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Lincoln Electric SVM148-B manual

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Table of contents for the manual

  • Page 1

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V iew Safety Info View Safety Info View Safety Info V iew Safety Info SVM148-B February , 2004 For use with machine code numbers 10399 thru 10850 RANGER 300 D and 300 DLX TM RETURN TO MAIN INDEX SER VICE MANUAL Safety Depends on Y ou Lincoln arc welding and cutting [...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i RANGER 300 D AND 300 DLX FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines i[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii RANGER 300 D AND 300 DLX ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii RANGER 300 D AND 300 DLX FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all loca[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv RANGER 300 D AND 300 DLX 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 su[...]

  • Page 6

    NOTES RANGER 300 D AND 300 DLX[...]

  • Page 7

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS vi vi RANGER 300 D AND 300 DLX Page Safety .................................................................................................................................................i-iv Installation .....................................................................................................[...]

  • Page 8

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 RANGER 300 D AND 300 DLX Installation ................................................................................................................... ..........Section A T echnical Specificati[...]

  • Page 9

    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 INST ALLA TION A-2 A-2 RANGER 300 D AND 300 DLX TECHNICAL SPECIFICA TIONS - RANGER 300 D AND 300 DLX INPUT - DIESEL ENGINE Starting Manufacturer Description Speed Displacement Sy[...]

  • Page 10

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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. ELECT[...]

  • Page 11

    HIGH AL TITUDE OPERA TION 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 requir ed above 5,000 ft. (1,500 m). Contact a Kubota Service Representative. T OWING The recommended trailer for use with this equipment for road[...]

  • Page 12

    FUEL Fill the fuel tank with clean No. 2, diesel fuel only . Do not fill to the top of the filler neck to allow room for expansion. The RANGER 300 has a 10 gallon (38 liter) fuel tank with a top fill and fuel gauge mounted on the control panel. See the Operation and Maintenance sections of this manual for more details about fuel. ENGINE COOLANT HOT[...]

  • Page 13

    HIGH FREQUENCY GENERA TORS FOR TIG APPLICA TIONS The K799 Hi-Freq Unit and the K930-1 or -2 TIG Module can be used with the Ranger 300. The machine is equipped with the requir ed RF bypass cir- cuitry for the connection of high frequency generating equipment. The high frequency bypass network sup- plied with the K799 Hi-Freq Unit does NOT need to b[...]

  • Page 14

    WELDING CABLE CONNECTIONS CABLE SIZE AND LENGTH Be sure to use welding cables that ar e large enough. The correct size and length becomes especially impor- tant when you are welding at a distance fr om the welder . T able A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length r efers to the distance from the welder t[...]

  • Page 15

    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 Never bypass the circuit br eakers. Without overload protection, the RANGER 300 D/DLX could overheat and/or cause damage to the equipment being used. PREMISES WIRING The RANGER 3[...]

  • Page 16

    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 INST ALLA TION A-9 A-9 RANGER 300 D AND 300 DLX FIGURE A.2 CONNECTION OF RANGER 300 TO PREMISES WIRING 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VO[...]

  • 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 RANGER 300 D AND 300 DLX T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions .......[...]

  • Page 19

    OPERA TING INSTRUCTIONS Read and understand this entire section befor e oper- ating your RANGER 300. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly r ead all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and mainte[...]

  • Page 20

    GENERAL DESCRIPTION The RANGER 300 is a diesel-engine driven, multi- process AC and DC ar c welder and AC power gener- ator for commercial and r esidential applications. As a generator it can supply up to 12,000 continuous watts of 120/240 volt, 60 Hz, single-phase AC power to operate AC power tools, battery char gers, and light- ing. It can also b[...]

  • Page 21

    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 OPERA TION B-4 B-4 RANGER 300 D AND 300 DLX ADDITIONAL FEA TURES RANGER 300 D (K1522-1) • One constant voltage wir e-feed welding range - 80 to 200 amps. The wire feed setting [...]

  • Page 22

    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 WELDER/GENERA TOR CONTROLS See Figure B.1 for the location of the following fea- tures: 1. OUTPUT RANGE SELECTOR: Selects continuous current output for constant curr ent stick or[...]

