Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM175-A service manual Ranger 305D

Models: SVM175-A

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			F-78

RANGER 305D

NOTES

F-78

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Lincoln Electric SVM175-A service manual Ranger 305D

Contents

RangerTM 305D Safety Powered equipmentFor Engine Electric Magnetic FieldsElectric Shock can kill ARC Rays can burn Fumes and GasesCan be dangerous Welding Sparks canSAFETY Cylinder may explodeCause fire or explosion If damaged For ElectricallyPrécautions DE Sûreté Précautions DE Sûreté PourLES Machines À Souder À Transformateur ET ÀMaster Table of Contents for ALL Sections Table of Contents Installation SectionSection A-1 Installation Height Width Depth WeightAIR Cleaner Engine Idler Muffler Protection Lubrication Emissions Fuel System GovernorAIR Cleaner Engine WarrantyEngine Protection Model NumberSafety Precautions StoringStacking Angle of Operation Location and VentilationHigh Temperature Operation LiftingTowing High Altitude OperationPRE-OPERATION Engine Service Battery Connection OILMuffler Outlet Pipe Spark ArresterRemote Control Machine Grounding AccessoriesElectrical Output Connections Welding Output Cables Auxiliary Power Receptacles Cable Installation Table A.1Standby Power Connections Total Combined LengthInstallation Figure A.2 Connection of Ranger 305D to Premises Wiring Premises or residential elecOperation Section Section B-1Safety Instructions Additional SafetyPrecautions Operating Instructions OperationDesign Features Control and SettingsOperation Figure B.1 Wire Feeder Voltmeter Switch Digital Output MetersEngine Operation Starting the EngineBefore Starting the Engine Stopping the Engine Diesel FuelBREAK-IN Period Stick WeldingTable B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 Downhill Pipe WeldingAuxiliary Power Wire WELDING-CVSee Table B.2 for reference settings TIG Welding ARC GougingAuxiliary Power Loads Ranger 305D Simultaneous Welding and Power LoadsSimultaneous Welding Ranger 305D Accessories Section C-1Options / Accessories Field Installed OptionsTIG Welding Accessories Welding AccessoriesElectric Wire Feeders Wire Feeders Using K867 UniversalConnection of Lincoln Connection of the Ranger 305D toConnection of the LN-25 to Ranger 305D Across the ARCSee Figure C.2 Volt Remote Output Control Module Connection Diagram Ranger 305D with 42 Volt RemoteOutput Control Module See Figure C.3 Connection Diagram with K857 Remote Control See Figure C.47ACCESSORIESC-7 Ranger 305D Using K595 Control Cable See Figure C.6 Connection of the LN-8 toFigure C.7 Ranger 305D/LN-742 Connection Diagram Connection of the LN-742 to Ranger 305D See Figure C.7Ranger 305D Maintenance Section D-1Safety Precautions Routine and Periodic Maintenance Engine MaintenanceMAINTENANCED-3 Kubota D722 Diesel Engine Ranger 305DEngine Oil Change See Table D.2Oil Filter Change Engine Oil Refill capacities5MAINTENANCED-5 AIR Cleaner Cooling SystemTightening the FAN Belt Do not remove cap if radiator isEngine Adjustment Battery MaintenanceCleaning the Battery Charging the BatteryWelder / Generator Checking the Electrolyte LevelGfci Receptacle Testing Resetting Procedure Maintenance Theory of Operation Section Section E-1Battery, Engine, Engine Protection BatteryTheory of Operation Charging SystemIdle Solenoid Operation Idle Switch Operation Engine Idle SystemGenerating Power FlashingBuilding Output AC outputWeld Power and Control Weld PowerTechnology Fundamentals Weld Control and