Lincoln Electric Ranger 305D Service Manual
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Lincoln Electric Ranger 305D Service Manual

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For use with machines having Code Numbers: 10926, 11121, 11188, 11275 (Domestic)
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased 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.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1-888-935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
All manuals and user guides at all-guides.com
Ranger 305D
11027, 11122, 11189, 11314 (UK)
11039, 11123, 11190, 11315 (EUROPE)
SERVICE MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
TM
Copyright© 2007 Lincoln Global Inc.
SVM175-A
July, 2007

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  • Page 1 SVM175-A All manuals and user guides at all-guides.com July, 2007 Ranger 305D For use with machines having Code Numbers: 10926, 11121, 11188, 11275 (Domestic) 11027, 11122, 11189, 11314 (UK) 11039, 11123, 11190, 11315 (EUROPE) Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.

  • Page 2: Safety

    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.
  • Page 3 SAFETY All manuals and user guides at all-guides.com ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY All manuals and user guides at all-guides.com WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY All manuals and user guides at all-guides.com PRÉCAUTIONS DE SÛRETÉ zones où lʼon pique le laitier. 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque dʼincendie dû aux étincelles. et les précautions de sûreté...

  • Page 6: Table Of Contents

    Maintenance ..........................Section D Theory of Operation ......................Section E Troubleshooting and Repair ....................Section F Electrical Diagrams ......................Section G 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 RANGER 305D...
  • Page 7 High Frequency Generators for TIG Applications..............A-6 Remote Control........................A-7 Electrical Output Connections.....................A-7 Machine Grounding ......................A-7 Welding Output Cables......................A-8 Cable Installation ......................A-8 Auxiliary Power Receptacles ....................A-8 Standby Power Connections ..................A-8 - A-9 Connection of Ranger 305D to Premises Wiring ..............A-10 RANGER 305D...

  • Page 8: Installation

    INSTALLATION All manuals and user guides at all-guides.com TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2) Code 10926, 11121, 11188, 11275 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (cu. cm.) System 3 cylinder 43.88(789) 12VDC Battery & Fuel: 12 gal.(45L)
  • Page 9 INSTALLATION TECHNICAL SPECIFICATIONS - All manuals and user guides at all-guides.com RANGER 305D (CE) K2279-1 (UK) Code 11027, 11122, 11189, 11314 & K2279-2 (EUROPE) Code 11039, 11123, 11190, 11315 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu.

  • Page 10: Safety Precautions

    See additional safety information in the front of this STACKING manual. Only qualified personnel should install, use or ser- vice this equipment. Ranger 305D machines CANNOT be stacked. ----------------------------------------------------------------------- ANGLE OF OPERATION LOCATION AND VENTILATION Engines are designed to run in the level of condition which is where the optimum performance is achieved.

  • Page 11: Lifting

    Cold Weather Starting & Operation: components to fail. The Kubota engine used in the Ranger 305D can be • Only transport this Equipment on serviceable started in temperatures as low as 5°F (-15°C). At tem- vehicles which are rated and designed for such peratures below 23°F (-5°C) it is recommended that...

  • Page 12: Pre-Operation Engine Service

    ------------------------------------------------------------------------ • Fill the tank at a moderate rate and do not overfill. The RANGER 305D is shipped with the negative bat- • Wipe up spilled fuel and allow the fumes to clear tery cable disconnected. Make certain that the RUN- before starting the engine.

  • Page 13: Remote Control

    All manuals and user guides at all-guides.com REMOTE CONTROL MACHINE GROUNDING The RANGER 305D is equipped with both a 6-pin and Because this portable engine driven welder creates its a 14-pin Amphenol connector. The 6-pin connector is own power, it is not necessary to connect its frame to...

  • Page 14: Welding Output Cables

    AUXILIARY POWER RECEPTACLES WELDING OUTPUT CABLES The auxiliary power of the RANGER 305D consists of With the engine off connect the electrode and work two 20 Amp-120 VAC (5-20R) duplex receptacles with cables to the output terminals. The welding process GFCI protection and one 50 Amp 120/240 VAC (14- dictates the polarity of the electrode cable.
  • Page 15 2. Take necessary steps to assure load is limited to 4. Plug this cable into th 50 amp, 120/240 VAC recep- the capacity of the Ranger 305D by installing a 50 tacle on the Ranger 305D case front. amp, 240 VAC double-pole circuit breaker.

