Ranger 305D | Lincoln Electric SVM175-A guide

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			F-90

RANGER 305D

NOTES

F-90

Image 144

Lincoln Electric SVM175-A service manual Ranger 305D

Contents

RangerTM 305D Safety Powered equipmentFor Engine Electric Magnetic Fields Electric Shock can kill ARC Rays can burn Fumes and GasesCan be dangerous Welding Sparks canSAFETY Cylinder may explodeCause fire or explosion If damaged For Electrically Précautions DE Sûreté Précautions DE Sûreté PourLES Machines À Souder À Transformateur ET À Master 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 Governor AIR Cleaner Engine WarrantyEngine Protection Model Number Safety Precautions StoringStacking Angle of Operation Location and Ventilation High Temperature Operation LiftingTowing High Altitude Operation PRE-OPERATION Engine Service Battery Connection OILMuffler Outlet Pipe Spark Arrester Remote Control Machine Grounding AccessoriesElectrical Output Connections Welding Output Cables Auxiliary Power Receptacles Cable Installation Table A.1Standby Power Connections Total Combined Length Installation Figure A.2 Connection of Ranger 305D to Premises Wiring Premises or residential elec Operation Section Section B-1 Safety Instructions Additional SafetyPrecautions Operating Instructions Operation Design Features Control and SettingsOperation Figure B.1 Wire Feeder Voltmeter Switch Digital Output Meters Engine Operation Starting the EngineBefore Starting the Engine Stopping the Engine Diesel Fuel BREAK-IN Period Stick WeldingTable B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 Downhill Pipe Welding Auxiliary Power Wire WELDING-CVSee Table B.2 for reference settings TIG Welding ARC Gouging Auxiliary Power Loads Ranger 305D Simultaneous Welding and Power LoadsSimultaneous Welding Ranger 305D Accessories Section C-1 Options / Accessories Field Installed OptionsTIG Welding Accessories Welding Accessories Electric Wire Feeders Wire Feeders Using K867 UniversalConnection of Lincoln Connection of the Ranger 305D to Connection 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.4 7ACCESSORIESC-7 Ranger 305D Using K595 Control Cable See Figure C.6 Connection of the LN-8 to Figure C.7 Ranger 305D/LN-742 Connection Diagram Connection of the LN-742 to Ranger 305D See Figure C.7 Ranger 305D Maintenance Section D-1 Safety Precautions Routine and Periodic Maintenance Engine Maintenance MAINTENANCED-3 Kubota D722 Diesel Engine Ranger 305D Engine Oil Change See Table D.2Oil Filter Change Engine Oil Refill capacities 5MAINTENANCED-5 AIR Cleaner Cooling SystemTightening the FAN Belt Do not remove cap if radiator is Engine Adjustment Battery Maintenance Cleaning the Battery Charging the BatteryWelder / Generator Checking the Electrolyte Level Gfci Receptacle Testing Resetting Procedure Maintenance Theory of Operation Section Section E-1 Battery, Engine, Engine Protection BatteryTheory of Operation Charging System Idle Solenoid Operation Idle Switch Operation Engine Idle System Generating Power FlashingBuilding Output AC output Weld Power and Control Weld PowerTechnology Fundamentals Weld Control and Feedback Remote output control Electronic Output ContactorDigital Meters Chopper Technology Fundamentals 90 VDCDiode Inductor ARC Pulse Width Modulation Minimum OutputMaximum Output Troubleshooting & Repair Section Troubleshooting & Repair Section Section FSection F-1 2TROUBLESHOOTING & REPAIRF-2 HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board Troubleshooting Procedures3F-3 PC Board can be damaged by static electricity Troubleshooting Guide Tests Engine ThrottleAdjus ment Test Brush and Slip Ring Problems Possible Areas Symptoms Misadjustments Course of ActionThrottle Adjustment test Engine Throttle Adjustment Control Adjustment Test Potentiometer Mode Switch Resistan TestSwitch Resistance Test Control Potentiometer Mode Switch Test Switch Test, Remote Chopper Module Resistance MISC. Weld Issues Welding output in any mode Potentiometer Test Engine and Idle Problems Engine Alter Fuel Solenoid Test Fuel Solenoid Test. See Perform the Fuel Solenoid Test Perform the Idle Solenoid TestShutdown Solenoid Test