Lincoln Electric RANGER 300 D Service Manual Download Page 1

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iew Safety Info

SVM148-B

February, 2004

For use with machine code numbers

10399

thru

10850

RANGER 300 D and 300 DLX

RETURN TO MAIN INDEX

SERVICE MANUAL

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part.

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN-
UAL AND THE SAFETY PRE-
CAUTIONS CONTAINED
THROUGHOUT.

And, most

importantly, think before you act
and be careful.

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Summary of Contents for RANGER 300 D

Page 1: ... and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MAN UAL AND THE SAFETY PRE CAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohi...

Page 2: ...BLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A...

Page 3: ... Ground the work or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be ...

Page 4: ...e welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to...

Page 5: ...llant à proximité au soudage à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans l...

Page 6: ...NOTES RANGER 300 D AND 300 DLX ...

Page 7: ...Remote Control A 6 Welding Terminals A 6 Electrical Output Connections A 6 Operation Section B Safety Instructions B 2 General Description B 3 Design Features B 3 Recommended Applications B 4 Limitations B 4 Controls and Settings B 5 Engine Operation B 9 Welding Operation B 11 Auxiliary Power B 17 Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair ...

Page 8: ...3 Storing A 3 Stacking A 3 Tilting A 3 High Altitude Operation A 4 Towing A 4 Lifting A 4 Additional Safety Precautions A 4 Pre operation Engine Service A 4 Oil A 4 Fuel A 5 Engine Coolant A 5 Battery Connections A 5 Exhaust Deflector A 5 Spark Arrester A 5 High Frequency Generation for TIG Applications A 6 Remote Control A 6 Welding Terminals A 6 Electrical Connections A 6 Machine Grounding A 6 W...

Page 9: ...Current 25 100 Duty Cycle 200 DC Constant Voltage 300 D 20 60 1 300 DC Constant Voltage 300 DLX 30 100 280 DC Constant Voltage 300 DLX 30 OUTPUT WELDER AND GENERATOR Max Open Auxiliary Power for Welding Ranges Circuit Voltage Auxiliary Power 2 Wire Feeders 40 300 Amps 80 Volts RMS 12 000 Continuous Watts 42V 60 Hz 8 Amps 3 Constant Current 3700 RPM 60 Hz 120 240 VAC 100 Duty Cycle 120V 60 Hz 8 Amp...

Page 10: ... of moving parts hot metal surfaces and live electrical devices STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the parts...

Page 11: ... specific requirements for use on public highways LIFTING The RANGER 300 weighs approximately 1150 lbs 522 kg A lift bail is mounted to the machine frame and should always be used when lifting the machine ADDITIONAL SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury Do not lift this machine using lift bail if it is equipped with a heavy acces sory such as trailer or gas cylinder Lift only with ...

Page 12: ...s shipped with the negative battery cable disconnected Before you operate the machine make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten the negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused fo...

Page 13: ...ing hot welding terminals WELDING TERMINALS ALWAYS ON position or cold welding terminals WELDING TERMINALS REMOTELY CONTROLLED position ELECTRICAL CONNECTIONS See Figure A 1 for location of the 120 and 240 volt receptacles weld output terminals circuit breakers and ground stud MACHINE GROUNDING Because the RANGER 300 creates its own power from its diesel engine driven generator and if the machine ...

Page 14: ...D EQUIPMENT The control panel of the RANGER 300 features three auxiliary power receptacles See Figure A 1 Two 15 amp 120 volt duplex double outlet recep tacles One 50 amp 120 240 volt simplex single outlet receptacle Through these receptacles the machine can supply up to 12 000 rated continuous watts of single phase 60 Hz AC power For further protection against electric shock any elec trical equip...

Page 15: ...uirements A double pole double throw transfer switch in con junction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter The following information and the connection diagram Figure A 2 can be used as a guide by the electrician for most applications to premises wiring 1 Install a double pole double throw switch between the power compan...

Page 16: ...CONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE No 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS 240 VOLT GROUNDED CONDUCTOR 50AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 50 AMP 120 240 VOLT RECE...

Page 17: ...NOTES RANGER 300 D AND 300 DLX Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 18: ...gine Controls B 7 Engine Operation B 9 Before Starting the Engine B 9 Starting the Engine B 9 Cold Weather Starting B 10 Stopping the Engine B 10 Break in Period B 10 Welding Operation B 11 General Information B 11 AC DC Stick Constant Current Welding B 11 AC DC TIG Constant Current Welding B 12 DC Wire Feed Welding CV with Ranger 300 DLX B 13 DC Wire Feed Welding CV with Ranger 300 D B 14 Carbon ...

Page 19: ...Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Ke...

Page 20: ...easy connection of Lincoln remote control accessories FOR AUXILIARY POWER 12 000 watts of 120 240 volt 60Hz AC auxiliary power Power for tools lights electric pumps and for standby emergency power Ability to drive a 2 HP motor provided it is started under no load Two 15 amp industrial grade 120 volt duplex recep tacles for up to 60 amps of 120 volt power One 50 amp 120 240 volt dual voltage recept...

Page 21: ... Voltmeter for reading CV wire feed welding arc volt age Built in contactor with front panel selection of cold or hot welding terminals Aluminum TIG welding when used with K930 1 TIG Module Output contactor control with Amptrol Recommended wire feeders are the LN 25 with 42 Volt Remote Output Control Module or with internal contactor and all models of the LN 7 RECOMMENDED APPLICATIONS WELDER The R...