  • Page 16: Connection Of Ranger 305D To Premises Wiring

    INSTALLATION A-10 A-10 All manuals and user guides at all-guides.com FIGURE A.2 CONNECTION OF RANGER 305D TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW...
  • Page 17 Before Starting the Engine ....................B-6 Starting the Engine .......................B-6 Stopping the Engine ......................B-6 Stick Welding ..........................B-7 Constant Current (CC-Stick) Welding................B-7 Pipe Welding........................B-7 TIG Welding..........................B-8 Wire Welding-CV ........................B-8 Arc Gouging..........................B-8 Auxiliary Power ...........................B-8 Simultaneous Welding and Auxiliary Power Loads ..............B-9 RANGER 305D...

  • Page 18: Operation

    GENERAL DESCRIPTION ------------------------------------------------------------------------ WELDING SPARKS can cause fire or The Ranger 305D is a diesel-engine-powered DC explosion. 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 cir- •...

  • Page 19: Design Features

    Some models have gauge located next to fuel cap on case top. are also located here. See Figure B.1. Some models have gauge located on front panel. • Voltmeter and ammeter display actual volts and amps at output terminals when welding. RANGER 305D...

  • Page 20: Engine Controls

    The engine will automatically return to high idle speed the engine, the engine will operate at full speed for when the welding load or AC power load is reapplied. approximately 12 seconds and then go to low idle speed. RANGER 305D...

  • Page 21: Welding Controls

    - TOUCH STARTING this reason, there can only be one device plugged into 11. ARC CONTROL the Ranger 305D at any time. - The ARC CONTROL dial is active in the CV-WIRE, CC-STICK, and DOWNHILL PIPE modes, and has different functions in these modes. This 14.

  • Page 22: Engine Operation

    SPEEDS. The maximum allowable high idle speed for 4. Press Glow Plug Button and hold 5 to 10 seconds. the Ranger 305D is 3650 RPM, no load. Do NOT 5. Press and hold both the “Glow Plug” Button and adjust...

  • Page 23: Stick Welding

    This slope controlled setting is intended for "out-of-posi- STICK WELDING tion" and "down hill" pipe welding where the operator The Ranger 305D can be used with a broad range of DC would like to control the current level by changing the arc stick electrodes.

  • Page 24: Tig Welding

    TABLE B.3 - CURRENT RANGE PER ELECTRODE DIAMETER The Ranger 305D can be used in a wide variety of DC TIG weld- ing applications. In general the “Touch Start” feature allows con- tamination-free starting without the use of a Hi-frequency unit. If...

  • Page 25: Simultaneous Welding And Auxiliary Power Loads

    120 VAC load is 40 amps. Each 120 VAC Duplex receptacle is limited to 20 amps maximum. TABLE B.5 - RANGER 305D Extension Cord Length Recommendations (Use the shortest length extension cord possible sized per the following table.) Maximum Allowable Cord Length in ft. (m) for Conductor Size...
  • Page 26 NOTES B-10 B-10 All manuals and user guides at all-guides.com RANGER 305D...
  • Page 27 Field Installed Options ......................C-2 TIG Welding Accessories .....................C-2 Semiautomatic FCAW and MIG Welding Accessories ............C-2 Connection of Lincoln Electric Wire Feeders ...............C-3 Connection of the K867 Universal Adapter ..............C-3 Connection of the LN-25 “Across the Arc” ..............C-4 Connection of the LN-25 with 42V Remote Output Control Module ......C-5 Connection of the LN-25 with K857 Remote Control.............C-6...

  • Page 28: Accessories

    Has a and gas flow. Provides the required control interface convenient 6-pin plug for easy connection to the between the Ranger 305D and the K487-25 Magnum welder. Spool Gun. Requires the K691-10 Input Cable.

  • Page 29: Connection Of Lincoln Electric Wire Feeders

    3. Connect the K867 Universal Adapter to the 14-pin CONNECTION OF LINCOLN amphenol of the Ranger 305D as shown in Figure C.1. Make the proper connections for local or ELECTRIC WIRE FEEDERS remote control according to Figure C.1. and the fol-...