  • Page 23

    5. WELDING TERMINALS SWITCH (DLX Model Only) The toggle switch labeled “WELDING TERMINALS AL WA YS ON” and “WELDING TERMINALS REMOTEL Y CONTROLLED” is used to control the operation of the RANGER 300 DLX output contac- tor . With the switch in the “WELDING TERMINALS AL WA YS ON” position, the contactor is closed at low and high idle. Whe[...]

  • Page 24

    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 OPERA TION B-7 B-7 RANGER 300 D AND 300 DLX FIGURE B.2 ENGINE CONTROLS ENGINE CONTROLS See Figure B.2 for the location of the following fea- tures: 1. GLOW PLUG PUSH-BUTTON: Acti[...]

  • Page 25

    3. ST ART 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 ST ART pushbutton when the engine is running, you may damage the ring gear or starter motor . 4. ENGINE HOUR METER: Records engine running time. Use to determine when to perform requir ed [...]

  • Page 26

    ENGINE OPERA TION DO NOT RUN THE ENGINE A T EXCESSIVE SPEEDS. The maximum allowable high idle speed for the RANGER 300 is 3700 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed. Read and understand all safety instruction[...]

  • Page 27

    6. Press the “GLOW PLUG” button to pr e- heat the cylinders per the following table: Never press the Glow Plug button continuously for more than 20 seconds. 7. Release the “GLOW PLUG” button and press the “ST ART” button to crank the engine. Release when the engine starts. 8. Check that the indicator lights are of f. If not, imme- diate[...]

  • Page 28

    WELDING OPERA TION Do not attempt to use this equipment until you have thoroughly r ead 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. • Do not touch electrically live parts or el[...]

  • Page 29

    DO NOT change the RANGE switch setting while welding. This can result in damage to the switch. FIGURE B.4 WELDING CIRCUIT CONNECTIONS AFTER YOU FINISH WELDING: 1. Stop the engine. 2. Allow the electrode and work to cool completely . 3. Remove the work clamp from the work. 4. Remove any remaining piece of electrode fr om the electrode holder . 5. If[...]

  • Page 30

    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 OPERA TION B-13 B-13 RANGER 300 D AND 300 DLX T ABLE B.2 AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS Pure (EWP) “Range” Appropriate T ungsten Diameter Switch Settings W e[...]

  • Page 31

    DC WIRE FEED WELDING (CV) WITH RANGER 300 D 1. Connect an LN-25 with inter nal contactor to the Ranger 300 D. 2. The only Innershield electrode r ecommended 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: The Ranger 300 D is recommended for [...]

  • Page 32

    OPERA TION B-15 B-15 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 SUMMAR Y OF WELDING PROCESSES AND MACHINE SETTINGS T ABLE B.3 SUMMAR Y OF WELDING PROCESSES FOR RANGER 300 DLX CONTROL CABLE & D[...]

  • Page 33

    INST ALLA TION B-16 B-16 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 CONTROL CABLE & DIAGRAM IDLE MODE OUTPUT CONTROL SWITCH ELECTRODE WHEN NOT WELDING TO ST ART WELDING PROCESS STICK - CC CARB[...]

  • Page 34

    AUXILIAR Y 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 thr ee r eceptacles 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. Do not connect any plugs that connect to the [...]

  • Page 35

    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 OPERA TION B-18 B-18 RANGER 300 D AND 300 DLX 120/240 V DUAL VOL T AGE RECEPT ACLE The 120/240 V receptacle can supply up to 50 amps of 240 V power to a two wire cir cuit, up to [...]

  • Page 36

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C General Options/Accessories .........................................................[...]

  • Page 37

    GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your RANGER 300 from your local Lincoln Distributor . K953-1 T wo-Wheeled T railer - 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. K802-R Power Plug Kit - Pr ovides four 15 amp, [...]

  • Page 38

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGA TIVE (-) BA TTER Y LEAD before servicing. • Do not touch electrically live parts. MOVING P ARTS can injure. • Keep guards in place. • Keep away from moving parts. • Only qualified personnel should install, use or ser[...]

  • Page 39

    CONNECTION OF THE LN-25 TO THE RANGER 300 D AND DLX “ACROSS THE ARC” USING THE K444-1 REMOTE CONTROL (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-25 to the ELECTRODE terminal of the welder . Connect the work cable to the WORK terminal of the welder . NOTE: W elding cable must be sized for current and dut[...]

