Lincoln Electric RANGER SVM148-B Service Manual
Lincoln Electric RANGER SVM148-B Service Manual

Lincoln Electric RANGER SVM148-B Service Manual

Lincoln electric welder user manual
Table of Contents

Advertisement

RETURN TO MAIN INDEX
SVM148-B
February, 2004
TM
RANGER 300 D and 300 DLX
For use with machine code numbers 10399 thru 10850
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. 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.

SERVICE MANUAL

Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RANGER SVM148-B and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Lincoln Electric RANGER SVM148-B

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM148-B February, 2004 RANGER 300 D and 300 DLX For use with machine code numbers 10399 thru 10850 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 ...
  • 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: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 NOTES RANGER 300 D AND 300 DLX...
  • Page 7: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Technical Specifications ...A-2 Safety Precautions...A-3 Location and Ventilation ...A-3 Pre-operation Engine Service ...A-4 High Frequency Generation for TIG Applications...A-6 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...
  • Page 8 Section A-1 - INSTALLATION SECTION - Installation ...Section A Technical Specifications ...A-2 Input - Diesel Engine ...A-2 Rated Output - Welder ...A-2 Output - Welder and Generator ...A-2 Physical Dimensions ...A-2 Safety Precautions...A-3 Location and Ventilation ...A-3 Storing ...A-3 Stacking...A-3 Tilting ...A-3...
  • Page 9: Installation

    100% Duty Cycle 200 DC Constant Voltage (300 D) 300 DC Constant Voltage (300 DLX) 100% 280 DC Constant Voltage (300 DLX) OUTPUT - WELDER AND GENERATOR Max. Open Welding Ranges Circuit Voltage 40 - 300 Amps 80 Volts RMS...
  • Page 10: Safety Precautions

    WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ELECTRIC SHOCK can kill.
  • Page 11: Pre-Operation Engine Service

    HIGH ALTITUDE OPERATION It may be necessary to de-rate the welder output at higher altitudes. Derate the welder output 0.4% for every 100 ft. (30 m) above 500 ft. (150 m). Some engine adjustment may be required above 5,000 ft.
  • Page 12: Fuel

    HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. The recovery bottle should be partially filled. See the Maintenance section and the engine Operator’s...
  • Page 13: Remote Control

    HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi-Freq Unit and the K930-1 or -2 TIG Module can be used with the Ranger 300. machine is equipped with the required RF bypass cir- cuitry for the connection of high frequency generating equipment.
  • Page 14: Welding Cable Connections

    Cable diameters are increased for long cable lengths to reduce voltage drops. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the Accessories section of this manual for more information.
  • Page 15: Premises Wiring

    CAUTION Never bypass the circuit breakers. Without overload protection, the RANGER 300 D/DLX could overheat and/or cause damage to the equipment being used. PREMISES WIRING The RANGER 300 is suitable for temporary, standby, or emergency power using the engine manufacturer’s recommended maintenance schedule.
  • Page 16 CONNECTION OF RANGER 300 TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER 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 RECEPTACLE...
  • Page 17 NOTES RANGER 300 D AND 300 DLX...
  • Page 18 General Description ...B-3 Design Features ...B-3 Recommended Applications ...B-4 Welder ...B-4 Generator ...B-4 Limitations...B-4 Controls and Settings ...B-5 Welder/Generator Controls ...B-5 Engine 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...
  • Page 19: Operation

    Only qualified personnel should install, use, or ser- vice this equipment. ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place. These provide maximum protection from moving parts and insure proper cooling air flow.
  • Page 20: General Description

    AC power tools, battery chargers, and light- ing. It can also be used to provide standby power. As a welder it provides 300 amps of AC current for weld- ing with AC stick electrodes or 300 amps of DC cur- rent for DC stick welding.
  • Page 21: Recommended Applications

    Volt Remote Output Control Module or with internal contactor and all models of the LN-7. OPERATION RECOMMENDED APPLICATIONS WELDER The RANGER 300 provides excellent constant current AC/DC welding output for stick (SMAW) welding and for TIG welding, and it offers constant voltage output for DC semiautomatic wire feed welding.
  • Page 22: Controls And Settings