Page 22: ...LARITY SWITCH Selects DC DC or AC welding output Color codings aid in the proper selection of stick blue or wire feed red polarity setting On the RANGER 300 DLX the color setting of the polarity switch must match the color setting of the OUTPUT RANGE SELECTOR Never change the polarity switch setting while welding since this could damage the switch 4 CONTROL AT WELDER REMOTE CONTROL SWITCH Allows t...

Page 23: ... volt power to operate one or two electrical devices 8 50 AMP 120 240 VOLT RECEPTACLE Connection point for supplying 240 volt power to operate one electrical device 9 WELD OUTPUT TERMINAL TO WORK WITH FLANGE NUT Provides the connection point for the work cable 10 WELD OUTPUT TERMINAL TO ELECTRODE HOLDER WITH FLANGE NUT Provides the con nection point for the electrode holder 11 GROUND STUD Provides...

Page 24: ...NALS ALWAYS ON mode or with a Ranger 300D When the electrode touches work the welding arc is initiated and the engine accelerates to full speed Low idle and in the WELDING TERMINALS REMOTELY CONTROLLED mode Pressing the gun trigger or Amptrol closes the Ranger 300 DLX output contactor and causes the engine to accel erate to full speed After the gun trigger or Amptrol is released and or welding cea...

Page 25: ...rns on while the engine is running the engine protection system will stop the engine It is normal for the light to go on when the Engine switch is switched to the ON position with the engine not running It will go off after one minute to prevent discharging the battery if the engine is not started If this happens the engine protection circuit must be reset by turning the Engine switch to the OFF p...

Page 26: ... tighten securely NOTE DO NOT allow the RANGER 300 to run out of fuel If it does you will have to bleed the injection sys tem See the Maintenance section of this manual and the Engine Operator s Manual for instructions on bleeding the fuel injection system USE DIESEL FUEL ONLY Purchase diesel fuel in quantities that will be used within 30 days to assure freshness STARTING THE ENGINE Remove all loa...

Page 27: ...n This turns off the fuel solenoid You can also stop the engine by turning off the fuel valve located on the fuel filter housing BREAK IN PERIOD Any engine will use a small amount of oil during its break in period For the diesel engine on the RANGER 300 break in is about 50 running hours Check the oil every four hours during break in Change the oil after the first 50 hours of operation every 100 h...

Page 28: ...sted by setting the POLARITY SWITCH the OUTPUT RANGE dial and the FINE CONTROL dial on the output control panel to the set tings that are best for your selected welding process AC DC STICK CONSTANT CURRENT WELDING 1 Remove the flange nuts from output terminals and place the work and electrode welding cables over the terminals See Figure B 4 Replace and tight en the flange nuts securely Be sure the...

Page 29: ...efer to IM 528 with the TIG module or refer to Table B 2 for AC TIG welding 4 Set the POLARITY SWITCH to the desired polarity 5 Do not AC TIG weld on the 300 AC range setting The output current may exceed the rating of the RANGER 300 6 Start the arc and begin welding NOTE When using the RANGER 300 for AC TIG weld ing of aluminum the TIG Module is to be set for CON TINUOUS HF AFTER YOU FINISH WELDI...

Page 30: ...tions can affect the ultimate results of this application Request Lincoln publi cation N 675 for additional information Recommended Outershield electrodes are 045 1 1 mm 052 1 3 mm and 1 16 1 6 mm Outershield 71 and 1 16 1 6 mm Outershield 70 Request Lincoln publication GS 200 for additional information For MIG welding the recommended electrodes are 030 0 8 mm 035 0 9 mm and 045 1 1 mm L 50 and L ...

Page 31: ... stable arc for the applica tion 7 Strike an arc and begin welding The OUTPUT control can be adjusted while welding DO NOT change the RANGE switch setting while welding This can result in damage to the switch AFTER YOU FINISH WELDING 1 Stop the engine 2 Allow the work to cool completely 3 Remove the work clamp from the work CARBON ARC GOUGING CONSTANT CURRENT 1 The recommended electrode is a 3 16 ...

Page 32: ...SPOOL GUN K488 CONTROL MODULE Touch electrode to work Welding starts immediately and engine goes to high idle Press Amptrol Welding starts immediately Press gun trigger Ranger 300 DLX contactor closes Welding starts immediately and engine goes to high idle Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger Ranger 300 DLX contactor clo...

Page 33: ...CV LN 25 INTERNAL CONTACTOR WIRE FEED CV LN 7 K240 CONTACTOR KIT Touch electrode to work Welding starts immediately and engine goes to high idle Press Amptrol Welding starts immediately Press gun trigger LN 25 contactor closes Electrode touches work welding starts immediately and engine goes to high idle Press gun trigger K240 contactor closes Welding starts immediately NO YES S23732 10 NO S23732 ...

Page 34: ...e of the 120 V duplex recepta cles SIMULTANEOUS WELDING AND POWER LOADS Auxiliary power ratings are with no welding load Simultaneous welding and power loads are permitted by the following table The permissible currents shown assume that current is being drawn from either the 120 V or 240 V supply not both at the same time OPERATION B 17 B 17 RANGER 300 D AND 300 DLX Return to Section TOC Return t...