  • Page 30: Connection Of The

    LN-25 if optional remote control kit is used. 4. Set the “MODE” switch to the “CV-WIRE” position. 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 6-PIN OPTIONAL K444-1...
  • Page 31 Cable Assembly to the 14-pin amphenol on the 9. Set the ARC control to “0” initially and adjust to Ranger 305D and the input cable plug on the LN- suit. 4. Set the “VOLTMETER” switch to “+” or “-” depend- ing on the polarity chosen.
  • Page 32 RANGER 305D “ACROSS THE ARC” WITH K857 REMOTE CONTROL (SEE FIGURE C.4.) If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the Ranger 305D is started. 1. Shut the welder off. ------------------------------------------------------------------------ 6. Set the “MODE” switch to “CV-WIRE.”...
  • Page 33 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. FIGURE C.5 - Ranger 305D/LN-7 WITH 584 CONTROL CABLE CONNECTION DIAGRAM 14-PIN TO LN-7 INPUT...
  • Page 34 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. FIGURE C.6 - Ranger 305D/LN-8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM TO LN-8 INPUT CABLE PLUG K595 CONTROL CABLE...
  • Page 35 9. Set the ARC control to “0” initially and adjust to 3. Connect the K619 Control Cable to the 14-pin suit. amphenol on the Ranger 305D and the input cable plug on the LN-742.. 4. Set the “VOLTMETER” switch to “+” or “-” depend- ing on the polarity chosen.
  • Page 36 NOTES C-10 C-10 All manuals and user guides at all-guides.com RANGER 305D...
  • Page 37 Cooling System ........................D-6 Tighten the Fan Belt ......................D-6 Fuel System Service ......................D-7 Battery Maintenance......................D-7 Welder/Generator Maintenance ....................D-8 Storage ..........................D-8 Cleaning ..........................D-8 Receptacles..........................D-8 Cable Connections .......................D-8 Brush Removal and Replacement..................D-8 GFCI Receptacle Testing and Resetting Procedure..............D-9 Major Component Location.......................D-10 RANGER 305D...

  • Page 38: Maintenance

    TABLE D.1 - ENGINE MAINTENANCE COMPONENTS, KUBOTA D722 DIESEL ENGINE ITEM MAKE AND PART NUMBER OIL FILTER KUBOTA 70000-15241 AIR FILTER DONALDOSON P822686 MAIN FUEL FILTER KUBOTA 15393-43017 FUEL FILTER (IN-LINE) KUBOTA 12581-43012 BATTERY GROUP 58, 550, CCA LINCOLN M9399-14 BELT KUBOTA 15881-97011 GLOW PLUGS KUBOTA 16851-65512 RANGER 305D...

  • Page 39: Maintenance

    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...

  • Page 40: Engine Oil Change

    S and C grade service classi- fications.) SAE 10W30 is recommended for general, all tempera- ture use, 5F to 104F (-15C to 40C). See engine ownerʼs manual for more specific informa- tion on oil viscosity recommendations. RANGER 305D...

  • Page 41: Service Instruction & Installation Tips

    (Engine manufacturers says that it takes only a few grams of dirt to ëdustí an engine!) Be careful not to damage the RANGER 305D sealing area on the tube.

  • Page 42: Cooling System

    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...

  • Page 43: Fuel System Service

    5. Follow the normal STARTING procedures. • Wear gloves and eye protection and be careful when working near FUEL FILTER battery. 1. Check the fuel filter and fuel pre-filter for water accu- • Follow instructions printed on battery. mulation or sediment. RANGER 305D...

  • Page 44: Welder/Generator Maintenance

    Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, discon- nect the battery cables and wash the terminals with an STORAGE: Store the RANGER 305D in clean, dry ammonia solution or a solution of 1/4 pound (0.1113 protected areas.

  • Page 45: Gfci Receptacle Testing And Resetting Procedure

    "Test" button is pushed, the GFCI is not work- ing 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 neces- sary or replace the device. RANGER 305D...
  • Page 46 All manuals and user guides at all-guides.com FIGURE D.1 – MAJOR COMPONENT LOCATIONS 1. CASE FRONT ASSEMBLY 2. CONTROL PANEL ASSEMBLY 3. STATOR & ROTOR ASSEMBLY 4. BLOWER BAFFLE ASSEMBLY 5. BASE, FUEL TANK ASSEMBLY 6. ENGINE ASSEMBLY 7. CASE COVERS RANGER 305D...
  • Page 47 Weld Power and Control......................E-5 Remote Output Control, Output Contactor, Digital Meters ............E-6 Chopper Technology Fundamentals ..................E-7 Pulse Width Modulation ......................E-8 Insulated Gate Bipolar Transistor (IGBT) Operation .............E-8 FIGURE E.1 – RANGER 305D BLOCK LOGIC DIAGRAM SHUNT IGBTs POWER CHOKE MODULE...

