Lincoln Electric Welder SVM148 B User Manual
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  
THROUGHOUT.  
CONTAINED  
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  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
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.  
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 Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn 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 local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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iv  
iv  
SAFETY  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie du  
corps.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
qu’un verre blanc afin de se protéger les yeux du rayon-  
nement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
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NOTES  
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vi  
vi  
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
RETURN TO MAIN INDEX  
Page  
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  
Recommended Applications ......................................................................................................B-4  
Limitations .................................................................................................................................B-4  
Controls and Settings.................................................................................................................B-5  
Engine Operation........................................................................................................................B-9  
Welding Operation ....................................................................................................................B-11  
Auxiliary Power .........................................................................................................................B-17  
Accessories...........................................................................................................................Section C  
Maintenance .........................................................................................................................Section D  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair.................................................................................................Section F  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual................................................................................................................................P-290  
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Section A-1  
Section A-1  
TABLE OF CONTENTS  
- 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  
High Altitude Operation........................................................................................................A-4  
Towing ..................................................................................................................................A-4  
Lifting....................................................................................................................................A-4  
Additional Safety Precautions ..............................................................................................A-4  
Pre-operation Engine Service.....................................................................................................A-4  
Oil .........................................................................................................................................A-4  
Fuel.......................................................................................................................................A-5  
Engine Coolant.....................................................................................................................A-5  
Battery Connections.............................................................................................................A-5  
Exhaust Deflector.................................................................................................................A-5  
Spark Arrester ......................................................................................................................A-5  
High Frequency Generation for TIG Applications.......................................................................A-6  
Remote Control...........................................................................................................................A-6  
Welding Terminals.......................................................................................................................A-6  
Electrical Connections................................................................................................................A-6  
Machine Grounding..............................................................................................................A-6  
Welding Cable Connections.................................................................................................A-7  
Cable Size and Length...................................................................................................A-7  
Cable Installation ...........................................................................................................A-7  
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment........................................A-7  
Circuit Breakers....................................................................................................................A-7  
Premises Wiring....................................................................................................................A-8  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - RANGER 300 D AND 300 DLX  
INPUT - DIESEL ENGINE  
Starting  
Manufacturer Description  
Speed  
Displacement  
System  
Capacities  
KUBOTA  
D905B-2  
3 cyl.,  
liquid-cooled  
diesel  
3600 RPM  
Full load  
54.9 cu. in.  
(898 cc)  
Electric  
12 VDC  
battery  
Fuel: 10 gal. (38 L)  
Oil: 5.4 qt. (5.1 L)  
26 HP @  
3600 RPM  
3700 RPM  
High idle  
Cooling system:  
5.7 qts. (5.4 L)  
2150 RPM  
Low idle  
RATED OUTPUT - WELDER  
Duty Cycle  
Amps  
Volts at Rated Amperes  
100% Duty Cycle  
100% Duty Cycle  
100% Duty Cycle  
60%(1)  
300 DC Constant Current  
300 AC Constant Current  
200 DC Constant Voltage (300 D)  
300 DC Constant Voltage (300 DLX)  
280 DC Constant Voltage (300 DLX)  
25  
25  
20  
30  
30  
100%  
OUTPUT - WELDER AND GENERATOR  
Max. Open  
Circuit Voltage  
Auxiliary Power for  
Wire Feeders  
Welding Ranges  
Auxiliary Power(2)  
40 - 300 Amps  
Constant Current  
80 Volts RMS  
@ 3700 RPM  
12,000 Continuous Watts  
60 Hz, 120/240 VAC  
100% Duty Cycle  
42V, 60 Hz, 8 Amps(3)  
120V, 60 Hz, 8 Amps(3)  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
37.38 in.  
949.4 mm  
24.75 in.  
628.7 mm  
60.50 in.  
1528.6 mm  
1093 lbs. (300 D)  
1133 lbs. (300 DLX)  
480.8 kg (300 D)  
499.0 kg (300 DLX)  
(1)Duty cycle is based on a 10-minute period. The machine can be loaded to 300 amps for 6 minutes out of every 10-minute period.  
(2)Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within 10% at all loads up to rated capacity.  
When welding, available auxiliary power will be reduced.  
(3)Ranger 300 DLX only.  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
Always operate the RANGER 300 with the case roof on  
and all machine components completely assembled.  
This will protect you from the dangers of moving parts,  
hot metal surfaces, and live electrical devices.  
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.  
STORING  
1. Store the machine in a cool, dry place when it is not  
in use. Protect it from dust and dirt. Keep it where  
it can’t be accidentally damaged from construction  
activities, moving vehicles, and other hazards.  