  • Page 40

    ACCESSORIES C-5 C-5 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 CONNECTION OF THE LN-25 TO THE RANGER 300 (DLX ONL Y) USING THE K624-1 42V REMOTE CONTROL (SEE FIGURE C.3.) 1. Shut the welder off. 2[...]

  • Page 41

    ACCESSORIES C-6 C-6 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 CONNECTION OF THE LN-7 TO THE RANGER (300 DLX ONL Y) USING K584 CONTROL CABLE (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect th[...]

  • Page 42

    ACCESSORIES C-7 C-7 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 CONNECTION OF THE LN-8 TO THE RANGER 300 (DLX ONL Y) USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connec[...]

  • Page 43

    ACCESSORIES C-8 C-8 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 CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE RANGER 300 (DLX ONL Y) (SEE FIGURE C.6.) 1. Shut the welder[...]

  • Page 44

    CONNECTION OF THE K930-1 TIG MODULE TO THE RANGER 300 (DLX ONL Y) USING K936 CONTROL CABLE (SEE FIGURE C.7.) 1. Shut the welder off. 2. Connect the electrode cable fr om the K930-1 TIG Module to the ELECTRODE terminal of the welder . Connect the work cable to the WORK terminal of the welder . NOTE: W elding cable must be sized for current and duty [...]

  • 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 RANGER 300 D AND 300 DLX T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions......................[...]

  • Page 47

    SAFETY PRECAUTIONS Have qualified personnel do the maintenance work. Tu rn the engine of f before working inside the machine. In some cases, it may be necessary to remove safety guards to perform r equired maintenance. Remove guards only when necessary and r eplace them when the maintenance requiring their r emoval is complete. Always use the great[...]

  • Page 48

    ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE (Refer to Figure D.3 for the location of maintenance components.) To prevent the engine fr om accidentally starting, dis- connect the negative battery cable before servicing the engine. See T able D.1 for a summary of maintenance intervals for the items listed below . More fr equent service may be[...]

  • Page 49

    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. See the Kubota Engine Operator's Manual for instruc- tions on replacing the fuel filter . See T[...]

  • Page 50

    Always premix the antifr eeze and clean tap water before adding to the radiator or the overflow tank. It is very important that a precise 50/50 solution be used with this engine year round. This gives pr oper cooling during hot weather and freezing pr otection to -34°F (-37°C). Cooling solution exceeding 50% ethylene glycol can r esult in engine [...]

  • Page 51

    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 MAINTENANCE D-6 D-6 RANGER 300 D AND 300 DLX CHARGING THE BA TTERY When you char ge, jump, replace, or otherwise connect battery cables to the battery , be sure the polarity is c[...]

  • Page 52

    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 MAINTENANCE D-7 D-7 RANGER 300 D AND 300 DLX FIGURE D.3 MAJOR COMPONENT LOCA TIONS 11. CAP ACITOR BANK (RANGER 300 DLX ONL Y) 12. RADIA TOR ASSEMBL Y 13. CHOKE ASSEMBL Y 14. LIFT[...]

  • 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 RANGER 300 D AND 300 DLX Theory of Operation ............................................................................................................. Section E Battery , Starter , Engine, Glow Plugs, Engine Protection, Rotor , Stator , a[...]

  • Page 55

    BA TTER Y , ST ARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION, ROTOR, ST A TOR AND IDLER SOLENOID The 12VDC battery powers the starter motor and glow plugs. The glow plugs are used to pr eheat the diesel engine to enhance starting. When the engine is start- ed and running, the battery circuit voltage is fed through the printed cir cuit board to the r[...]

  • Page 56

    ROTOR FIELD FEEDBACK, AUXILIAR Y AND WIRE FEEDER POWER The AC voltage developed in the field winding is fed to the full wave field bridge. The DC output of the field bridge is filtered by the field capacitor and contr olled by the printed circuit boar d according to the setting of the machine’ s output control or remote contr ol. This filtered an[...]

  • Page 57

    WELD WINDING, REACTOR AND RANGE SWITCH The stator weld winding is connected to the reactor and range switch. The inductance in the reactor of fers an impedance to current flow . The reactor coil is tapped at various points. As the range switch is rotat- ed, differ ent amounts of reactor coil are br ought into the current path. As mor e tur ns of re[...]