  • Page 48: Theory Of Operation

    GENERAL DESCRIPTION CONTROL Starting the engine: The Ranger 305D is a diesel engine-driven welding Starting the engine first requires that the Run/Stop power source capable of producing 300 amps at switch be in the run position. The glow plug button is 29VDC at a 100% duty cycle.

  • Page 49: Engine Idle System

    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...

  • Page 50: Generating Power

    IGBTs on the power module and the even stronger. weld control PC board. This process of strengthening the magnetic field through feedback from the output continues to increase RANGER 305D...

  • Page 51: Weld Power And Control

    (See Pulse Width Modulation) are used by the microprocessor, together with pre-pro- grammed internal parameters, current feedback from the shunt, and voltage feedback from the output studs, to control the IGBTʼs via the PWM signal discussed ear- lier. RANGER 305D...
  • Page 52 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 indi- cate actual weld volts and amps. RANGER 305D...

  • Page 53: Chopper Technology Fundamentals

    This is the basis for Chopper Technology: through the diode. The repetition rate of switch closure Controlling the switch in such a way as to produce is 20Khz, which allows ultra-fast control of the arc. By superior welding. RANGER 305D...

  • Page 54: Pulse Width Modulation

    The top drawing shows the minimum output sig- mized. The darkened area under the top curve can be nal possible over a 50-microsecond time period. compared to the area under the bottom curve. The more darkened area under the curve, the more power is present. RANGER 305D...
  • Page 55 Normal Open Circuit Voltage Waveform (120 VAC Supply)..........F-97 Normal Open Circuit Voltage Waveform (Stick) ............F-98 Normal Weld Voltage Waveform (Stick CC)..............F-99 Normal Open Circuit Voltage Waveform (Wire CV Tap)..........F-100 Normal Weld Voltage Waveform (Wire CV) ..............F-101 Retest After Repair......................F-102 RANGER 305D...

  • Page 56: Troubleshooting And 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.

  • Page 57: Pc Board Troubleshooting Procedures

    • If you return a PC Board to The Lincoln Electric Sometimes machine failures appear to be due to PC Company for credit, it must be in the static-shielding board failures.

  • Page 58: Troubleshooting Guide

    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...
  • Page 59 4. Perform the Stator Voltage Test. Test. 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...
  • Page 60 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...
  • Page 61 RESISTANCE TEST. 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...
  • Page 62 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...
  • Page 63 14 pin amphenol receptacle. 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...
  • Page 64 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...
  • Page 65 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...
  • Page 66 AGE TEST. 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...
  • Page 67 5. The wire feeder may be defec- tive. 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...
  • Page 68 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...
  • Page 69 Replace the fuel filter if neces- sary. 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...
  • Page 70 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...
  • Page 71 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...
  • Page 72 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...
  • Page 73 “HIGH IDLE” position. 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...
  • Page 74 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...

  • Page 75: Case Cover Removal And Replacement Procedure

    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.
  • Page 76 Screw the cap back on when working on the 3. To remove each door, partially close the Ranger 305D. door until the locking tabs at the hinges dis- engage from the slots in the base. Hold the...

  • Page 77: Chopper Module Capacitor Discharge Procedure

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 78 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...

  • Page 79: Fuel Shutdown Solenoid Test

    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.
  • Page 80 Re-connect fuel solenoid and replace any Ohms or more. If any of the above resis- previously removed cable ties. tance values are incorrect, the solenoid 7. If finished testing, close the engine ser- may be faulty. Replace. vice access doors. RANGER 305D...
  • Page 81 All manuals and user guides at all-guides.com FUEL SHUTDOWN SOLENOID TEST ( ontinued) FIGURE F.4 – FUEL SOLENOID CONNECTIONS GND-L BLACK 225B TO "D-4" TO FRAME WHITE TO STARTER SOLENOID FUEL SOLENOID FUEL SOLENOID WIRING HARNESS CONNECTOR CONNECTOR (LEAD ENTRY VIEW) (LEAD ENTRY VIEW) RANGER 305D...
  • Page 82 NOTES F-28 F-28 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 83: Engine Throttle Adjustment Test

    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.
  • Page 84 5. Start the engine and place the idle switch in the “HIGH IDLE” position. Make sure that If either of the readings is incorrect, proceed there is no load on the machine. to the “THROTTLE ADJUSTMENT PROCE- DURE” later in this section. RANGER 305D...
  • Page 85 2. Start the engine and place the idle switch in PROCEDURE” later in this section. the “HIGH IDLE” position. Make sure that NOTE: For the Ranger 305D, and any other there is no load on the machine. Lincoln Electric 3600 RPM (2 Pole) machine, The frequency should read between 60.5...
  • Page 86 (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. See Figure F.6. RANGER 305D...