Page 35: ...20 V DUPLEX RECEPTACLES The 120 V auxiliary power receptacles should only be used with three wire grounding type plugs or approved double insulated tools with two wire plugs MAXIMUM CURRENT DRAW FROM 120 V DUPLEX RECEPTACLES NO WELDING EACH HALF OF EACH 120 V DUPLEX TOTAL FROM ONE 120 V DUPLEX TOTAL FROM BOTH 120 V DUPLEXES 240 V LOAD FROM FULL KVA RECEPTACLE 0 20 AMPS 30 AMPS 40 AMPS 50 AMPS 15 A...

Page 36: ... Ranger 300 D Options Accessories C 2 Connection of Lincoln Electric Wire Feeders C 3 Connection of the LN 25 Using the K857 Remote Control C 3 Connection of the LN 25 Using the K444 1 Remote Control C 4 Connection of the LN 25 Using the K624 1 42 Volt Remote Control C 5 Connection of the LN 7 C 6 Connection of the LN 8 Using the K867 Universal Adapter C 7 Connection of the K488 SG Control Module ...

Page 37: ...separately K939 1 Docking Kit For mounting the K930 1 TIG Module on top of the Ranger 300 K936 1 Control Cable Control cable for connecting the K930 1 TIG Module to a RANGER 300 DLX K936 3 Control Cable Control cable for connecting the K930 1 TIG module to a Ranger 300 D K814 Arc Start Switch A remote start switch used in conjunction with the K930 1 TIG Module to energize the RANGER 300 DLX output...

Page 38: ... Attach the single lead from the LN 25 to the work using the spring clip on the end of the lead This is only a sense lead it carries no welding current 4 Place the IDLER switch in the AUTO or HIGH position as desired If you are using an LN 25 without an internal contac tor the electrode will be HOT when the Ranger 300 is started 5 Set the OUTPUT RANGE switch to WIRE WELD ING CV 6 Set the WELDING T...

Page 39: ... IDLER switch in the AUTO or HIGH position as desired If you are using an LN 25 without an internal contac tor the electrode will be HOT when the Ranger 300 is started 5 Set the OUTPUT RANGE switch to WIRE WELD ING CV 6 Set the WELDING TERMINALS switch to WELD ING TERMINALS ALWAYS ON 7 Adjust wire feed speed at the LN 25 8 Set the LOCAL REMOTE switch to REMOTE if a K444 1 remote control is used El...

Page 40: ...henol of the Ranger 300 DLX as indicated in Figure C 3 Make the proper connections for local or remote control according to Figure C 3 4 Connect the K626 XX Control Cable to the LN 25 Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control ...

Page 41: ...X 5 Place the IDLER switch in the HIGH position Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manu...

Page 42: ... connections for local or remote control according to Figure C 5 4 Connect the K196 input cable to the LN 8 5 Place the IDLER switch in the HIGH position Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The en...

Page 43: ...e Incorrect switch position could result in damage to the SG Control Module and or the Ranger 300 DLX 5 Place the IDLER switch in the HIGH position Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine g...

Page 44: ... Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 6 Set the LOCAL REMOTE switch to REMOTE 7 Se...

Page 45: ...NOTES RANGER 300 D AND 300 DLX Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 46: ...tenance D 3 Engine Maintenance D 3 Oil D 3 Changing the Oil D 3 Oil Filter D 3 Fuel D 4 Bleeding the Fuel System D 4 Air Cleaner D 4 Tightening the Fan Belt D 4 Cooling System D 4 Spark Arrester Screen D 5 Battery Maintenance D 5 Cleaning the Battery D 5 Checking Specific Gravity D 5 Checking Electrolyte Level D 5 Charging the Battery D 6 Welder Generator Maintenance D 6 Storage D 6 Cleaning D 6 B...

Page 47: ...ENANCE SCHEDULE TABLE D 1 1 Replace air filter element after 600 hours of operation or sooner under dusty operating conditions 2 If the engine is operated under heavy load in high ambient temperatures or under dusty conditions change the oil and oil filter every 100 hours Refer to your Kubota Engine Operator s Manual for periodic maintenance at 500 hours and beyond KUBOTA ENGINE MAINTENANCE COMPON...

Page 48: ...oil level again FIGURE D 1 OIL COMPONENT LOCATIONS OIL FILTER Change the oil filter the first time after 50 hours of operation Then under normal operating conditions change the oil filter at every oil change See Table D 2 for recommended oil filters Change the oil filter as follows 1 Drain the oil from the engine and allow the oil filter to drain 2 Remove the old filter spin it off and discard it ...

Page 49: ...t is sticking to the element blow compressed air through the element from the inside out Turn the element as you apply air Air pressure should be under 99 psi 68 newton cm2 Replace the fil ter if there is carbon or oil on the element 3 Replace the element at least every 600 hours of operation and sooner under dusty conditions TIGHTENING THE FAN BELT If the fan belt is loose the engine can overheat...

Page 50: ...ter Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an igni tion switch turn it off when engine is not running CLEANING THE BATTERY 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 ammonia solution or a solution of 1 4 pound 0 1113 kg of baking soda and 1 qua...

Page 51: ...ery charger manu facturer for proper charger settings and charging time WELDER GENERATOR MAINTENANCE STORAGE Store the RANGER 300 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in par ticularly dirty areas BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly I...