    CONTROLS AND SETTINGS All generator/welder controls are located on the Output Control Panel of the machine case front. Diesel engine glow plug, idler control, and start/stop controls are also on the case front. See Figure B.1 and the explanations that follow.
  • Page 23 5. WELDING TERMINALS SWITCH (DLX Model Only) The toggle switch labeled “WELDING TERMINALS ALWAYS ON” and “WELDING TERMINALS REMOTELY CONTROLLED” is used to control the operation of the RANGER 300 DLX output contac- tor. With the switch in the “WELDING TERMINALS ALWAYS ON”...
  • Page 24: Engine Controls

    ENGINE CONTROLS See Figure B.2 for the location of the following fea- tures: 1. GLOW PLUG PUSH-BUTTON: Activates glow plugs to preheat engine for starting. 2. IDLER CONTROL SWITCH: The idler switch has two positions, “HIGH” and “AUTO”. When in “HIGH” ( ) position, the engine will run continuously at high speed.
  • Page 25: Maintenance

    3. START PUSHBUTTON: When the push- button is held, the starter motor cranks over the engine - release the button once the engine starts. NOTE: If you press the START pushbutton when the engine is running, you may damage the ring gear or starter motor.
  • Page 26: Engine Operation

    30 days, to assure freshness. STARTING THE ENGINE Remove all loads connected to the AC power recepta- cles and the welder before starting the diesel engine. 1. Open the engine compartment door and check that the fuel shutoff valve located above the clear plas- tic fuel filter housing is in the open position (lever in the vertical position).
  • Page 27: Cold Weather Starting

    B-10 6. Press the “GLOW PLUG” button to pre- heat the cylinders per the following table: Pre-Heat Time Ambient Temperature NOT REQUIRED Above 50°F (10°C) Approximately 5 seconds 50°F (10°C) to 23°F(-5°C) Approximately 10 seconds Below 23°F (-5°C) CAUTION Never press the Glow Plug button continuously for more than 20 seconds.
  • Page 28: Welding Operation

    CAUTION Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safe- ty precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ELECTRIC SHOCK can kill.
  • Page 29: Ac/Dc Tig (Constant Current) Welding

    B-12 CAUTION DO NOT change the RANGE switch setting while welding. This can result in damage to the switch. RANGE SETTING ON MACHINE CURRENT RANGE 30 to 50 AMPS 50 to 75 AMPS 70 to 100 AMPS 95 to 140 AMPS 110 to 180 AMPS 130 to 225 AMPS 160 to 300 AMPS...
  • Page 30: Dc Wire Feed Welding (Cv) With Ranger 300 Dlx

    B-13 AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS Pure (EWP) Tungsten Diameter 1/8” 3/32” 1/16” 1% Thoriated Tungsten Diameter 1/8” 3/32” 1/16” The welding current will be approximately 200 amps with the range switch set at 120 and the OUTPUT CON- TROL set at 10.
  • Page 31: Dc Wire Feed Welding (Cv) With Ranger 300 D

    B-14 DC WIRE FEED WELDING (CV) WITH RANGER 300 D 1. Connect an LN-25 with internal contactor to the Ranger 300 D. 2. The only Innershield electrode recommended for use with the Ranger 300 D is NR211MP. The elec- trode sizes and welding ranges that can be used with the Ranger 300 D are shown in the following table: Electrode...
  • Page 32: Summary Of Welding Processes And Machine Settings

    CV SPOOL GUN / K488 S23732-8 CONTROL MODULE OPERATION TABLE B.3 IDLE OUTPUT WELDING ELECTRODE MODE CONTROL TERMINALS WHEN NOT SWITCH SWITCH WELDING AUTO ALWAYS WELDER AUTO REMOTE REMOTE AUTO REMOTE REMOTE AUTO ALWAYS WELDER AUTO REMOTE REMOTE HIGH REMOTE REMOTE HIGH REMOTE...
  • Page 33: Installation

