Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM175-A service manual Ranger 305D

Models: SVM175-A

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			F-28

RANGER 305D

NOTES

F-28

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Lincoln Electric SVM175-A service manual Ranger 305D

Contents

RangerTM 305D For Engine SafetyPowered equipment Electric Magnetic FieldsFumes and Gases Electric Shock can kill ARC Rays can burnCan be dangerous Cause fire or explosion If damaged Welding Sparks canSAFETYCylinder may explode For ElectricallyLES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET ÀMaster Table of Contents for ALL Sections Installation Section Table of ContentsSection A-1 AIR Cleaner Engine Idler Muffler Protection InstallationHeight Width Depth Weight Lubrication Emissions Fuel System GovernorEngine Protection AIR CleanerEngine Warranty Model NumberStacking Safety PrecautionsStoring Angle of Operation Location and VentilationTowing High Temperature OperationLifting High Altitude OperationMuffler Outlet Pipe PRE-OPERATION Engine Service Battery ConnectionOIL Spark ArresterAccessories Remote Control Machine GroundingElectrical Output Connections Standby Power Connections Welding Output Cables Auxiliary Power ReceptaclesCable Installation Table A.1 Total Combined LengthInstallation Figure A.2 Connection of Ranger 305D to Premises Wiring Premises or residential elecOperation Section Section B-1Precautions Safety InstructionsAdditional Safety Operating Instructions OperationControl and Settings Design FeaturesOperation Figure B.1 Wire Feeder Voltmeter Switch Digital Output MetersBefore Starting the Engine Engine OperationStarting the Engine Stopping the Engine Diesel FuelTable B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 BREAK-IN PeriodStick Welding Downhill Pipe WeldingSee Table B.2 for reference settings Auxiliary PowerWire WELDING-CV TIG Welding ARC GougingRanger 305D Simultaneous Welding and Power Loads Auxiliary Power LoadsSimultaneous Welding Ranger 305D Accessories Section C-1TIG Welding Accessories Options / AccessoriesField Installed Options Welding AccessoriesConnection of Lincoln Electric Wire FeedersWire Feeders Using K867 Universal Connection of the Ranger 305D toRanger 305D Across the ARC Connection of the LN-25 toSee Figure C.2 Ranger 305D with 42 Volt Remote Volt Remote Output Control Module Connection DiagramOutput 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 305DOil Filter Change Engine Oil ChangeSee Table D.2 Engine Oil Refill capacities5MAINTENANCED-5 Tightening the FAN Belt AIR CleanerCooling System Do not remove cap if radiator isEngine Adjustment Battery MaintenanceWelder / Generator Cleaning the BatteryCharging the Battery Checking the Electrolyte LevelGfci Receptacle Testing Resetting Procedure Maintenance Theory of Operation Section Section E-1Theory of Operation Battery, Engine, Engine ProtectionBattery Charging SystemIdle Solenoid Operation Idle Switch Operation Engine Idle SystemBuilding Output Generating PowerFlashing AC outputTechnology Fundamentals Weld Power and ControlWeld Power Weld Control and FeedbackElectronic Output Contactor Remote output controlDigital Meters Diode Chopper Technology Fundamentals90 VDC Inductor ARCMinimum Output Pulse Width ModulationMaximum Output Troubleshooting & Repair Section Section F Troubleshooting & Repair SectionSection F-1 2TROUBLESHOOTING & REPAIRF-2 HOW to USE Troubleshooting Guide3F-3 Troubleshooting & RepairPC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Adjus ment Test TestsEngine Throttle Brush and Slip RingThrottle Adjustment test Problems Possible AreasSymptoms Misadjustments Course of Action Engine Throttle AdjustmentControl Adjustment Test Switch Resistance Test Potentiometer ModeSwitch Resistan 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. SeeShutdown Perform the Fuel Solenoid TestPerform the Idle Solenoid Test Solenoid TestEngine and Idle Problems If the solenoid does not hold Engine and Idle Problems Rottle Adjustment Test Materials Needed Case Cover Removal and Replacement ProcedureTest Description 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 Fuel Shutdown Solenoid Test 26TROUBLESHOOTING & REPAIRF-26See 27TROUBLESHOOTING & REPAIRF-27 Figure F.4 Fuel Solenoid ConnectionsRanger 305D Engine Throttle Adjustment Test 29F-29Engine Throttle Adjustment Test Strobe-Tach MethodEngine Throttle Adjustment Test 31TROUBLESHOOTING & REPAIRF-31Frequency Counter Method High idle adjustment Low Idle adjustmentVibratach Method Idler Solenoid Test 33F-3334TROUBLESHOOTING & REPAIRF-34 Idler Solenoid TestEngine Alternator Test DescriptionTest Procedure 36TROUBLESHOOTING & REPAIRF-36Engine Alternator Test Brush and Slip Ring Service Procedure Cleaning slip rings Brush and Slip Ring Service ProcedurePerform the Case Cover Removal Procedure 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-43TheEngineS Throttle Adjustment Test . tator Short 44TROUBLESHOOTING & REPAIRF-44Rotor 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-51To test the 120 VAC auxiliary winding Stator Voltage TestsTo 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-57Output Rectifier Bridge Test 58TROUBLESHOOTING & REPAIRF-58Dis harge procedure 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 Chopper Module Function Test Procedure. CaseCover ReplacementWeld. Control Board PWM Gate Drive Test Ranger 305D Chopper Module Resistance Test Chopper Module Resistance Test Capacitor Discharge ProcedureCase 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 Perform .the Case cover Removal Procedure 76TROUBLESHOOTING & REPAIRF-76Control Potentiometer and Mode Switch Resistance Test Cover Replacement procedureMode Switch Table F.3Ranger 305D Remote Receptacle Resistance Test Remote Receptacle Resistance Test Perform the Case Cover ReplacementSee Table F.4 Welding Terminal Ohmmeter Ohmmeter Reading Table F.4Ranger 305D Output Rectifier Bridge and Choke Removal Replacement Discharge procedure 84TROUBLESHOOTING & REPAIRF-84Removal Procedure Output Rectifier Bridge and Choke Removal and ReplaceReplacing the Output Rectifier Perform the Case Cover RemovalRanger 305D Chopper Module Removal and Replacement Terminal Chopper Module Removal and ReplacementProcedure RemovalReplacement HL W8 HL W6Ranger 305D STATOR/ROTOR Removal and Replacement Discharge Pr Cedure 92TROUBLESHOOTING & REPAIRF-92STATOR/ROTOR Removal and Replacement 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 SupplyNormal Open Circuit Voltage Waveform Stick 98TROUBLESHOOTING & REPAIRF-98MAX Control POT High Idle no Load Normal Weld Voltage Waveform Stick CC 99TROUBLESHOOTING & REPAIRF-99Machine Loaded to 300 Amps AT 27 Volts 100TROUBLESHOOTING & REPAIRF-100 Normal Open Circuit Voltage Waveform Wire CV TAPNormal Weld Voltage Waveform Wire CV 101TROUBLESHOOTING & REPAIRF-101Machine Loaded to 300 Amps AT 28 Volts Auxiliary Power Output Retest After RepairElectrical Diagrams Section G Electrical Diagrams SectionSection 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