Page 52: ...DLX ONLY 12 RADIATOR ASSEMBLY 13 CHOKE ASSEMBLY 14 LIFT BAIL WELDED ASSEMBLY 15 CASE BACK ASSEMBLY 16 FIELD CAPACITOR AND RECTIFIER BRIDGE 17 CONTACTOR RANGER 300 DLX ONLY 18 FUEL SHUTOFF IDLER ASSEMBLY 19 CASE TOP 20 DOOR ASSEMBLY 1 OUTPUT TERMINALS 2 ENGINE CONTROLS 3 AUXILIARY POWER RECEPTACLES 4 OUTPUT CONTROL PANEL 5 REACTOR ASSEMBLY 6 FUEL TANK 7 DIESEL ENGINE 8 ROTOR STATOR ASSEMBLY 9 BASE ...

Page 53: ...NOTES RANGER 300 D AND 300 DLX Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 54: ...als E 5 TABLE OF CONTENTS THEORY OF OPERATION SECTION RANGE SWITCH REACTOR STATOR ROTOR MECHANICAL ROTATION ENGINE GLOW PLUGS BATTERY 6 PIN AMPHENOL 14 PIN AMPHENOL OUTPUT CONTROL REMOTE SWITCH BY PASS BOARD SHUTDOWN SOLENOID STARTER MOTOR ALTERNATOR IDLER SOLENOID PRINTED CIRCUIT BOARD FIELD CAPACITOR FIELD BRIDGE 115 230VAC RECEPTACLES AC AC OUTPUT RECTIFIER BRIDGE CAPACITORS PART OF RANGE SWITC...

Page 55: ...board and also for the idler sole noid The idler solenoid is mechanically connected to the engine s throttle linkage If welding or auxiliary current is being drawn from the Ranger 300 the print ed circuit board activates the idler solenoid which then brings the engine to the high RPM state When no output current is sensed either weld or auxiliary the printed circuit board deactivates the idler sol...

Page 56: ...ng offers 115VAC and is tapped to also provide 42VAC The current draw from this winding should be limited to 8 amps These volt ages and remote control signals are fed through the by pass filter board to the amphenol receptacles THEORY OF OPERATION E 3 E 3 RANGER 300 D AND 300 DLX Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to ...

Page 57: ... output voltage THEORY OF OPERATION E 4 E 4 RANGER 300 D AND 300 DLX Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 4 WELD WINDING REACTOR AND RANGE SWITCH NOTE Unshaded areas of Block Logic Diagram are the subject of discussion RANGE SWITCH REACTOR STATOR ROTOR MEC...

Page 58: ... lower but stiffer DC output is passed through the tapped portion of the choke the polarity switch and output contactor to the output terminals In the Ranger 300DLX machines the output contactor is in series with the electrode terminal and must be energized closed to provide welding voltage at the output terminals THEORY OF OPERATION E 5 E 5 RANGER 300 D AND 300 DLX Return to Section TOC Return to...

Page 59: ...NOTES RANGER 300 D AND 300 DLX Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 60: ...eld Output Voltage Waveform CV Mode High Tap F 42 Typical DC Weld Output Voltage Waveform F 43 Typical AC Weld Output Voltage Waveform F 44 Abnormal Open Circuit DC Weld Voltage Waveform F 45 Abnormal Open Circuit Weld Voltage Waveform High CV Mode F 46 Normal Open Circuit Weld Voltage Waveform High CV Mode F 47 Normal Open Circuit DC Weld Voltage Waveform F 48 Normal Open Circuit AC Weld Voltage ...

Page 61: ...n labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machin...

Page 62: ... on equipment Do not touch electrically hot parts Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installa...

Page 63: ...D COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical dam age is evident 1 Contact your local Lincoln Authorized Field Service Facility 1 Contact The Lincoln Electric Service Dept 1 800 833 9353 WELD No weld output and no auxiliary power Engine operates normally 1 Make sure the REMOTE switch S8 is in the proper position MACHINE CONTROL if a remote control unit is NOT con nected to the ma...

Page 64: ...s 64 to 74VDC If the open circuit voltage is NOT present at the welder output terminals contact your local Lincoln Authorized Field Service Facility 3 If normal open circuit voltage is present at the output terminals check the welding cables clamps and electrode holder for loose or broken connec tions 1 On DLX machines the output contactor or associated leads may be faulty See the Wiring Diagram T...

Page 65: ...roubleshooting assistance before you proceed Call 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS continued from page F 5 3 Check the reactor range switch S2 and associated wires for loose or faulty connections Check the reactor winding for continuity and test to be sure it is NOT grounded to the reactor iron 4 Check the choke L1 pola...

Page 66: ...n Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No auxiliary power at receptacles welding output is normal engine runs normally 1 If the machine is equipped with circuit breakers check circuit breakers Reset if tripped 2 Make sure the outpu...

Page 67: ...has low welding output and low auxiliary output 1 If a remote control unit is NOT connected to the machine make sure the REMOTE switch is in the proper position MACHINE CONTROL 2 The brushes may be worn Contact your local Lincoln Authorized Field Service Facility 3 The Engine RPM may be low 1 If the engine high idle RPM is low perform the Engine Throttle Adjustment Test 2 Perform the Rotor Voltage...