2. Drain the engine oil and refill with fresh 10W30 oil.  
Run the engine for about five minutes to circulate oil  
to all the parts. See the Maintenance section of  
this manual for details on changing oil.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
3. If you are storing the machine for more than 30  
days, drain the coolant from the radiator. Open the  
cock at the bottom of the radiator and remove the  
pressure cap so that the coolant drains completely.  
Attach a note that says “NO WATER” on the radia-  
tor.  
• Always wear dry insulating gloves.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
4. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
MOVING PARTS can injure.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
5. If the engine is not used for a long period of time,  
every two to three months fill the radiator and run  
the engine for about five minutes to keep it free from  
rust.  
STACKING  
See additional warning information at front of this  
operator’s manual.  
RANGER 300 machines CANNOT be stacked.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
TILTING  
Place the machine on a secure, level surface whenev-  
er you use it or store it. Any surfaces you place it on  
other than the ground must be firm, non-skid, and  
structurally sound.  
LOCATION AND VENTILATION  
Whenever you use the RANGER 300, be sure that  
clean cooling air can flow through the machine’s diesel  
engine and the machine case. Avoid dusty, dirty  
areas. Also, keep the machine away from heat  
sources. Do not place the engine end of the machine  
anywhere near hot engine exhaust from another  
machine or closer than two feet from a wall. And of  
course, make sure that engine exhaust is ventilated to  
an open, outside area.  
The diesel engine is designed to run in a level position  
for best performance. It can operate at an angle, but  
this should never be more than 20 degrees in any  
direction. If you do operate it at a slight angle, be sure  
to check the oil regularly and keep the oil level at the  
FULL mark as it would be in its normal level condition.  
Also, fuel capacity will be a little less at an angle.  
The RANGER 300 may be used outdoors. Do not set  
the machine in puddles or otherwise submerge it in  
water. Such practices pose safety hazards and cause  
improper operation and corrosion of parts.  
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A-4  
A-4  
INSTALLATION  
HIGH ALTITUDE OPERATION  
ADDITIONAL SAFETY PRECAUTIONS  
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.  
(1,500 m). Contact a Kubota Service Representative.  
WARNING  
FALLING EQUIPMENT can cause  
injury.  
• Do not lift this machine using lift bail  
if it is equipped with a heavy acces-  
sory such as trailer or gas cylinder.  
TOWING  
• Lift only with equipment of adequate lifting  
capacity.  
The recommended trailer for use with this equipment  
for road, in-plant, and yard towing by a vehicle1 is  
Lincoln’s K-953-1. If the user adapts a non-Lincoln  
trailer, he must assume responsibility that the method  
of attachment and usage does not result in a safety  
hazard nor damage the welding equipment. Some of  
the factors to be considered are as follows:  
• Be sure machine is stable when lifting.  
PRE-OPERATION ENGINE SERVICE  
CAUTION  
READ and UNDERSTAND the engine operating and  
maintenance instructions supplied with this machine.  
1. Design capacity of the trailer vs. weight of the  
Lincoln equipment and likely additional attach-  
ments.  
2. Proper support of and attachment to the base of  
the welding equipment so that there will be no  
undo stress to the trailer’s framework.  
WARNING  
• Keep hands away from the engine muffler or HOT  
engine parts.  
3. Proper alignment of the equipment on the trailer to  
insure stability side-to-side and front-to-back when  
it is being moved and when standing by itself.  
• Stop the engine when fueling.  
• Do not smoke when fueling.  
• Do not overfill the fuel tank.  
4. Typical conditions of use, such as travel speed,  
roughness of the surface on which the trailer will be  
operated, and environmental conditions.  
• Wipe up spilled fuel and allow the fumes to clear  
before starting the engine.  
5. Proper preventative maintenance of the trailer.  
6. Conformance with federal, state, and local laws.1  
1 Consult applicable federal, state, and local laws regarding specific  
requirements for use on public highways.  
• Keep sparks and flame away from the fuel tank.  
LIFTING  
OIL  
The RANGER 300 weighs approximately 1150 lbs/522  
kg. A lift bail is mounted to the machine frame and  
should always be used when lifting the machine.  
The RANGER 300 is shipped with the engine filled with  
SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE  
YOU START THE ENGINE. If it is not full, add enough  
oil to fill it to the full mark.  
Always use oil that is rated for diesel engine service  
(API classification of CD/CE).  
For more information on oil viscosity and service con-  
ditions, see the Maintenance section of this manual  
and the engine Operator’s Manual.  
