENGINE ALTERNATORTEST
ENGINE ALTERNATOR TEST (continued)
BRUSH AND SLIP RING SERVICE PROCEDURE
BRUSH AND SLIP RING SERVICE PROCEDURE (continued)
ROTOR RESISTANCEAND GROUND TEST (STATIC)
ROTOR RESISTANCEAND GROUND TEST (STATIC)(continued)
+ -
ROTOR RESISTANCEAND GROUND TEST (DYNAMIC) (Also referred to as flying resistance test)
ROTOR RESISTANCEAND GROUND TEST (DYNAMIC) (continued)
ROTOR VOLTAGETEST
ROTOR VOLTAGETEST (continued)
+ -
ROTOR VOLTAGETEST (continued)
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FLASHING VOLTAGE TEST (Engine Not Running)
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FLASHING VOLTAGETEST (continued)
#229
The engine protection light should be off during this tes
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STATORVOLTAGE TESTS
AMPHENOL 1
KEY
POS. NEG. W3 W2 W1 W4,W5 W10
W6,W11
FROM SHUNT
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STATORSHORT CIRCUIT & GROUND TEST
STATORSHORT CIRCUIT & GROUND TEST (continued)
OUTPUT RECTIFIER BRIDGE TEST
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OUTPUT RECTIFIER BRIDGE TEST (continued)
OR
POS. NEG. W3 W2 W1 W4,W5 W10
W6,W11
Rectifier Terminal Connections
CHOPPER MODULE FUNCTION TEST
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CHOPPER MODULE FUNCTION TEST (continued)
TEST PROCEDURE (CONTINUED)
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CHOPPER MODULE RESISTANCE TEST
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CHOPPER MODULE RESISTANCE TEST (continued)
Chopper Terminal Connections
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WELD CONTROL BOARD PWM GATE SIGNAL TEST
WELD CONTROL BOARD PWM GATE SIGNAL TEST (continued)
WELD CONTROL FEEDBACK TEST
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WELD CONTROL FEEDBACK TEST (continued)
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CONTROL POTENTIOMETER AND MODE SWITCH RESIS- TANCE TEST
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CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCETEST (continued)
POT/MODE SWITCH RESISTANCE TEST
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REMOTE RECEPTACLE RESISTANCETEST
REMOTE RECEPTACLE RESISTANCETEST (continued)
AMPHENOL 1
E
I
C D
A
AMPHENOL RESISTANCE TEST
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OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVALAND REPLACEMENT
OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVALAND REPLACE- MENT (continued)
REMOVALPROCEDURE
REPLACEMENT PROCEDURE
OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVALAND REPLACE- MENT(continued) Replacing the Output Rectifier
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CHOPPER MODULE REMOVALAND REPLACEMENT
CHOPPER MODULE REMOVALAND REPLACEMENT (continued)
PROCEDURE
TERMINAL LEADS B4
B5 HL W5, SL 13 B6 HL W8 B1 HL W6 B2 HL W4, SL 301 B3 HL W9, SL 302
CHOPPER MODULE REMOVALAND REPLACEMENT(continued) Replacement
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STATOR/ROTOR REMOVALAND REPLACEMENT
Battery Terminals
Remove Through Here
HOLE
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Removing the Rotor
COUPLING DISC CLAMPING RING
Replacing the Stator
NORMAL OPEN CIRCUIT VOLTAGEWAVEFORM (120VAC SUPPLY)
HIGH IDLE NO LOAD
NORMAL OPEN CIRCUIT VOLTAGEWAVEFORM (STICK)
MAX CONTROL POT - HIGH IDLE - NO LOAD
NORMAL WELD VOLTAGEWAVEFORM (STICK CC)
MACHINE LOADED TO 300 AMPS AT27 VOLTS
NORMAL OPEN CIRCUIT VOLTAGEWAVEFORM (WIRE CV TAP)
MAX CONTROL POT - HIGH IDLE - NO LOAD
NORMAL WELD VOLTAGEWAVEFORM (WIRE CV)
MACHINE LOADED TO 300 AMPS AT28 VOLTS
RETEST AFTER REPAIR
ENGINE OUTPUT
WELDER DC (STICK) OUTPUT (ARC control @ -10)
WELDER CV (WIRE) OUTPUT (ARC Control @ +10)
TOUCH START TIG (ARC Control @ +10)
- ELECTRICAL DIAGRAMS SECTION -
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10926 (G4250)
RANGER 305D- KUBOTA - WIRING DIAGRAM
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11121(G4571)
HOT
C
ALTERNATOR
RANGER 305D- KUBOTA - WIRING DIAGRAM
FRAME GROUND
G-4
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11027 (G4226)
RANGER 305D CE KUBOTA WIRING DIAGRAM - UK
G-5
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11122(G4572)
RANGER 305D CE KUBOTA WIRING DIAGRAM - UK
G-6
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11189,11314 (G4572-1)
RANGER 305D CE KUBOTA WIRING DIAGRAM - UK
G-7
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11039 (G4409)
RANGER 305D CE KUBOTA - WIRING DIAGRAM - EUROPE
G-8
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11123(G4573)
RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE
G-9
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODES 11190,11315 (G4573-1)
RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 10926 (L11946)PAGE 1 OF 2
baffle near top of machine.
Shunt on back of positive
Chokeis beneath bearing end
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 10926 (L11946)PAGE 2 OF 2
2/5/03
NA CRM33549
L11943
ELECTRICAL DIAGRAMS
G-13 G-13
SCHEMATIC - ENTIRE MACHINE - CODE 11121(L12212) PAGE 1 OF 2
of generator on support.
baffle near top of
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11121(L12212) PAGE 2 OF 2
RELEASED "A.02" FROM "X"
G-14
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODES 11188,11275 (L12212-1) PAGE 1 OF 2
on left side near bottom of
G-15
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODES 11188,11275 (L12212-1) PAGE 2 OF 2
L12212
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11027(L12039) PAGE 1 OF 2
bafflenear top of machine.
G-17
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11027(L12039) PAGE 2 OF 2
6/20/03
UF CRM33673
EN-168
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11122(L12213) PAGE 1 OF 2
G-19
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11122(L12213) PAGE 2 OF 2
L12039
REL EASED "A.02" FROM "X"
G-20
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODES 11189,11314 (L12213-1) PAGE 1 OF 2
G-21
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODES 11189,11314 (L12213-1) PAGE 2 OF 2
L12213
G-22
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11039(L12038) PAGE 1 OF 2
bafflenear top of machine.
G-23
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11039(L12038) PAGE 2 OF 2
6/20/03
UF CRM33673
EN-168
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11123(L12214) PAGE 1 OF 2
G-25
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODE 11123(L12214) PAGE 2 OF 2
L12038
RELEASED "A.02" FROM " X"
G-26
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODES 11190,11315 (L12214-1) PAGE 1 OF 2
G-27
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - CODES 11190,11315 (L12214-1) PAGE 2 OF 2
L12214-1
G-28
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ELECTRICAL DIAGRAMS
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ELECTRICAL DIAGRAMS
13 4 E3768-4 LABEL
12 2 S25347 T HERMAL INTERFACE PAD
10 280g. E2527 EPOXYENCAPSULATINGRESIN
91 M19436-7 POTTING T RAY