Page 68: ...wer are nor mal 1 Make sure the polarity mode switch S1 is in the proper posi tion and is seated correctly 2 Make sure the electrode and polarity are correct for the process being used 1 Perform the Output Rectifier Bridge Test 2 Check the choke L1 the polar ity mode switch S1 and asso ciated wires for loose or faulty connections Check the choke winding for continuity and test to be sure it is NOT...

Page 69: ...2 is in the proper position and seated correctly 2 Make sure the wire feeder and welding cables are connected correctly 1 Check the operation of the range switch S2 and check the associated wires for loose or faulty connections See the Wiring Diagram 2 Check the continuity from leads C1 to lead W1 located in the main stator See the Wiring Diagram On DLX machines also check leads C2 C3 and C4 to le...

Page 70: ...S OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will not idle down to low speed Machine has normal weld output and auxiliary power 1 Make sure the idler switch S5 is in the Auto position 2 Make sure there is NOT an external load on the weld termi nals nor the auxiliary power receptacles 1 With the idler switch S5 in the Auto position no external load connected to the machi...

Page 71: ...MS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will not go to high idle when attempting to weld Welding out put is normal when idler switch is in HIGH position Automatic idle function works properly when the auxiliary power is loaded 1 Make sure the welding cables and connections are tight 2 If welding without a control cable connected to the DLX machine t...

Page 72: ...n or faulty con nections in the sensing leads 254 254A and lead 3 and 6 Make sure leads 3 and 6 are looped through the AC cur rent sensor 2 The control board may be faulty Replace 3 Perform the High Speed Solenoid Resistance Test 4 Check the leads and associat ed connections between the high speed solenoid and the control board The engine will not crank or cranks very slowly 1 Check for loose or f...

Page 73: ...osition 3 The oil level or pressure may be low causing the engine protec tion system to shut off fuel flow to the engine Check the oil pressure light 4 The engine coolant may be overheated causing the engine protection system to shut off fuel flow to the engine Check the water temperature light 5 The engine glow plugs may not be operating correctly 1 The fuel solenoid may be faulty Perform the Fue...

Page 74: ...e protec tion system to shut off fuel flow to the engine Check the oil pressure light 2 Check for adequate fuel supply 3 Circuit breaker CB9 located in the engine compartment may be open If CB9 is tripped the oil pressure and charging indi cator lights will not be on when the engine switch is in the ON position and the engine is not running 1 The fuel shutdown solenoid may be faulty Perform the Fu...

Page 75: ... 1 Check the output control R3 Normal resistance is 10 000 ohms Replace if defective 2 Check the REMOTE switch S8 and associated wiring See the Wiring Diagram leads 75 76 and 77 3 The control board may be faulty Replace Remote output control not func tioning 1 Make sure the remote switch S8 is in the REMOTE position 2 The remote control unit may be faulty Repair or replace 1 Check the remote switc...

Page 76: ... Reset if tripped 2 The wire feeder control cable may be faulty Check or replace 3 The wire feeder may be faulty Check or replace 1 Check for the presence of 115VAC at leads 31A and 32 See the Wiring Diagram 2 Check for the presence of 42VAC at leads 31B to 42 See the Wiring Diagram 3 If any of the above voltages are missing or low check the circuit breaker CB1 for proper opera tion 4 The RF bypas...

Page 77: ... pins D to C on the 14 pin am phenol If the output contactor activates the problem is exter nal to the RANGER 300 DLX The wire feeder or control cable may be faulty 1 With Welding Terminals switch S8 in the Welding Terminals Always On position check for 12VDC from leads 224 to 232 at the output contactor If 12VDC is present and the contactor does NOT activate the contactor may be defective See the...

Page 78: ...HIS MANUAL PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The battery does not stay charged 1 Check for loose or faulty con nections at the battery and engine charging system 1 Perform the Charging Circuit Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln...

Page 79: ...ns 2 The welding cables may be too long or coiled causing an excessive voltage drop 1 Check for the correct open cir cuit voltage OCV at the weld ing output terminals If the cor rect voltage is present at the output terminals check for loose connections on the heavy current carrying leads inside the Ranger 300 D See the Wiring Diagram 2 If the OCV is low at the welder output terminals perform the ...

Page 80: ...trical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there is a shorted...

Page 81: ...ure F 1 This will electrically isolate the rotor windings 4 Using the volt ohmmeter check the rotor winding resistance across the slip rings Set the meter on the low scale X1 Normal resistance is approximately 5 or 6 ohms 5 Measure the resistance to ground Set the meter on the high scale X100 000 Place one meter probe on either of the slip rings Place the other probe on any good unpainted ground T...

Page 82: ... 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 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 trou bleshooting assistance before you proceed Call 1 800 833 ...

Page 83: ... lower right side of the machine behind the case front See Figure F 2 5 Using the 1 2 wrench remove the nuts and washers holding the diode pigtails and the heavy current carrying leads to the studs on the rectifier plates Note leads and pig tail placement for reassembly 6 Electrically isolate the diode pigtail leads by carefully bending them out into free air 7 With an ohmmeter or diode tester che...

Page 84: ...he 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 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 trou bleshooting assistan...