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A-5  
A-5  
INSTALLATION  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
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.  
a) Installing new batteries.  
b) Using a booster.  
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.  
Use correct polarity — Negative Ground.  
The RANGER 300 is shipped with the negative battery  
cable disconnected. Before you operate the machine,  
make sure the Engine Switch is in the OFF position  
and attach the disconnected cable securely to the  
negative (-) battery terminal.  
ENGINE COOLANT  
WARNING  
Remove the insulating cap from the negative battery  
terminal. Replace and tighten the negative battery  
cable terminal.  
HOT COOLANT can burn skin.  
• Do not remove cap if radiator is hot.  
NOTE: This machine is furnished with a wet charged  
battery; if unused for several months, the battery may  
require a booster charge. Be sure to use the correct  
polarity when charging the battery.  
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  
Manual for more information on coolant.  
EXHAUST DEFLECTOR  
CAUTION  
Shut off the machine and allow the muffler to cool  
before touching the muffler.  
BATTERY CONNECTIONS  
WARNING  
The RANGER 300 is shipped with the exhaust deflec-  
tor detached. Install it on the muffler outlet using the  
clamp supplied. Rotate the deflector to the desired  
direction before tightening the clamp.  
GASES FROM BATTERY can explode.  
• Keep sparks, flame and cigarettes  
away from battery.  
SPARK ARRESTER  
To prevent EXPLOSION when:  
Diesel engine mufflers may emit sparks when the  
engine is running. Some federal, state, or local laws  
require spark arresters in locations where unarrested  
sparks could present a fire hazard.  
•
INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and connect to  
new battery last.  
Standard muffler and deflectors (like the ones includ-  
ed with the RANGER 300) do not act as spark  
arresters. When local laws require it, a spark arrester  
must be installed on the machine and properly main-  
tained. An optional spark arrester kit (K903-1) is avail-  
able for your RANGER 300. See the Accessories sec-  
tion of this manual for more information.  
•
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.  
•
USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to negative  
battery lead at engine foot.  
CAUTION  
BATTERY ACID can burn eyes and skin.  
An incorrect spark arrester may lead to damage to the  
engine or reduce performance.  
• Wear gloves and eye protection and  
be careful when working near battery.  
• Follow instructions printed on battery.  
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A-6  
A-6  
INSTALLATION  
MACHINE GROUNDING  
HIGH FREQUENCY GENERATORS  
FOR TIG APPLICATIONS  
Because the RANGER 300 creates its own power from  
its diesel-engine driven generator, and if the machine  
is not connected to premises wiring (home, shop, etc.),  
you do not need to connect the machine frame to an  
earth ground. However, for best protection against  
electrical shock, connect a heavy gauge wire (#8 AWG  
or larger) from the ground stud located on the bottom  
of the output panel (Figure A.1) to a suitable earth  
ground such as a metal pipe driven into the ground.  
The ground stud is marked with the ground symbol.  
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 required 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 be  
installed into the Ranger 300.  
The Ranger 300 and any high frequency generating  
equipment must be properly grounded. See the K799  
Hi-Freq Unit and the K930-1 TIG Module operating  
manuals for complete instructions on installation,  
operation, and maintenance. Also see the Acces-  
sories section of this manual.  
WARNING  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
REMOTE CONTROL  
When the Ranger 300 is mounted on a truck or a trail-  
er, the machine generator ground stud MUST be  
securely connected to the metal frame of the vehicle.  
See Figure A.1.  
The Ranger 300 DLX is equipped with a 6-pin and a  
14-pin connector. The 6-pin connector is for connect-  
ing the K857 or K857-1 Remote Control (optional) or  
the K870 hand Amptrol or K812 foot Amptrol (TIG  
applications).  
If the RANGER 300 is connected to premises wiring  
such as a home or shop, it must be properly connect-  
ed to the system earth ground.  
The 14-pin connector is used to connect a wire feeder  
or K930-1 TIG Module control cable. When a remote  
output control is used, the output control toggle switch  
must be set at REMOTE.  
FIGURE A.1  
RANGER 300 OUTPUT CONNECTIONS  
NOTE: When using the 14-pin connector, do NOT  
connect anything to the 6-pin connector if the wire  
feeder has a built-in power source output control.  
Also see the Accessories section of this manual for  
more information on wire feeder connections.  
2
E
F
WELDING TERMINALS  
The Ranger 300 DLX has a toggle switch for selecting  
“hot” welding terminals (WELDING TERMINALS  
ALWAYS ON position) or “cold” welding terminals  
(WELDING TERMINALS REMOTELY CONTROLLED  
position).  