  • Page 87: Idler Solenoid Test

    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.
  • Page 88 500,000 previously removed cable ties. Ohms or more. If any of the above resis- tance values are incorrect, the solenoid 10. If finished testing, close the engine service may be faulty. Replace. See Figure F.7. access door. RANGER 305D...

  • Page 89: Engine Alternator Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 90 “IGN” from the battery, and open the engine access terminal; check the run/stop switch and the door on the left side of the machine. wiring connecting the “IGN” terminal to the switch. See Figure F8. RANGER 305D...

  • Page 91: Brush And Slip Ring Service Procedure

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 92 Another sign of sticking brushes is instability or loss of both weld and auxiliary output, but the machine may Note: See Figure F.9 for general locations. begin to work properly, for a short time, after being jarred or moved. RANGER 305D...

  • Page 93: Rotor Resistance And Ground Test

    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.
  • Page 94 7. If this test meets the resistance specifica- 4. Using the ohmmeter, check the rotor winding tions, continue testing using the dynamic resistance across the slip rings. See Figure rotor resistance and ground test. F.9. Normal resistance is approximately 4.7 *ohms, degrees Fahrenheit. (25degreesC.). RANGER 305D...
  • Page 95 (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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 96 4. Start the engine and run it at high idle speed peratures will produce lower resistance. (3650 RPM). The resistance should read approximately 5* ohms at 77 degrees Fahrenheit (25 deg. C.) RANGER 305D...

  • Page 97: Rotor Voltage Test

    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.
  • Page 98 6. If the voltage measures zero or very near “If the voltage measures about 3 to 5 zero, the rotor flashing circuit may be faulty VDC” or the rotor may be shorted. RANGER 305D...
  • Page 99 #7 and #9 to the field bridge rectifier, (D3). the stator. All other stator leads should remain discon- nected and isolated at this time. RANGER 305D...
  • Page 100 NOTES F-46 F-46 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 101: 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 102 10. Perform the Rotor Resistance Test. Perform the Brush and Slip Ring Service Procedure. RANGER 305D...
  • Page 103 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...
  • Page 104 NOTES F-50 F-50 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 105: Stator Voltage Test

    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.
  • Page 106 For the lower receptacle, place the probes lems, and the circuit breakers are not tripped directly into the receptacle, or connect to or defective, the stator is defective and leads #6E and 5B. See Figure F.12. See should be replaced. wiring diagram. RANGER 305D...
  • Page 107 Amphenol and the stator winding. windings. See wiring diagram. RANGER 305D...
  • Page 108 If there are no wiring lems, and the circuit breakers are not tripped problems, the stator is defective and should or defective, the stator is defective and be replaced. should be replaced. * These values ar maximum for a cold machine. RANGER 305D...

  • Page 109: Stator Short Circuit & Ground Test

    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.
  • Page 110 . 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...

  • Page 111: Output Rectifier Bridge Test

    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.
  • Page 112 Remove these leads and position them so they do not come in contact with any part of the rectifier. See figure F16. See wiring diagram. Electrically isolate the DC output termi- nals of the rectifier: RANGER 305D...
  • Page 113 Precise ohm values for this test will vary depending on a test equipment used. FIGURE F.16 – SHUNT/RECTIFIER LEADS NEG. POS. OUTPUT RECTIFIER CENTER BRIDGE BOTTOM W4,W5 W6,W11 FROM SHUNT CHOKE RANGER 305D...
  • Page 114 (High Resistance) DC(-) REVERSE BIAS (High Resistance) DC(-) REVERSE BIAS (High Resistance) DC(+) REVERSE BIAS (High Resistance) DC(+) REVERSE BIAS (High Resistance) DC(+) REVERSE BIAS (High Resistance) 11. Reconnect all leads. 12. Perform the Case Cover replacement Procedure. RANGER 305D...