  • Page 58

    OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, OUTPUT CONT ACTOR AND OUTPUT TERMINALS The AC voltage developed in the stator weld winding is delivered, thr ough the reactor and range switch, to the output bridge and polarity switch. Depending upon the setting of the polarity switch, either AC volt- age or DC voltage is delivered to the output terminals. If[...]

  • 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 RANGER 300 D AND 300 DLX Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide .....................................................[...]

  • Page 61

    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 TROUBLESHOOTING & REP AIR F-2 F-2 RANGER 300 D AND 300 DLX HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained [...]

  • Page 62

    TROUBLESHOOTING & REP AIR F-3 F-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 Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor el[...]

  • Page 63

    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 TROUBLESHOOTING & REP AIR F-4 F-4 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any reaso[...]

  • Page 64

    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 TROUBLESHOOTING & REP AIR F-5 F-5 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any reaso[...]

  • Page 65

    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 TROUBLESHOOTING & REP AIR F-6 F-6 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any reaso[...]

  • Page 66

    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 TROUBLESHOOTING & REP AIR F-7 F-7 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any reaso[...]

  • Page 67

    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 TROUBLESHOOTING & REP AIR F-8 F-8 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any reaso[...]

  • Page 68

    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 TROUBLESHOOTING & REP AIR F-9 F-9 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any reaso[...]

  • Page 69

    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 TROUBLESHOOTING & REP AIR F-10 F-10 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any rea[...]

  • Page 70

    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 TROUBLESHOOTING & REP AIR F-11 F-11 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any rea[...]

  • Page 71

    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 F-12 F-12 RANGER 300 D AND 300 DLX TROUBLESHOOTING & REP AIR OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. CAUTION If for any rea[...]

  • Page 72

    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 TROUBLESHOOTING & REP AIR F-13 F-13 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 73

    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 TROUBLESHOOTING & REP AIR F-14 F-14 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 74

    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 TROUBLESHOOTING & REP AIR F-15 F-15 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 75

    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 TROUBLESHOOTING & REP AIR F-16 F-16 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 76

    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 TROUBLESHOOTING & REP AIR F-17 F-17 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 77

    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 TROUBLESHOOTING & REP AIR F-18 F-18 RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 78

    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 TROUBLESHOOTING & REP AIR F-19 F-19 RANGER 300 D AND 300 DLX TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 79

    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 F-20 F-20 TROUBLESHOOTING & REP AIR RANGER 300 D AND 300 DLX OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DET AILED IN THE BEGINNING OF THIS MANUAL. PROBLEMS (SYMPTOMS) PO[...]

  • Page 80

    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 ROTOR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in [...]

  • Page 81

    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 TROUBLESHOOTING & REP AIR F-22 F-22 RANGER 300 D AND 300 DLX ROTOR RESIST ANCE TEST (continued) FIGURE F .1 – ROTOR BRUSH LEADS REMOVED TEST PROCEDURE 1. Conduct the test w[...]

  • Page 82

    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 TROUBLESHOOTING & REP AIR F-23 F-23 RANGER 300 D AND 300 DLX W ARNING OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory tra[...]

  • Page 83

    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 TROUBLESHOOTING & REP AIR F-24 F-24 RANGER 300 D AND 300 DLX OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .2 – LOCA TION OF OUTPUT RECTIFIER DIODE LEADS TEST PROCEDURE[...]

  • Page 84

    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 TROUBLESHOOTING & REP AIR F-25 F-25 RANGER 300 D AND 300 DLX W ARNING FUEL SHUTDOWN SOLENOID RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric [...]

  • Page 85

    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 TEST PROCEDURE 1. Conduct this test with the engine off. 2. Unlatch and open the right side engine access door . 3. Locate and disconnect plug J12. See Figure F .3. Also see the [...]

  • Page 86

    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 TROUBLESHOOTING & REP AIR F-27 F-27 RANGER 300 D AND 300 DLX W ARNING HIGH SPEED SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained[...]

  • Page 87

    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 TROUBLESHOOTING & REP AIR F-28 F-28 RANGER 300 D AND 300 DLX HIGH SPEED SOLENOID TEST (continued) FIGURE F .5 – SOLENOID LEADS PULL-IN COIL (LARGER TERMINALS TOP AND BOTTOM[...]