Engine 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-21 Case Cover Removal and Replacement Procedure Replacement Procedure Chopper Module Capacitor Discharge Procedure 23F-23 Test Procedure Perform the Case Cover Removal proce Fuel Shutdown Solenoid Test 26TROUBLESHOOTING & REPAIRF-26 Fuel Shutdown Solenoid TestSee 27TROUBLESHOOTING & REPAIRF-27 Figure F.4 Fuel Solenoid Connections Ranger 305D Engine Throttle Adjustment Test 29F-29 Engine Throttle Adjustment Test Strobe-Tach Method 31TROUBLESHOOTING & REPAIRF-31 Engine Throttle Adjustment TestFrequency Counter Method Low Idle adjustment High idle adjustmentVibratach Method Idler Solenoid Test 33F-33 34TROUBLESHOOTING & REPAIRF-34 Idler Solenoid Test Engine Alternator Test Description 36TROUBLESHOOTING & 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 Procedure Rotor Resistance and Ground Test Static 39F-39 40TROUBLESHOOTING & REPAIRF-40 Rotor Resistance and Ground Test Static Rotor Resistance and Ground Test Dynamic Also referred to as flying resistance test Perform theifbrushnecessaryand.slip ring service procedure Rotor Resistance and Ground Test Dynamic Rotor Voltage Test 43F-43 44TROUBLESHOOTING & REPAIRF-44 TheEngineS Throttle Adjustment Test . tator ShortRotor Voltage Test Rotor Voltage Test Ranger 305D Flashing Voltage Test Engine Not Running Case Cover Removal Procedure Flashing Voltage Test 49TROUBLESHOOTING & REPAIRF-49 Flashing Voltage Test Ranger 305D Stator Voltage Tests 51F-51 Stator Voltage Tests To test the 120 VAC auxiliary windingTo test the 240 VAC auxiliary winding 53TROUBLESHOOTING & REPAIRF-53 Stator Voltage Tests To test the 42 VAC wire feeder winding To test the three-phase weld winding Stator Short Circuit & Ground Test 55F-55 Perform Case Cover Removal Procedure Stator Short Circuit & Ground Test Output Rectifier Bridge Test 57F-57 58TROUBLESHOOTING & REPAIRF-58 Dis harge procedureOutput Rectifier Bridge Test Perform the Chopper Module Capacitor Output Rectifier Bridge Test Figure F.16 SHUNT/RECTIFIER Leads Perform the Case Cover replacement Procedure Table F.1 Diode Test Table Chopper 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 Table Ranger 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 procedure Mode Switch Table F.3 Ranger 305D Remote Receptacle Resistance Test Perform the Case Cover Replacement Remote Receptacle Resistance TestSee Table F.4 Welding Terminal Ohmmeter Ohmmeter Reading Table F.4 Ranger 305D Output Rectifier Bridge and Choke Removal Replacement 84TROUBLESHOOTING & REPAIRF-84 Removal ProcedureDischarge procedure Output Rectifier Bridge and Choke Removal and Replace Replacing the Output Rectifier Perform the Case Cover Removal Ranger 305D Chopper Module Removal and Replacement Chopper Module Removal and Replacement ProcedureTerminal Removal Replacement HL W8 HL W6 Ranger 305D STATOR/ROTOR Removal and Replacement 92TROUBLESHOOTING & REPAIRF-92 STATOR/ROTOR Removal and ReplacementDischarge Pr Cedure See Figure F.21 Figure F.21 Wire Guide Hole Figure F.22 Alternator Leads Do not Hold the Rotor by the Slip Rings Figure F.23 DISC/RING Location Replacing the Rotor Replacing the Stator 97TROUBLESHOOTING & REPAIRF-97 Normal Open Circuit Voltage Waveform 120VAC Supply 98TROUBLESHOOTING & 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 TAP 101TROUBLESHOOTING & REPAIRF-101 Normal Weld Voltage Waveform Wire CVMachine Loaded to 300 Amps AT 28 Volts Auxiliary Power Output Retest After Repair Electrical Diagrams Section Electrical Diagrams Section GSection G-1 Electrical Diagrams Wiring Diagram Entire Machine Code 10926 G4250 Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11121 G4571 Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11188, 11275 G4571-1 Ranger 305D CE Kubota Wiring Diagram UK Wiring Diagram Entire Machine Codes 11027 G4226 Wiring Diagram Entire Machine Codes 11122 G4572 Alternator Ranger 305D CE Kubota Wiring Diagram UK Ranger 305D CE Kubota Wiring Diagram Europe Wiring Diagram Entire Machine Codes 11039 G4409 Ranger 305D CE Kubota Wiring Diagram -EUROPE Wiring Diagram Entire Machine Codes 11123 G4573 Wiring 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