FeedbackRemote output control Electronic Output ContactorDigital Meters Chopper Technology Fundamentals 90 VDCDiode Inductor ARCPulse Width Modulation Minimum OutputMaximum Output Troubleshooting & Repair Section Troubleshooting & Repair Section Section FSection F-1 2TROUBLESHOOTING & REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting & Repair PC Board Troubleshooting Procedures3F-3 PC Board can be damaged by static electricityTroubleshooting Guide Tests Engine ThrottleAdjus ment Test Brush and Slip RingProblems Possible Areas Symptoms Misadjustments Course of ActionThrottle Adjustment test Engine Throttle AdjustmentControl Adjustment Test Potentiometer Mode Switch Resistan TestSwitch Resistance Test ControlPotentiometer Mode Switch Test Switch Test, Remote Chopper Module ResistanceMISC. Weld Issues Welding output in any mode Potentiometer TestEngine and Idle Problems Engine AlterFuel Solenoid Test Fuel Solenoid Test. SeePerform the Fuel Solenoid Test Perform the Idle Solenoid TestShutdown Solenoid TestEngine and Idle Problems If the solenoid does not hold Engine and Idle Problems Rottle Adjustment Test Case Cover Removal and Replacement Procedure Test DescriptionMaterials Needed 21F-21Case Cover Removal and Replacement Procedure Replacement ProcedureChopper Module Capacitor Discharge Procedure 23F-23Test Procedure Perform the Case Cover Removal proceFuel Shutdown Solenoid Test 26TROUBLESHOOTING & REPAIRF-26 Fuel Shutdown Solenoid TestSee 27TROUBLESHOOTING & REPAIRF-27 Figure F.4 Fuel Solenoid ConnectionsRanger 305D Engine Throttle Adjustment Test 29F-29Engine Throttle Adjustment Test Strobe-Tach Method31TROUBLESHOOTING & REPAIRF-31 Engine Throttle Adjustment TestFrequency Counter Method Low Idle adjustment High idle adjustmentVibratach Method Idler Solenoid Test 33F-3334TROUBLESHOOTING & REPAIRF-34 Idler Solenoid TestEngine Alternator Test Description36TROUBLESHOOTING & REPAIRF-36 Test ProcedureEngine Alternator Test Brush and Slip Ring Service Procedure Brush and Slip Ring Service Procedure Perform the Case Cover Removal ProcedureCleaning slip rings Case Cover Replacement ProcedureRotor Resistance and Ground Test Static 39F-3940TROUBLESHOOTING & REPAIRF-40 Rotor Resistance and Ground Test StaticRotor Resistance and Ground Test Dynamic Also referred to as flying resistance testPerform theifbrushnecessaryand.slip ring service procedure Rotor Resistance and Ground Test DynamicRotor Voltage Test 43F-4344TROUBLESHOOTING & REPAIRF-44 TheEngineS Throttle Adjustment Test . tator ShortRotor Voltage Test Rotor Voltage Test Ranger 305D Flashing Voltage Test Engine Not RunningCase Cover Removal Procedure Flashing Voltage Test49TROUBLESHOOTING & REPAIRF-49 Flashing Voltage TestRanger 305D Stator Voltage Tests 51F-51Stator Voltage Tests To test the 120 VAC auxiliary windingTo test the 240 VAC auxiliary winding 53TROUBLESHOOTING & REPAIRF-53 Stator Voltage TestsTo test the 42 VAC wire feeder winding To test the three-phase weld windingStator Short Circuit & Ground Test 55F-55Perform Case Cover Removal Procedure Stator Short Circuit & Ground TestOutput Rectifier Bridge Test 57F-5758TROUBLESHOOTING & REPAIRF-58 Dis harge procedureOutput Rectifier Bridge Test Perform the Chopper Module CapacitorOutput Rectifier Bridge Test Figure F.16 SHUNT/RECTIFIER LeadsPerform the Case Cover replacement Procedure Table F.1 Diode Test TableChopper Module Function Test Chopper Module Function Test Procedure. CaseCover Replacement Chopper Module Function TestWeld. Control Board PWM Gate Drive Test Ranger 305D