  • Page 88

    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 TROUBLESHOOTING & REP AIR F-29 F-29 RANGER 300 D AND 300 DLX W ARNING ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory [...]

  • Page 89

    TROUBLESHOOTING & REP AIR F-30 F-30 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 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .6 – STROBE MARK LOCA TION TEST PROCEDURE 1. Conduct this [...]

  • Page 90

    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 TROUBLESHOOTING & REP AIR 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 ADJUSTM[...]

  • Page 91

    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 TROUBLESHOOTING & REP AIR F-32 F-32 RANGER 300 D AND 300 DLX ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorr ect, adjust the throttle as fo[...]

  • Page 92

    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 TROUBLESHOOTING & REP AIR F-33 F-33 RANGER 300 D AND 300 DLX W ARNING AUXILIAR Y AND FIELD WINDING TEST Service and repair should be performed by only Lincoln Electric factor[...]

  • Page 93

    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 TROUBLESHOOTING & REP AIR F-34 F-34 RANGER 300 D AND 300 DLX AUXILIAR Y AND FIELD WINDING TEST (continued) FIGURE F .9 – LOCA TION OF LEADS #3A AND #3B TEST PROCEDURE To te[...]

  • Page 94

    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 TROUBLESHOOTING & REP AIR F-35 F-35 RANGER 300 D AND 300 DLX AUXILIAR Y AND FIELD WINDING TEST (continued) FIGURE F .10 – LOCA TION OF LEADS #7 AND #9 A T FIELD BRIDGE RECT[...]

  • Page 95

    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 TROUBLESHOOTING & REP AIR F-36 F-36 RANGER 300 D AND 300 DLX AUXILIAR Y AND FIELD WINDING TEST (continued) FIGURE F .11 – 14-PIN AMPHENOL PIN ASSIGNMENTS To test the feeder[...]

  • Page 96

    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 TROUBLESHOOTING & REP AIR F-37 F-37 RANGER 300 D AND 300 DLX W ARNING ROTOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained per[...]

  • Page 97

    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 TROUBLESHOOTING & REP AIR F-38 F-38 RANGER 300 D AND 300 DLX ROTOR VOL T AGE TEST (continued) FIGURE F .12 – LOCA TION OF LEADS 200A AND 219 FOR ROTOR VOL T AGE TEST TEST P[...]

  • Page 98

    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 INST ALLA TION F-39 F-39 RANGER 300 D AND 300 DLX W ARNING CHARGING CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauth[...]

  • Page 99

    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 INST ALLA TION F-40 F-40 RANGER 300 D AND 300 DLX CHARGING CIRCUIT TEST (continued) FIGURE F .13 – VOL T AGE REGULA TOR LEADS TEST PROCEDURE 1. With the 5/16” and 3/8” nut [...]

  • Page 100

    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 TROUBLESHOOTING & REP AIR F-41 F-41 RANGER 300 D AND 300 DLX This is the typical auxiliary output voltage generated from a pr operly operating machine. Note that each vertica[...]

  • Page 101

    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 TROUBLESHOOTING & REP AIR F-42 F-42 RANGER 300 D AND 300 DLX This is the typical CV output voltage generated from a pr operly operating machine. Note that each vertical divis[...]

  • Page 102

    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 TROUBLESHOOTING & REP AIR F-43 F-43 RANGER 300 D AND 300 DLX This is the typical DC output voltage generated from a pr operly operating machine. Note that each vertical divis[...]

  • Page 103

    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 TROUBLESHOOTING & REP AIR F-44 F-44 RANGER 300 D AND 300 DLX This is the typical AC output voltage generated from a pr operly operating machine. Note that each vertical divis[...]

  • Page 104

    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 TROUBLESHOOTING & REP AIR F-45 F-45 RANGER 300 D AND 300 DLX This is NOT the typical DC (+) output voltage waveform. One output diode is not functioning. Note the “gap” i[...]

  • Page 105

    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 TROUBLESHOOTING & REP AIR F-46 F-46 RANGER 300 D AND 300 DLX This is NOT the typical CV output voltage waveform. The capacitor bank is not functioning. Note the “ripple” [...]

  • Page 106

    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 TROUBLESHOOTING & REP AIR F-47 F-47 RANGER 300 D AND 300 DLX This is the typical CV output voltage generated from a pr operly operating machine. Note that each vertical divis[...]