  • Page 115: Chopper Module Function Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 116 Module Terminals B2+ to B3-, and B5+ to B6 tifier, and the stator weld winding. See Figure and between the welder output terminals. F.17. See the wiring diagram. Perform the See Figure F.17. See the wiring diagram. Stator Voltage Tests, and the Output Rectifier Test. RANGER 305D...
  • Page 117 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 sig- nal between leads #23 +and #25-, where they connect to the chopper module PC board. RANGER 305D...
  • Page 118 NOTES F-64 F-64 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 119: Chopper Module Resistance Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 120 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. RANGER 305D...
  • Page 121 6K to 9K 200k or higher 400k or higher 200k or higher 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...
  • Page 122 NOTES F-68 F-68 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 123: Weld Control Board Pwm Gate Signal Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 124 12. If voltage is very low or not present, check 20. Perform the Case Cover Replacement leads #13 and #14 for faulty or damaged wiring or connections between the control PC board and the chopper module. Procedure. RANGER 305D...

  • Page 125: Weld Control Feedback Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 126 PC board Molex plugs. The voltage should plays are about the same or very close to be the same as was measured at the weld the reading on the external meters, the terminals. feedback is probably good, and this test is complete. RANGER 305D...
  • Page 127 19. The shunt used in this machine will produce 50 millivolts at a load of 400 amps, or 8 22. Perform the Case Cover Replacement amps per millivolt. Procedure. RANGER 305D...
  • Page 128 NOTES F-74 F-74 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 129: Control Potentiometer And Mode Switch Resistance Test

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 130 Be very careful that the connec- tion pins in P7 are not damaged or spread out. Cover Replacement procedure. 6. The resistance should be very high. A read- ing of 500,000 (500k) ohms or higher is acceptable. RANGER 305D...
  • Page 131 If the resistance readings are not as specified in the table, replace the potentiome- ter 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...
  • Page 132 NOTES F-78 F-78 All manuals and user guides at all-guides.com RANGER 305D...
  • Page 133 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 134 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. RANGER 305D...
  • Page 135 PIN “C” (#2B) to PIN “D” (#4B) 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...
  • Page 136 NOTES F-82 F-82 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 137: Output Rectifier Bridge And Choke Removal And Replacement

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 138 11. Remove the nuts and lock washers hold- ing 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...
  • Page 139 3. Swing the case front back into position. 4. Mount the D4 diode bridge and the CR1 engine protection relay to the center baf- fle assembly. See Wiring Diagram. 5. Attach the case front to the machine base with four screws. RANGER 305D...
  • Page 140 NOTES F-86 F-86 All manuals and user guides at all-guides.com RANGER 305D...

  • Page 141: Chopper Module Removal And Replacement

    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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 142 HL W9, SL 302 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. RANGER 305D...
  • Page 143 (but not the threads). Tighten the fasteners to between 50-60 in- lbs. TERMINAL LEADS Heavy lead W11, small lead 14 HL W5, SL 13 HL W8 HL W6 HL W4, SL 301 HL W9, SL 302 RANGER 305D...
  • Page 144 NOTES F-90 F-90 All manuals and user guides at all-guides.com RANGER 305D...
  • Page 145 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 146 11. Remove the coolant recovery tank by pulling Be sure to mark leads for accurate re-con- it straight up and off of its mounting bracket. nection. See Figure F.22. RANGER 305D...
  • Page 147 TROUBLESHOOTING & REPAIR F-93 F-93 All manuals and user guides at all-guides.com STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – WIRE GUIDE HOLE HOLE FIGURE F.22 – ALTERNATOR LEADS BATTERY IGNITION OIL PRESSURE SWITCH RANGER 305D...
  • Page 148 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...
  • Page 149 8. Evenly tighten all the screws to a torque of 17 to 19 Ft-Lbs. 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. RANGER 305D...
  • Page 150 (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. RANGER 305D...

  • Page 151: Normal Open Circuit Voltage Waveform (120 Vac Supply

    Note that each vertical division represents 50 volts and that each horizontal division rep- resents 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...

  • Page 152: Normal Open Circuit Voltage Waveform (Stick

    Note that each vertical division represents 50 volts and that each horizontal division rep- resents 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...

  • Page 153: Normal Weld Voltage Waveform (Stick Cc

    The machine was loaded with a resis- tance 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...

  • Page 154: Normal Open Circuit Voltage Waveform (Wire Cv Tap

    Note that each vertical division represents 50 volts and that each horizontal division rep- resents 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...