Page 85: ...FIGURE F 4 PLUG J12 PIN LEAD ASSIGNMENTS LEAD 237 LEAD 224B LEAD 5K 4 Using the ohmmeter check the resistance from lead 237 to lead 5K See Figure F 4 Normal resistance of the pull in coil is approximately 0 5 ohms 5 Using the ohmmeter check the resistance from lead 224B to lead 5K See Figure F 4 Normal resistance of the hold in coil is approximately 11 5 ohms NOTE This solenoid is activated with 1...

Page 86: ...actory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPT...

Page 87: ...ximately 20 ohms If either coil resistance is not correct the solenoid may be faulty Replace 5 Using the external 12VDC supply apply 12VDC to the larger solenoid terminals 222H to 213A The solenoid should activate The solenoid should deactivate when the 12VDC is removed When the solenoid activates remove the volt age immediately Do not leave the external supply connected to terminals 222H and 213A...

Page 88: ...bserve all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION If the machine output is low or high this test will determine wheth...

Page 89: ...ch lift and secure the right side ser vice access door With the 3 8 nut driver remove the right front side cover 3 With a white or red marking pencil place a mark on one of the flywheel bolts See Figure F 6 for location 4 Connect the strobe tach according to the manufacturer s instructions 5 Start the engine and direct the strobe tach light on the flywheel bolt Synchronize it to the rotating mark ...

Page 90: ...aster TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR F 31 F 31 RANGER 300 D AND 300 DLX ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 7 HIGH IDLE ADJUSTMENT FIGURE F 8 LOW IDLE ADJUSTMENT SOLENOID LINKAGE LOW SPEED SET SCREW AND LOCKING NUT LOCKING NUT ...

Page 91: ... the 7 16 wrench adjust the high speed solenoid linkage to lengthen the linkage until the engine speed starts to decrease See Figure F 7 Adjust the linkage in the opposite direction until the frequency is 63 Hz Tighten the locking nut The high speed set screw is preset and sealed by the engine manufacturer and nor mally should not be adjusted Adjust LOW IDLE First make sure there is NOT a load on ...

Page 92: ...or 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 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 trou bleshooting assistance before you proceed Call 1 80...

Page 93: ...e Figure F 9 5 Start the engine and run it at high idle 3700 RPM 6 Set the output control to the maximum position position 10 7 Check the AC voltage reading It should be approximately 125 VAC To test the 230 VAC winding 1 With the 5 16 and 3 8 nut drivers remove the case left side 2 Set the voltmeter to the AC volts position 3 Connect the volt ohmmeter probes to leads 6 and 3 where they connect to...

Page 94: ...ht side 2 Connect the volt ohmmeter probes to leads 7 and 9 where they connect to the Field Bridge Rectifier See Figure F 10 3 Start the engine and run it at high idle 3700 RPM 4 Set the output control to the maximum position position 10 5 Check the AC voltage reading It should be between 40 and 47 VAC If the reading is missing or not within spec ifications check for loose or broken wires between ...

Page 95: ... Set the output control to the maximum position position 10 6 Check the AC voltage reading It should be between 115 and 126 VAC 7 Connect the volt ohmmeter probes to leads 31 and 42 where they connect to 15 amp circuit breaker CB1 and the 14 pin amphenol See the Wiring Diagram NOTE It is possible to check this voltage read ing at the amphenol by inserting the test probes at pin K for lead 42 and p...

Page 96: ...ec trical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct DC ...

Page 97: ...t the rotor lamination lead 200A See Figure F 12 for location 4 Connect the negative meter probe to the other brush lead 219 5 Set the LOCAL REMOTE switch S8 to the CONTROL AT WELDER position Start the engine and run it at high idle 3700 RPM Set the output control to the MAXIMUM position position 10 6 Check the voltage reading on the voltmeter It should read approximately 37 40 VDC 7 If the voltag...

Page 98: ...invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 W...

Page 99: ...he engine alternator is operating normally If any of the voltage readings are missing or not normal the engine alternator or associ ated wiring may be faulty See the Wiring Diagram CHARGING CIRCUIT TEST CHART TEST CONDITIONS TEST POINTS TYPICAL VOLTAGE Ignition Switch Off Lead 222D to Frame Ground 12 VDC Ignition Switch Off Lead 224A to Frame Ground 0 VDC Ignition Switch Off Lead 227 to Frame Grou...

Page 100: ...liary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time Note Scope probes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD...

Page 101: ...from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal MACHINE LOADED TO 250 AMPS AT 30VDC TYPICAL DC WEL...

Page 102: ...nerated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MA...

Page 103: ...enerated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal MACHINE LOADED TO 250 AMPS AT 25VDC TYPIC...

Page 104: ...ing Note the gap in the waveform One output diode was disconnected to simulate an open or non functioning output diode Each vertical division represents 50 volts and each horizontal division repre sents 5 milliseconds in time Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal ABNORMAL OPEN CIRCUIT DC WELD ...

Page 105: ... ripple in the waveform The capac itor bank was disconnected to simu late an open or non functioning capacitor bank Each vertical divi sion represents 50 volts and each horizontal division represents 5 mil liseconds in time Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal ABNORMAL OPEN CIRCUIT WELD VOLTA...

Page 106: ...l CV output voltage generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH CV MODE HIGH IDLE NO LOA...

Page 107: ...INGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal 0 volts 5 ms 50V This is the typical DC output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM H...