  • Page 107

    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 TROUBLESHOOTING & REP AIR F-48 F-48 RANGER 300 D AND 300 DLX SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Coupling ...............[...]

  • Page 108

    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 TROUBLESHOOTING & REP AIR F-49 F-49 RANGER 300 D AND 300 DLX 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Co[...]

  • Page 109

    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 TROUBLESHOOTING & REP AIR F-50 F-50 RANGER 300 D AND 300 DLX BRUSH REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory t[...]

  • Page 110

    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 TROUBLESHOOTING & REP AIR F-51 F-51 RANGER 300 D AND 300 DLX BRUSH REMOV AL AND REPLACEMENT (continued) FIGURE F .14 – BRUSH LEADS/BRUSHES RET AINED WITH CABLE TIE PROCEDUR[...]

  • Page 111

    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 TROUBLESHOOTING & REP AIR F-52 F-52 RANGER 300 D AND 300 DLX 12. Slowly remove the non-metallic retainer from the brush holder and let the brushes snap back against the slip [...]

  • Page 112

    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 TROUBLESHOOTING & REP AIR F-53 F-53 RANGER 300 D AND 300 DLX W ARNING FIELD CAP ACITOR AND/OR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed[...]

  • Page 113

    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 TROUBLESHOOTING & REP AIR F-54 F-54 RANGER 300 D AND 300 DLX FIELD CAP ACITOR AND/OR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .15 – RECTIFIER BRIDGE L[...]

  • Page 114

    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 TROUBLESHOOTING & REP AIR F-55 F-55 RANGER 300 D AND 300 DLX FIELD CAP ACITOR AND/OR RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) 8. Connect the wires to the proper [...]

  • Page 115

    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 TROUBLESHOOTING & REP AIR F-56 F-56 RANGER 300 D AND 300 DLX W ARNING CONTROL BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric f[...]

  • Page 116

    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 TROUBLESHOOTING & REP AIR F-57 F-57 RANGER 300 D AND 300 DLX CONTROL BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .16 – PRINTED CIRCUIT BOARD LOCA TION PROCEDURE Bef[...]

  • Page 117

    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 TROUBLESHOOTING & REP AIR F-58 F-58 RANGER 300 D AND 300 DLX 11. With the 1/4” nut driver , remove the screws holding the contr ol board. 12. Replace the old control board [...]

  • Page 118

    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 TROUBLESHOOTING & REP AIR F-59 F-59 RANGER 300 D AND 300 DLX W ARNING OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln [...]

  • Page 119

    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 TROUBLESHOOTING & REP AIR F-60 F-60 RANGER 300 D AND 300 DLX OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .17 – OUTPUT RECTIFIER CONNECTIONS PROCED[...]

  • Page 120

    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 TROUBLESHOOTING & REP AIR F-61 F-61 RANGER 300 D AND 300 DLX OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) Reassembly: Refer to the Wiring Diagram for proper c[...]

  • Page 121

    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 TROUBLESHOOTING & REP AIR F-62 F-62 RANGER 300 D AND 300 DLX W ARNING OUTPUT CAP ACITOR BANK REMOV AL AND REPLACEMENT (RANGER 300 DLX ONL Y) Service and repair should be perf[...]

  • Page 122

    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 TROUBLESHOOTING & REP AIR F-63 F-63 RANGER 300 D AND 300 DLX OUTPUT CAP ACITOR BANK REMOV AL AND REPLACEMENT (RANGER 300 DLX ONL Y) (continued) FIGURE F .18 - OUTPUT CAP ACIT[...]

  • Page 123

    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 TROUBLESHOOTING & REP AIR F-64 F-64 RANGER 300 D AND 300 DLX W ARNING OUTPUT CONT ACTOR REMOV AL AND REPLACEMENT (RANGER 300 DLX ONL Y) Service and repair should be performed[...]

  • Page 124

    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 TROUBLESHOOTING & REP AIR F-65 F-65 RANGER 300 D AND 300 DLX OUTPUT CONT ACTOR REMOV AL AND REPLACEMENT (RANGER 300 DLX ONL Y) (continued) FIGURE F .19 – OUTPUT CONT ACTOR [...]