  • Page 155: Normal Weld Voltage Waveform (Wire Cv

    1 millisecond in time. The machine was loaded with a resis- tance 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...

  • Page 156: Retest After Repair

    240-270* 216-240 40-45 120-135 115-130 18-22 * Upper limit reflects cold machine, voltage will be below 132/264 for machine at normal operating temperature. 42 VOLT WIRE FEEDER POWER Open Circuit Voltage Load Volts Load Amps 42-46 40-44 7.0-9.0 RANGER 305D...
  • Page 157 Schematic - Chopper PC Bd - All Codes (M19792-1) ..............G-37 PC Board Assembly - Chopper PC Bd - All Codes (L11845-1)..........G-38 NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice- able. The Assembly drawings are provided for reference only. RANGER 305D...
  • Page 158 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 10926 (G4250) RANGER 305D- KUBOTA - WIRING DIAGRAM Twisted Pair D1 - THREE PHASE BRIDGE RECTIFIER 206S P6-J6 VOLTS STATOR 204S Shunt HEATSINK WELD...
  • Page 159 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11121 (G4571) RANGER 305D- KUBOTA - WIRING DIAGRAM Twisted TWISTED PAIR Pair P6-J6 206S 204S Shunt D1 - THREE PHASE BRIDGE RECTIFIER VOLTS STATOR...
  • Page 160 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11188, 11275 (G4571-1) RANGER 305D- KUBOTA - WIRING DIAGRAM Twisted Pair TWISTED PAIR 206S 204S P6-J6 Shunt D1 - THREE PHASE BRIDGE RECTIFIER STATOR...
  • Page 161 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11027 (G4226) RANGER 305D CE KUBOTA WIRING DIAGRAM - UK Twisted Pair D1 - THREE PHASE BRIDGE RECTIFIER 206S P6-J6 VOLTS STATOR 204S Shunt...
  • Page 162 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11122 (G4572) RANGER 305D CE KUBOTA WIRING DIAGRAM - UK Twisted Pair D1 - THREE PHASE BRIDGE RECTIFIER P6-J6 206S VOLTS STATOR 204S Shunt...
  • Page 163 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11189, 11314 (G4572-1) RANGER 305D CE KUBOTA WIRING DIAGRAM - UK Twisted TWISTED PAIR Pair 206S P6-J6 204S Shunt D1 - THREE PHASE BRIDGE RECTIFIER...
  • Page 164 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11039 (G4409) RANGER 305D CE KUBOTA - WIRING DIAGRAM - EUROPE Twisted Pair D1 - THREE PHASE BRIDGE RECTIFIER 206S P6-J6 VOLTS STATOR 204S...
  • Page 165 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11123 (G4573) RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE Twisted TWISTED PAIR Pair 206S P6-J6 204S Shunt D1 - THREE PHASE BRIDGE RECTIFIER VOLTS...
  • Page 166 All manuals and user guides at all-guides.com G-10 G-10 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11190, 11315 (G4573-1) RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE Twisted TWISTED PAIR Pair 206S P6-J6 204S Shunt D1 - THREE PHASE BRIDGE RECTIFIER...
  • Page 167 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: RANGER 305D TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. EQUIPMENT TYPE:...
  • Page 168 + STUD THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: RANGER 305D EQUIPMENT TYPE: UNLESS OTHERWISE SPECIFIED TOLERANCE TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
  • Page 169 R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION OF LIN C OLN GLOBAL, INC. 20-35 OHMS FULL PROPRIETARY & CONFIDENTIAL: RANGER 305D EQUIPMENT TYPE: UNLESS OTHERW ISE SPEC IF IE D TOLERAN CE...
  • Page 170 DESIGN INFORM ATION PA GE ___ O F ___ MANUFAC TURIN G TOLERANCE PER E205 REFERENCE: RANGER 305D ON 2 PLAC E DECIMA LS IS ± .02 DRAW N BY: SUBJECT: ON 3 P LACE D ECIM ALS IS ± .002 L11946 ON ALL ANG LES IS ±...
  • Page 171 R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION OF LIN C OLN GLOBAL, INC. 20-35 OHMS FULL PROPRIETARY & CONFIDENTIAL: RANGER 305D EQUIPMENT TYPE: UNLESS OTHERW ISE SPEC IF IE D TOLERAN CE...
  • Page 172 PA GE ___ O F ___ MANUFAC TURIN G TOLERANCE PER E205 REFERENCE: ON 2 PLAC E DECIMA LS IS ± .02 RANGER 305D ON 3 P LACE D ECIM ALS IS ± .002 DRAW N BY: SUBJECT: ON ALL ANG LES IS ± .5 OF A DEGREE...