    S23732-11 CONTACTOR KIT INSTALLATION TABLE B.4 IDLE OUTPUT ELECTRODE MODE CONTROL WHEN NOT SWITCH WELDING AUTO WELDER AUTO REMOTE AUTO COLD WELDER HIGH COLD WELDER RANGER 300 D AND 300 DLX B-16 TO START WELDING Touch electrode to work. Welding starts immediately and engine goes to high idle.
  • Page 34: Auxiliary Power

    B-17 AUXILIARY POWER The Ranger 300 can provide up to 12,000 watts of 120/240 volts AC, single-phase 60 HZ power for con- tinuous use. The front of the machine includes three receptacles for connecting AC power plugs, one 50 amp 120/240 V NEMA 14-50R receptacle and two 15 amp 120 V NEMA 5-15R receptacles.
  • Page 35: 120/240 V Dual Voltage Receptacle

    B-18 120/240 V DUAL VOLTAGE RECEPTACLE The 120/240 V receptacle can supply up to 50 amps of 240 V power to a two wire circuit, up to 50 amps of 120 V power from each side of the three wire circuit, (up to 100 amps total).
  • Page 36 Semiautomatic FCAW and MIG Welding (Ranger 300 DLX) Options/Accessories...C-2 Semiautomatic FCAW and MIG Welding ( 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...
  • Page 37: Accessories

    GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your RANGER 300 from your local Lincoln Distributor. K953-1 Two-Wheeled Trailer - For in-plant or yard towing of the RANGER 300. Suitable for road towing with optional Fender and Light Kit. Load capacity is 2,100 lbs.
  • Page 38: Connection Of Lincoln Electric Wire Feeders

    1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 39 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 40 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 41 1. Shut the welder off. 2. Connect the electrode cable from the LN-7 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 42 1. Shut the welder off. 2. Connect the electrode cable from the LN-8 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 43 (DLX ONLY) (SEE FIGURE C.6.) 1. Shut the welder off. 2. Connect the electrode cable from the SG Control Module to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 44: Connection Of The K930-1 Tig Module

    (SEE FIGURE C.7.) 1. Shut the welder off. 2. Connect the electrode cable from the K930-1 TIG Module to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
  • Page 45 NOTES RANGER 300 D AND 300 DLX...
  • Page 46 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 Brush Removal and Replacement ...D-6 Nameplates ...D-6 Receptacles ...D-6 Cable Connections...D-6 Major Component Locations ...D-7...
  • Page 47: Maintenance

    SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. guards only when necessary and replace them when the maintenance requiring their removal is complete.
  • Page 48: Routine And Periodic Maintenance

    ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE (Refer to Figure D.3 for the location of maintenance components.) CAUTION To prevent the engine from accidentally starting, dis- connect the negative battery cable before servicing the engine. See Table D.1 for a summary of maintenance intervals for the items listed below.
  • Page 49: Fuel

    FUEL At the end of each day’s use, refill the fuel tank to minimize moisture condensation and dirt contami- nation in the fuel line. Do not overfill; leave room for the fuel to expand. Use only fresh, No. 2 grade DIESEL fuel. Do not use kerosene.
  • Page 50: Spark Arrester Screen

    • CONNECTING A BATTERY CHARGER – remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.
  • Page 51: Charging The Battery

    Follow the instructions of the battery charger manu- facturer for proper charger settings and charging time. WELDER / GENERATOR MAINTENANCE STORAGE Store the RANGER 300 in clean, dry protected areas.
  • Page 52: Major Component Locations

    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 WELDED ASSEMBLY 10. P.C. BOARD COVER MAINTENANCE FIGURE D.3 MAJOR COMPONENT LOCATIONS RANGER 300 D AND 300 DLX 11.
  • Page 53 NOTES RANGER 300 D AND 300 DLX...
  • Page 54: Theory Of Operation Section

    Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E Battery, Starter, Engine, Glow Plugs, Engine Protection, Rotor, Stator, and Idler Solenoid ...E-2 Rotor Field Feedback, Auxiliary and Wire Feeder Power...E-3 Weld Winding, Reactor, and Range Switch ...E-4 Output Bridge, Choke, Polarity Switch, CV Contactor, and Output Terminals ...E-5 RANGER 300 DLX SHUTDOWN SOLENOID...
  • Page 55: Theory Of Operation

    THEORY OF OPERATION BATTERY, STARTER, ENGINE, GLOW PLUGS,ENGINE PROTECTION, ROTOR, STATOR AND IDLER SOLENOID RANGER 300 DLX SHUTDOWN SOLENOID GLOW PLUGS STARTER MOTOR ALTERNATOR BATTERY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL REMOTE SWITCH 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE...
  • Page 56 THEORY OF OPERATION ROTOR FIELD FEEDBACK, AUXILIARY AND WIRE FEEDER POWER RANGER 300 DLX SHUTDOWN SOLENOID GLOW PLUGS STARTER MOTOR ALTERNATOR BATTERY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL REMOTE SWITCH 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL ROTOR FIELD FEEDBACK, AUXILIARY AND WIRE FEEDER POWER The AC voltage developed in the field winding is fed to...
  • Page 57: Theory Of Operation

    THEORY OF OPERATION WELD WINDING, REACTOR AND RANGE SWITCH RANGER 300 DLX SHUTDOWN SOLENOID GLOW PLUGS STARTER MOTOR ALTERNATOR BATTERY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL REMOTE SWITCH 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL WELD WINDING, REACTOR AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch.
  • Page 58 THEORY OF OPERATION FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, OUTPUT CONTACTOR RANGER 300 DLX SHUTDOWN SOLENOID STARTER MOTOR ALTERNATOR BATTERY BY-PASS BOARD CONTACTOR CLOSURE OUTPUT CONTROL 42VAC 115VAC 6 PIN 14 PIN AMPHENOL AMPHENOL OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, OUTPUT CONTACTOR AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding...
  • Page 59 NOTES RANGER 300 D AND 300 DLX...
  • Page 60 Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F4 - F-20 Test Procedures ...F-21 Rotor Resistance Test ...F-21 Output Rectifier Bridge Test ...F-23 Fuel Shutdown Solenoid Resistance Test ...F-25 High Speed Solenoid Test ...F-27 Engine Throttle Adjustment Test ...F-29...
  • Page 61: Troubleshooting & Repair Section

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 62: Pc Board Troubleshooting Procedures

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.
  • Page 63: Troubleshooting Guide

    Engine operates normally. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 64 Engine operates normally. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 65 (continued from page F-5) If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 66 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 67 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 68 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 69 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 70 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 71 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 72 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 73 The engine cranks but will not start. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 74 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 75 Remote output control not func- tioning. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 76 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. DETAILED IN THE BEGINNING OF THIS MANUAL.
  • Page 77 300 DLX amphenol. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 78 The battery does not stay charged. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.
  • Page 79: Troubleshooting And Repair

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 80: Test Description

    F-21 TROUBLESHOOTING & REPAIR 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 81: Test Procedure

    F-22 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.1 – ROTOR BRUSH LEADS REMOVED TEST PROCEDURE 1. Conduct the test with the engine OFF. 2. Using the 5/16” and 3/8” nut drivers, remove the right front case side. 3. Locate, label and remove the two leads from the rotor brush holder assembly (lead #219 from the negative brush and lead #220A from the positive brush).
  • Page 82: Output Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST 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 83 F-24 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.2 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS Left side (–) TEST PROCEDURE 1. Conduct this test with the engine off. 2. Using the 3/8” wrench, remove the sheet metal screws from the right and left front case sides.
  • Page 84: Fuel Shutdown Solenoid Resistance Test