  • Page 125

    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 TROUBLESHOOTING & REP AIRs F-66 F-66 RANGER 300 D AND 300 DLX OUTPUT CONT ACTOR REMOV AL AND REPLACEMENT (RANGER 300 DLX ONL Y) (continued) FIGURE F .20 – CONT ACTOR COIL L[...]

  • Page 126

    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 TROUBLESHOOTING & REP AIR F-67 F-67 RANGER 300 D AND 300 DLX W ARNING ST A TOR AND/OR ROTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln El[...]

  • Page 127

    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 TROUBLESHOOTING & REP AIR F-68 F-68 RANGER 300 D AND 300 DLX ST A TOR AND/OR REMOV AL AND REPLACEMENT (continued) FIGURE F .21 – COMPONENT LOCA TIONS, ST A TOR/ROTOR REMOV [...]

  • Page 128

    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 TROUBLESHOOTING & REP AIR F-69 F-69 RANGER 300 D AND 300 DLX ST A TOR AND/OR REMOV AL AND REPLACEMENT (continued) ST A TOR REMOV AL PROCEDURE 1. Conduct this procedur e with [...]

  • Page 129

    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 TROUBLESHOOTING & REP AIR F-70 F-70 RANGER 300 D AND 300 DLX 21. Using the 1/2” wrench, remove the thr ee r eactor mounting bolts fr om the machine base. 22. Using the 5/16[...]

  • Page 130

    REASSEMBL Y NOTES 1. Be sure to r emove the rotor bearing from the stator frame before r einstalling the r otor/stator Also r emove the tolerance ring. 2. Install the rotor to the flex plate and install the flex plate to the engine. 3. Carefully install the stator . Tighten the eight bolts finger -tight only . 4. Install a new tolerance ring and pr[...]

  • Page 131

    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 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any r eason that requires you to r emove any mechanical part which could affect the machine’ s elect[...]

  • Page 132

    G-1 G-1 RANGER 300 D AND 300 DLX Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM RAN[...]

  • Page 133

    ELECTRICAL DIAGRAMS G-2 RANGER 300 WIRING DIAGRAM - RANGER 300 D (CODE 10399) 67 75A 3C PCB2 BYPASS PC 4 1 76B 2 J10 227 76A 5E 4 BLACK BLACK 11 RECEPTACLE 3B 125/250V. SINGLE BLACK BLACK BLACK BLACK 3F 3A 3B 201 B 1J10 2J10 222B 225 223 3J10 HIGH GLOW PLUG GLOW PLUGS FLASHING CURRENT 5 AC 9 15A 50A 77B 201 CB2 75B 3 CB7 15A J10 5 W4 254 TERMINALS [...]

  • Page 134

    ELECTRICAL DIAGRAMS G-3 RANGER 300 WIRING DIAGRAM - RANGER 300 DLX (CODE 10400) 5A 221 INDICATES JACK NUMBER 5 1 CAPACITORS 236A OUTPUT 4 RECTIFIER 5A _ C2 (-) A2 + 245 DC+ 232 R4 R3 W7 224 224C C1 3B WHITE 3F 11 3A 15A BLACK BLACK 12 BLACK BLACK WHITE 120/240V J8 BLACK BLACK BLACK BLACK BLACK BLACK CB7 3D (15AMP) SWITCH A1 210 W14 S2A (CLOSED POSI[...]

  • Page 135

    ELECTRICAL DIAGRAMS G-4 RANGER 300 WIRING DIAGRAM - RANGER 300 DLX (CODE 10850) 5A 221 INDICAT ES JACK NUMBER 5 1 CA PACITORS 236A W OUTPUT 4 RECTIFIER 5A _ C2 (-) A2 + 245 DC+ 232 R4 R3 W7 224 224C C1 3B W H IT E 3F 11 3A 15A BLACK B L A C K 12 BLACK B L A C K W H IT E 120/240V J8 B L A C K A B L A C K B L A C K B L A C K BLACK B L A C K CB7 3D (1[...]

  • Page 136

    ELECTRICAL DIAGRAMS G-5 RANGER 300 SCHEMA TIC - CONTROL PC BOARD A G-5 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 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 137

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 138

    ELECTRICAL DIAGRAMS G-7 RANGER 300 SCHEMA TIC - BYP ASS PC BOARD G-7 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 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 139

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 140

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]