  • Page 173 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: RANGER 305D CE (UK) TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
  • Page 174 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: RANGER 305D CE (UK) TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
  • Page 175 R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION OF LIN C OLN GLOBAL, INC. PROPRIETARY & CONFIDENTIAL: 240-265 OHMS EMPTY RANGER 305D CE (UK) EQUIPMENT TYPE: UNLESS OTHERW ISE SPEC IF IE D TOLERAN CE...
  • Page 176 PA GE ___ O F ___ MANUFAC TURIN G TOLERANCE PER E205 REFERENCE: ON 2 PLAC E DECIMA LS IS ± .02 RANGER 305D CE (UK) ON 3 P LACE D ECIM ALS IS ± .002 DRAW N BY: SUBJECT: ON ALL ANG LES IS ±...
  • Page 177 R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION OF LIN C OLN GLOBAL, INC. PROPRIETARY & CONFIDENTIAL: 240-265 OHMS EMPTY RANGER 305D CE (UK) EQUIPMENT TYPE: UNLESS OTHERW ISE SPEC IF IE D TOLERAN CE...
  • Page 178 PA GE ___ O F ___ MANUFAC TURIN G TOLERANCE PER E205 REFERENCE: ON 2 PLAC E DECIMA LS IS ± .02 RANGER 305D CE (UK) ON 3 P LACE D ECIM ALS IS ± .002 DRAW N BY: SUBJECT: ON ALL ANG LES IS ±...
  • Page 179 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: RANGER 305D CE (UK) TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
  • Page 180 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: RANGER 305D CE (UK) TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
  • Page 181 R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION OF LIN C OLN GLOBAL, INC. 240-265 OHMS EMPTY PROPRIETARY & CONFIDENTIAL: RANGER 305D CE (EUROPE) EQUIPMENT TYPE: 20-35 OHMS FULL UNLESS OTHERW...
  • Page 182 PA GE ___ O F ___ MANUFAC TURIN G TOLERANCE PER E205 REFERENCE: ON 2 PLAC E DECIMA LS IS ± .02 RANGER 305D CE (EUROPE) ON 3 P LACE D ECIM ALS IS ± .002 DRAW N BY: SUBJECT: ON ALL ANG LES IS ±...
  • Page 183 R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION OF LIN C OLN GLOBAL, INC. 240-265 OHMS EMPTY PROPRIETARY & CONFIDENTIAL: RANGER 305D CE (EUROPE) EQUIPMENT TYPE: 20-35 OHMS FULL UNLESS OTHERW...
  • Page 184 PA GE ___ O F ___ MANUFAC TURIN G TOLERANCE PER E205 REFERENCE: ON 2 PLAC E DECIMA LS IS ± .02 RANGER 305D CE (EUROPE) ON 3 P LACE D ECIM ALS IS ± .002 DRAW N BY: SUBJECT: ON ALL ANG LES IS ±...
  • Page 185 All manuals and user guides at all-guides.com G-29 G-29 ELECTRICAL DIAGRAMS SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 1 OF 5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 186 All manuals and user guides at all-guides.com G-30 G-30 ELECTRICAL DIAGRAMS SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 2 OF 5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 187 All manuals and user guides at all-guides.com G-31 G-31 ELECTRICAL DIAGRAMS SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 3 OF 5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 188 All manuals and user guides at all-guides.com G-32 G-32 ELECTRICAL DIAGRAMS SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 4 OF 5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 189 All manuals and user guides at all-guides.com G-33 G-33 ELECTRICAL DIAGRAMS SCHEMATIC - WELD CONTROL PC BD - ALL CODES (G4108-1) PG 5 OF 5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 190 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.
  • Page 191 All manuals and user guides at all-guides.com G-35 G-35 ELECTRICAL DIAGRAMS SCHEMATIC - PULL COIL PC BD - ALL CODES (G4117-1) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 192 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.
  • Page 193 All manuals and user guides at all-guides.com G-37 G-37 ELECTRICAL DIAGRAMS SCHEMATIC - CHOPPER PC BD - ALL CODES (M19792-1) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 305D...
  • Page 194 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.

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