    TROUBLESHOOTING & REPAIR FUEL SHUTDOWN SOLENOID RESISTANCE TEST 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 85 F-26 TROUBLESHOOTING & REPAIR FUEL SHUTDOWN SOLENOID RESISTANCE TEST (continued) TEST PROCEDURE 1. Conduct this test with the engine off. 2. Unlatch and open the right side engine access door. FIGURE F.4 – PLUG J12 PIN/LEAD ASSIGNMENTS LEAD #224B 4. Using the ohmmeter, check the resistance from lead #237 to lead #5K.
  • Page 86: High Speed Solenoid Test

    TROUBLESHOOTING & REPAIR HIGH SPEED SOLENOID TEST 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 87 F-28 TROUBLESHOOTING & REPAIR HIGH SPEED SOLENOID TEST (continued) TEST PROCEDURE 1. Turn the engine off. 2. Unlatch, lift and secure the right side engine service access door. 3. Locate and remove the four spade connec- tors that attach the solenoid terminals to the wiring harness leads (#222J, #222H, #213A and #214A).
  • Page 88: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST 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 89 F-30 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.6 – STROBE MARK LOCATION TEST PROCEDURE 1. Conduct this procedure with the engine OFF. 2. Unlatch, lift, and secure the right side ser- vice access door. With the 3/8” nut driver, remove the right front side cover.
  • Page 90 F-31 F-31 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – HIGH IDLE ADJUSTMENT SOLENOID LINKAGE LOCKING NUT FIGURE F.8 – LOW IDLE ADJUSTMENT LOW SPEED SET SCREW AND LOCKING NUT RANGER 300 D AND 300 DLX...
  • Page 91 F-32 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjust HIGH IDLE: First make sure there is NOT a load on the machine. Set the IDLER switch to the HIGH position. The solenoid should activate.
  • Page 92: Auxiliary And Field Winding Test

    TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST 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 93 1. With the 5/16” and 3/8” nut drivers, remove the case left side. 2. Make sure that the LOCAL/REMOTE switch (S8) is in the CONTROL AT WELDER posi- tion. 3. Set the voltmeter to the AC volts position. 4. Connect the volt/ohmmeter probes to leads #3A and #3B where they connect to the 15 amp circuit breakers.
  • Page 94 F-35 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.10 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER 201A To test the field winding: 1. With the 5/16” and 3/8” nut drivers, remove the case right side. 2.
  • Page 95 F-36 TROUBLESHOOTING & REPAIR AUXILIARY AND FIELD WINDING TEST (continued) FIGURE F.11 – 14-PIN AMPHENOL PIN ASSIGNMENTS To test the feeder winding: Ranger 300 DLX Models 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.
  • Page 96: Rotor Voltage Test

    F-37 TROUBLESHOOTING & REPAIR 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 97 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).
  • Page 98: Charging Circuit Test

    F-39 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 99 F-40 CHARGING CIRCUIT TEST (continued) FIGURE F.13 – VOLTAGE REGULATOR LEADS TEST PROCEDURE 1. With the 5/16” and 3/8” nut drivers, remove the right case side. 2. Locate the engine alternator and leads. See Figure F.13. 3. Set the voltmeter for DC volts and check for the typical DC voltages according to the Charging Circuit Test Chart below.
  • Page 100: Normal Open Circuit Voltage Waveform (115 Vac Supply

    F-41 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 15.8 ms 50 volts This is the typical auxiliary 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.
  • Page 101: Typical Dc Weld Output Voltage Waveform (Cv Mode High Tap

    F-42 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP) MACHINE LOADED TO 250 AMPS AT 30VDC MACHINE LOADED 5 ms 20 volts This is the typical 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.
  • Page 102: Typical Dc Weld Output Voltage Waveform

    F-43 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 250 AMPS AT 25 VDC MACHINE LOADED 5 ms 20 volts This is the typical DC 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.
  • Page 103: Typical Ac Weld Output Voltage Waveform

    F-44 TROUBLESHOOTING & REPAIR TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 250 AMPS AT 25VDC MACHINE LOADED 5 ms 20 volts This is the typical AC 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.
  • Page 104: Abnormal Open Circuit Dc Weld Voltage Waveform