Page 108: ...50 volts SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal This is the typical AC output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM...

Page 109: ...r factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTI...

Page 110: ...e the brushes use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly 7 Remove the old brushes and insert the new ones One corner of the terminal clip is beveled so that the brush can go in only one way 8 Snap the plastic retainer back onto the brush holder The brushes may need some repositioning wiggle them slightly to help them seat properly on the...

Page 111: ...edle nose pliers connect the red and the white wires to the appropriate terminals on the brushes The red wire is nearest to the rotor lamination 14 Check the wire connections for clearance and tightness 15 Install the right case side NOTE A slight amount of darkening and wear of the slip rings and brushes is normal Brushes should be inspected when a general overhaul is necessary If brushes are to ...

Page 112: ...d elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the techni...

Page 113: ...Leave the clips on for at least 5 seconds then remove 4 With the needle nose pliers gently remove the seven wires from the field rectifier bridge Label the wires for reassembly 5 Both the capacitor and the rectifier bridge are mounted in a molded plastic holder To remove it pull the assembly away from the metal baffle and slide the assembly out ward 6 With the diagonal cutters cut the wire wrap fr...

Page 114: ...See Figure F 15 and the Wiring Diagram Leads 200 200A and 200B are piggy backed on the positive terminal Depending on the bridge used this corner may be beveled and or marked with a sign Leads 201 and 201A are located on the negative terminal which will always be located diagonally across from the posi tive terminal The two leads 7 and 9 are the AC side of the bridge and attach to the other two co...

Page 115: ...ory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this man ual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The...

Page 116: ...ve the fuel cap and the rubber gasket for the fill tube 6 Unlatch the double door assembly and use the slot head screw driver and 3 8 wrench to remove the door support rod from the door assembly 7 Remove the case top and door assembly then reinstall the fuel cap 8 With the 5 16 nut driver remove the con trol board cover See Figure F 16 9 Remove the three molex plugs from the control board J1 J2 J3...

Page 117: ...3 Connect current sensing leads 254 and 254A Thread the leads through the cur rent sensor the same number of turns noted during removal Connect the leads and install new wire ties See the Wiring Diagram for the proper connections 14 Connect the three molex plugs 15 Connect the three individual leads 213 222 and 5A 16 Replace any wire ties that were cut during the removal procedure 17 With the 5 16...

Page 118: ...invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 ...

Page 119: ...ds from the terminal studs Note lead and washer placement nut split washer flat washer leads Label leads for reassembly See the Wiring Diagram 4 With the 1 2 wrench remove the two heavy leads and one small lead from the rectifier heat sink plate Note that the small lead is always on top for reassembly 5 With the 7 16 wrench remove the nut and washers holding the top stud assembly to the rectifier ...

Page 120: ...bottom mounting screws Note the place ment of the nylon insulators These must be in place when you install the rectifi er bridge assembly in order to electri cally insulate the bridge from the frame 11 With the 7 16 wrench install the washers and nuts to hold the top stud assembly to the rectifier mounting bolts Install insula tors as previously removed 12 With the 7 16 wrench install the flat was...

Page 121: ...ctory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION T...

Page 122: ...att resistor to dis charge each capacitor See Figure F 18 4 With the 1 2 wrench remove the two nuts bolts and washers holding the two heavy leads W14 and W3 and the two small leads 236A negative and 245 red positive to the capacitor bank buss bars Note lead placement 5 With the 5 16 nut driver remove the four mounting screws holding the capacitor bank assembly to the base of the machine 6 Carefull...

Page 123: ...r your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following proc...

Page 124: ...4 With the 1 2 wrench remove the nut bolt and washers holding the heavy leads W8 and W9 to the output contactor See the Wiring Diagram 5 With the slot head screw driver and the 3 8 nut driver remove the three mounting screws nuts and washers that hold the contactor to the vertical baffle The contactor can now be removed 6 To reinstall the output contactor use the slot head screw driver and 3 8 nut...

Page 125: ...ion TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIRs F 66 F 66 RANGER 300 D AND 300 DLX OUTPUT CONTACTOR REMOVAL AND REPLACEMENT RANGER 300 DLX ONLY continued FIGURE F 20 CONTACTOR COIL LEAD PLACEMENT W8 W9 224 224C 232 ...

Page 126: ...understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing the Ranger 300 sta tor and rotor for maintenance or replacement The key to successful stator remova...

Page 127: ...68 F 68 RANGER 300 D AND 300 DLX STATOR AND OR REMOVAL AND REPLACEMENT continued FIGURE F 21 COMPONENT LOCATIONS STATOR ROTOR REMOVAL 1 STATOR MOUNTING BRACKET 2 MOUNTING BRACKET BOLT 2 3 ROTOR BEARING SCREWS 2 4 BLOWER 5 TOLERANCE RING 6 BRUSH ASSEMBLY BRACKET 7 STATOR MOUNTING BOLT 8 8 ROTOR BEARING 9 ROTOR 10 FLEX PLATE 11 ENGINE 12 ROTOR BOLT 6 13 CLAMPING BAR 3 13 12 6 10 9 8 7 11 5 4 3 2 1 ...

