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The machine will weld, but the
welding arc is “cold”. The engine
runs normally and the auxiliary
power is normal. (continued)
7. The weld cables may be coiled,
or wrapped around metal reels
or racks. This can cause exces-
sive electrical inductance in the
weld circuit. Try welding after
uncoiling the cables, or discon-
nect the existing cables and
weld with a set of adequately
sized, short test cables.
6. With the above load applied, the
engine should maintain at least
3350 RPM. If the engine cannot
maintain this RPM, make sure
there is an adequate supply of
clean, fresh fuel. Check the fuel
filter and the air filter. Replace
any filter that is dirty or dam-
aged. If this doesnʼt help, the
engine should be serviced.
7. Compare the volt and amp
readings shown on the external
meters with the readings dis-
played on the machineʼs front
panel. If these readings differ
significantly, perform the WELD
CONTROL FEEDBACK TEST.
8. If the maximum weld output
cannot be obtained even though
the engine maintains correct
RPM, and the front panel dis-
plays are reading accurately.
Check for damaged conductors
and loose or damaged connec-
tions at each of the large weld-
current carrying conductors that
connect the stator, output rectifi-
er, chopper module, choke,
shunt, and output terminals.
See the wiring diagram.
9. If all of the these connections
are good, perform the Rotor
Voltage Test, the Stator
Voltage Test, the Output
Rectifier Test, and the Power
Module Resistance Test..
10. Perform the CONTROL
POTENTIOMETER AND
MODE SWITCH RESIS-
TANCE TEST. Perform the
REMOTE RECEPTACLE
RESISTANCE TEST.
Replace the weld control PC
board.
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F-7 F-7
RANGER 305D
TROUBLESHOOTING & REPAIR
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.
CAUTION
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELD OUTPUT PROBLEMS