    F-45 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM ONE OUTPUT DIODE NOT FUNCTIONING 5 ms 50 volts This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning.
  • Page 105: Abnormal Open Circuit Weld Voltage Waveform (High Cv Mode

    F-46 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM OUTPUT CAPACITOR BANK NOT FUNCTIONING (HIGH CV MODE) 5 ms 50 volts This is NOT the typical CV output voltage waveform. The capacitor bank is not functioning.
  • Page 106: Normal Open Circuit Weld Voltage Waveform (High Cv Mode

    F-47 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 5 ms 20 volts This is the typical 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.
  • Page 107: Normal Open Circuit Dc Weld Voltage Waveform

    F-48 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 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.
  • Page 108: Normal Open Circuit Ac Weld Voltage Waveform

    F-49 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 5 ms 50 volts 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.
  • Page 109: Brush Removal And Replacement

    TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT 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-...
  • Page 110 F-51 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE 1. BRACKET MOUNTING HOLES PROCEDURE 1. Conduct this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the right case side.
  • Page 111 F-52 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) 12. Slowly remove the non-metallic retainer from the brush holder and let the brushes snap back against the slip rings. 13. With the needle nose pliers, connect the red and the white wires to the appropriate terminals on the brushes.
  • Page 112: Field Capacitor And/Or Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL 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-...
  • Page 113 F-54 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – RECTIFIER BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR 201A PROCEDURE 1. Conduct this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the right case side.
  • Page 114 F-55 TROUBLESHOOTING & REPAIR FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) Connect the wires to the proper terminals on the rectifier bridge. 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.
  • Page 115: Control Board Removal And Replacement

    TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT 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 man- ual.
  • Page 116 F-57 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – PRINTED CIRCUIT BOARD LOCATION CONTROL PROCEDURE Before starting the following procedure, refer to topic “PC Board Procedures” at the beginning of this section. 1. Conduct this procedure with the engine OFF.
  • Page 117 F-58 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 11. With the 1/4” nut driver, remove the screws holding the control board. 12. Replace the old control board with a new one. 13. Connect current sensing leads #254 and #254A.
  • Page 118: Output Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL 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-...
  • Page 119 F-60 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – OUTPUT RECTIFIER CONNECTIONS Left Side (–) PROCEDURE 1. Conduct this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, carefully remove the left and right case sides. Note that the output rectifier is divided into two parts.
  • Page 120 F-61 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) Reassembly: Refer to the Wiring Diagram for proper connec- tions to the positive and negative sides of the rectifier assembly. The two sides of the bridge are marked + and –, respectively. NOTE: Use Penetrox A-13 on aluminum elec- trical connection surfaces.
  • Page 121: Output Capacitor Bank Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR BANK REMOVAL AND REPLACEMENT 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-...
  • Page 122 F-63 TROUBLESHOOTING & REPAIR OUTPUT CAPACITOR BANK REMOVAL AND REPLACEMENT (RANGER 300 DLX ONLY) (continued) FIGURE F.18 - OUTPUT CAPACITOR BANK PROCEDURE 1. Conduct this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the right case side. 3.
  • Page 123: Output Contactor Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT CONTACTOR REMOVAL AND REPLACEMENT 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-...
  • Page 124 F-65 TROUBLESHOOTING & REPAIR OUTPUT CONTACTOR REMOVAL AND REPLACEMENT (RANGER 300 DLX ONLY) (continued) FIGURE F.19 – OUTPUT CONTACTOR LOCATION PROCEDURE 1. Conduct this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the left case side. 3.
  • Page 125: Troubleshooting And Repairs

    F-66 F-66 TROUBLESHOOTING & REPAIRs OUTPUT CONTACTOR REMOVAL AND REPLACEMENT (RANGER 300 DLX ONLY) (continued) FIGURE F.20 – CONTACTOR COIL LEAD PLACEMENT 224C RANGER 300 D AND 300 DLX...
  • Page 126: Stator And/Or Rotor Removal And Replacement

    TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT 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-...
  • Page 127 F-68 TROUBLESHOOTING & REPAIR STATOR AND/OR REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL 10. FLEX PLATE 11. ENGINE 12. ROTOR BOLT (6) 13. CLAMPING BAR (3) RANGER 300 D AND 300 DLX F-68 1. STATOR MOUNTING BRACKET 2.
  • Page 128 F-69 TROUBLESHOOTING & REPAIR STATOR AND/OR REMOVAL AND REPLACEMENT (continued) STATOR REMOVAL PROCEDURE 1. Conduct this procedure with the engine OFF. 2. With the 5/16” and 3/8” nut drivers, remove the screws from the case top and right and left case sides. If necessary, use the 1/2”...
  • Page 129 F-70 TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) MACHINE FRONT COMPONENTS PIVOTED TO SIDE 21. Using the 1/2” wrench, remove the three reactor mounting bolts from the machine base. 22. Using the 5/16” wrench, remove the three screws holing the front vertical baffle to the machine base.
  • Page 130: Reassembly Notes

    F-71 TROUBLESHOOTING & REPAIR STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued) REASSEMBLY NOTES 1. Be sure to remove the rotor bearing from the stator frame before reinstalling the rotor/stator Also remove the tolerance ring. 2. Install the rotor to the flex plate and install the flex plate to the engine.
  • Page 131: Retest After Repair

    Open Circuit Voltage 40 - 46 RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 2150 - 2220 3700 - 3650 WELDER DC OUTPUT Open Circuit Volts 64 - 74 WELDER AC OUTPUT Open Circuit Volts 70 - 79 WELDER CV OUTPUT...
  • Page 132: Electrical Diagrams Section

    ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM RANGER 300 D (CODE 10399) .
  • Page 133: Electrical Diagrams

    WIRING DIAGRAM - RANGER 300 D (CODE 10399) (CHOKE) ELECTRODE POLARITY SWITCH 254B 254A WORK ELECTRODE PCB2 BYPASS PC REMOTE CONTROL GND-B GROUND AMPHENOL GROUND SCREW IDLER SOLENOID ABOVE AMPHENOL HOLE (HARNESS LEAD END) 222F NOTES: ELECTRICAL SYMBOLS PER E1537 ALL CASE FRONT COMPONENTS VIEWED FROM REAR.
  • Page 134: Wiring Diagram Ranger 300 Dlx (Code 10400

    WIRING DIAGRAM - RANGER 300 DLX (CODE 10400) (CHOKE) ELECTRODE POLARITY SWITCH 254B OUTPUT 254A CONTACTOR 224C WORK ELECTRODE AMPHENOL 1 115VAC PCB2 CONTACTOR BYPASS PC WORK REMOTE CONTROL 42VAC GND-A GROUND REMOTE CONTROL CONTACTOR GND-B GROUND AMPHENOL 2 GROUND SCREW IDLER SOLENOID ABOVE AMPHENOL HOLE (HARNESS LEAD END)
  • Page 135: Electrical Diagrams

    WIRING DIAGRAM - RANGER 300 DLX (CODE 10850) (CHOKE) ELECTRODE POLARITY SWITCH 254B OUTPUT 254A CONTACTOR 25 OHM 224C WORK ELECTRODE AMPHENOL 1 115VAC CONTACTOR PCB2 BYPASS PC WORK REMOTE CONTROL 42VAC GND-A GROUND REMOTE CONTROL CONTACTOR GND-B GROUND AMPHENOL 2 GROUND SCREW IDLER SOLENOID ABOVE AMPHENOL HOLE...
  • Page 136 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 300...
  • Page 137 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 138 ELECTRICAL DIAGRAMS SCHEMATIC - BYPASS PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. RANGER 300...
  • Page 139: Bypass Pc Board Assembly

    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 140 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

This manual is also suitable for:

Ranger 300 dRanger 300 dlx

Table of Contents