Page 128: ...o the S2 range switch Use care excessive force will break the terminals away from the rivets DLX only D machines have only one lead 15 Remove all stator leads from connection points on the front panel See the Wiring Diagram Remove lead 6 from circuit breaker CB2 Note that it passes through the idler current sensor Remove lead 3 from circuit breaker CB3 Note that it passes through the idler current...

Page 129: ...d to the right side of the machine See Figure F 22 Support the unit with a box or large pan 26 Remove the two 1 2 nuts and bolts that hold the stator mounting bracket to the base of the machine See Figure F 21 27 Remove the blower fan by turning it coun terclockwise to unscrew it from the rotor shaft Prevent engine rotation as you turn the blower 28 Remove the two 3 8 screws that hold the rotor be...

Page 130: ...n and wire ties previous ly removed 14 Mount the output rectifier assemblies LEAD RECONNECTION CHECKLIST ENGINE Lead 226 and 5W to fuel gauge FRONT PANEL Lead E to common ground screw Lead 6 to CB2 note that it passes through the idler current sensor Lead 3 to CB3 note that it passes through the idler current sensor Stator leads C1 C2 C3 and C4 to the S2 range switch DLX machines In line connector...

Page 131: ...74 25 35 295 325 WELDER AC OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Maximum 70 79 27 35 295 325 WELDER CV OUTPUT Output Control Range Switch Open Circuit Load Volts Load Amps Volts Maximum Wire Feed CV High 62 71 27 34 295 325 Maximum Wire Feed CV Med HI 46 53 25 30 220 240 Maximum Wire Feed CV Med LO 46 53 20 25 155 170 Maximum Wire Feed CV Low 46 53 15 2...

Page 132: ...RAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS SECTION G WIRING DIAGRAM RANGER 300 D CODE 10399 G 2 WIRING DIAGRAM RANGER 300 DLX CODE 10400 G 3 WIRING DIAGRAM RANGER 300 DLX CODE 10850 G 4 CONTROL PC BOARD SCHEMATIC G 5 CONTROL PC BOARD ASSEMBLY G 6 BYPASS PC BOARD SCHEMATIC G 7 BYPASS PC BOARD ASSEMBLY G 8 ...

Page 133: ... VIEWED FROM REAR GROUND J12 FRAME BLACK J13 SHUTDOWN 220A 235B CONTACTOR 237 5K 5K REMOTE SWITCH L1 CHOKE W6 224G R 224H 5G 221A 225 R 6J10 STARTER SOLENOID COIL S5 SWITCH IDLER 224B 222 RED S4 S3 START 222G 222G SWITCH 223A ON OFF S6 5B PRESSURE 235A 222C FUEL 8J10 FUEL 9J10 235C 235B BLUE 221B CB9 222D 11J10 220 222B BLUE STARTER ELECTRODE POLARITY 77B REMOTE CONTROL AC DC AC DC DC OUTPUT D1 W1...

Page 134: ...0 31 IDLER S6 ON OFF IDLER AC J12 237 224B W4 L10262 PCB1 7 3 R CHARGER 5F 220 6 20 97 W13 C2 SWITCH W1 C3 2C 232 77A W5 224C GROUND SCREW BLOWER BAFFLE W4 5E SLIP RINGS 220 221 E GROUND AMPHENOL 2 247 SOLENOID SPEED HIGH HOLD 76B 75B 4B J10 1J10 INDICATES CAVITY NUMBER 800 MFD GREEN RECEPTACLE SILVER 3C GND G 6 W7 50W 240 241 R W2 3 5A 76A CB1 42 213 W6 ELECTRODE POLARITY 240 25W W15 WITH S2 IN 2...

Page 135: ...N OFF IDLER AC J12 237 224B W4 L11702 PCB1 7 3 R CHARGER 5F 220 5 4 2001B W13 C2 SWITCH W1 C3 2C 232 77A W5 224C GROUND SCREW BLOWER BAFFLE W4 5E 220 221 E GROUND AMPHENOL 2 247 SOLENOID SPEED HIGH HOLD 76B 75B 4B J10 1J10 A A INDICATES CAVITY NUMBER 800 MFD GREEN RECEPTACLE SILVER 3C GND G 6 W7 50W 240 241 R W2 3 5A 76A CB1 42 213 W6 ELECTRODE POLARITY 240 25W W15 WITH S2 IN 236 WORK C4 76A 12 VO...

Page 136: ...turn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 137: ... Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 6 RANGER 300 PC BOARD ASSEMBLY CONTROL BOARD G IDENTIFICATION PART No REQ D ITEM 04 0 04 20 0 20 3 13 11 30 11 50 5 75 6 00 5 80 3132 2 xxxxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxxxxxx xxxxxxxxxx xxxxxxxxxxxxxx xxxxxxxxxxxxxx xxxx xxxx xxxx xxxx xxxxxxxx xxxxxxxx xxxxxxx xxxxxxx xxxxxx xxxxxx 2 2 1 2 RANGER 3...

Page 138: ...rn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 139: ...e the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 8 RANGER 300 PC BOARD ASSEMBLY BYPASS BOARD CAPACITORS MFD VOLTS 1 18 2 83 4 00 75 1 75 04 0 0 04 BYPASS M18733 1 XXXX XX XXXXXXXXX X X X X X X X X X X X X X X X X X X X X X X 11 20 98E ENGINE WELDERS BYPASS P C BD ASSEMBLY...

Page 140: ...____________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________...

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