Chopper Module Resistance Test Capacitor Discharge Procedure Chopper Module Resistance TestCase Cover Removal Rocedure Ohmmeter Reading Table F.2 Diode Test TableRanger 305D Weld Control Board PWM Gate Signal Test Weld Control Board PWM Gate Signal Test Weld Control Feedback Test Weld Control Feedback Test Return to Section Ranger 305D Control Potentiometer and Mode Switch Resis Tance Test 76TROUBLESHOOTING & REPAIRF-76 Control Potentiometer and Mode Switch Resistance TestPerform .the Case cover Removal Procedure Cover Replacement procedureMode Switch Table F.3Ranger 305D Remote Receptacle Resistance Test Perform the Case Cover Replacement Remote Receptacle Resistance TestSee Table F.4 Welding Terminal Ohmmeter Ohmmeter Reading Table F.4Ranger 305D Output Rectifier Bridge and Choke Removal Replacement 84TROUBLESHOOTING & REPAIRF-84 Removal ProcedureDischarge procedure Output Rectifier Bridge and Choke Removal and ReplaceReplacing the Output Rectifier Perform the Case Cover RemovalRanger 305D Chopper Module Removal and Replacement Chopper Module Removal and Replacement ProcedureTerminal RemovalReplacement HL W8 HL W6Ranger 305D STATOR/ROTOR Removal and Replacement 92TROUBLESHOOTING & REPAIRF-92 STATOR/ROTOR Removal and ReplacementDischarge Pr Cedure See Figure F.21Figure F.21 Wire Guide Hole Figure F.22 Alternator LeadsDo not Hold the Rotor by the Slip Rings Figure F.23 DISC/RING Location Replacing the RotorReplacing the Stator 97TROUBLESHOOTING & REPAIRF-97 Normal Open Circuit Voltage Waveform 120VAC Supply98TROUBLESHOOTING & REPAIRF-98 Normal Open Circuit Voltage Waveform StickMAX Control POT High Idle no Load 99TROUBLESHOOTING & REPAIRF-99 Normal Weld Voltage Waveform Stick CCMachine Loaded to 300 Amps AT 27 Volts 100TROUBLESHOOTING & REPAIRF-100 Normal Open Circuit Voltage Waveform Wire CV TAP101TROUBLESHOOTING & REPAIRF-101 Normal Weld Voltage Waveform Wire CVMachine Loaded to 300 Amps AT 28 Volts Auxiliary Power Output Retest After RepairElectrical Diagrams Section Electrical Diagrams Section GSection G-1 Electrical Diagrams Wiring Diagram Entire Machine Code 10926 G4250Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11121 G4571Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11188, 11275 G4571-1Ranger 305D CE Kubota Wiring Diagram UK Wiring Diagram Entire Machine Codes 11027 G4226Wiring Diagram Entire Machine Codes 11122 G4572 AlternatorRanger 305D CE Kubota Wiring Diagram UK Ranger 305D CE Kubota Wiring Diagram Europe Wiring Diagram Entire Machine Codes 11039 G4409Ranger 305D CE Kubota Wiring Diagram -EUROPE Wiring Diagram Entire Machine Codes 11123 G4573Wiring Diagram Entire Machine Codes 11190, 11315 G4573-1 L11946 +12V Isolated Circuitry for Engine Functions L12212 Machine Schematic L12212-1 L12212-1 L12039 Diagrams L12213 Schematic Entire Machine Code 11122 L12213 page 2 L12213-1 Schematic Entire Machine Codes 11189, 11314 L12213-1 page 2 Schematic Entire Machine Code 11039 L12038 page 1 Schematic Entire Machine Code 11039 L12038 L12214 Schematic Entire Machine Code 11123 L12214 page 2 L12214-1 L12214-1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 2 Schematic Weld Control PC BD ALL Codes G4108-1 PG 3 Schematic Weld Control PC BD ALL Codes G4108-1 PG 4 Schematic Weld Control PC BD ALL Codes G4108-1 PG 5 PC Board Assembly Weld Control PC BD ALL Codes G4107-1 Schematic Pull Coil PC BD ALL Codes G4117-1 PC Board Assembly Pull Coil PC BD ALL Codes L11768-1 Schematic Chopper PC BD ALL Codes M19792-1 PC Board Assembly Chopper PC BD ALL Codes L11845-1 54811L