1
ELECTRICAL CONNECTIONS  
4
3
See Figure A.1 for location of the 120 and 240 volt  
receptacles, weld output terminals, circuit breakers  
and ground stud.  
1. 120/240 VOLT, 50 AMP RECEPTACLE  
2. 120 VOLT, 15 AMP RECEPTACLES (2)  
3. WELD OUTPUT TERMINALS  
4. GROUND STUD  
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A-7  
A-7  
INSTALLATION  
WELDING CABLE CONNECTIONS  
CAUTION  
CABLE SIZE AND LENGTH  
• Loose connections will cause the output terminals to  
overheat. The terminals may eventually melt.  
Be sure to use welding cables that are large enough.  
The correct size and length becomes especially impor-  
tant when you are welding at a distance from the  
welder.  
• Do not cross the welding cables at the output termi-  
nal connection. Keep the cables isolated and sepa-  
rate from one another.  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
AUXILIARY POWER RECEPTACLES,  
PLUGS, AND HAND-HELD EQUIPMENT  
Lincoln Electric offers a welding accessory kit with the  
properly specified welding cables. See the Accessories  
section of this manual for more information.  
The control panel of the RANGER 300 features three  
auxiliary power receptacles. See Figure A.1.  
• Two 15 amp, 120 volt duplex (double outlet) recep-  
tacles.  
TABLE A.1  
TOTAL COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
• One 50 amp 120/240 volt simplex (single outlet)  
receptacle.  
Through these receptacles the machine can supply up  
to 12,000 rated continuous watts of single-phase, 60  
Hz AC power.  
Cable Size for  
300 Amps  
100% Duty Cycle  
Cable Length  
1/0 AWG  
1/0 AWG  
2/0 AWG  
2/0 AWG  
3/0 AWG  
0-50 Ft. (0-15 meters)  
For further protection against electric shock, any elec-  
trical equipment connected to the generator recepta-  
cles must use a three-blade, grounded type plug or an  
Underwriter’s Laboratories (UL) approved double insu-  
lation system with a two-blade plug. Lincoln offers an  
accessory plug kit that has the right type of plugs. See  
the Accessories section of this manual for more infor-  
mation.  
50-100 Ft. (15-30 meters)  
100-150 Ft. (30-46 meters)  
150-200 Ft. (46-61 meters)  
200-250 Ft. (61-76 meters)  
CABLE INSTALLATION  
If you need ground fault protection for hand-held  
equipment, refer to the K896-1 GFCI Receptacle kit in  
the Accessories section of this manual for more infor-  
mation.  
Install the welding cables to your RANGER 300 as fol-  
lows. See Figure A.1 for location of parts.  
CIRCUIT BREAKERS  
1. The diesel engine must be OFF to install welding  
cables.  
The RANGER 300 machines are equipped with 50  
amp circuit breakers on the 120/240 V receptacle and  
15 amp circuit breakers on the 120 V receptacles for  
overload protection. Under high heat a breaker may  
tend to trip at lower loads than it would normally.  
2. Remove the flanged nuts from the weld output ter-  
minals.  
3. Connect the electrode holder and work cables to  
the weld output terminals. The terminals are iden-  
tified on the case front.  
4. Tighten the flanged nuts securely.  
5. Be certain that the metal piece you are welding (the  
“work”) is properly connected to the work clamp  
and cable.  
6. Check and tighten the connections periodically.  
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A-8  
A-8  
INSTALLATION  
• A double pole, double throw transfer switch in con-  
junction with the properly rated double throw circuit  
breaker is connected between the generator power  
and the utility meter.  
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.  
The following information and the connection diagram,  
Figure A.2, can be used as a guide by the electrician  
for most applications to premises wiring.  
PREMISES WIRING  
The RANGER 300 is suitable for temporary, standby,  
or emergency power using the engine manufacturer’s  
recommended maintenance schedule. With its three-  
wire grounded neutral generator, it can be permanent-  
ly installed as a standby power unit for 240 volt, three-  
wire, single phase 50 ampere service.  
1. Install a double pole, double throw switch between  
the power company meter and the premises dis-  
connect. The switch rating must be the same as  
or greater than the premises disconnect and  
service overcurrent protection.  
2. Take the necessary steps to assure that the load is  
limited to the capacity of the RANGER 300 by  
installing a 50 amp 240 volt double pole circuit  
breaker. Maximum rated load for the 240 volt aux-  
iliary is 50 amperes. Loading above 50 amperes  
will reduce output voltage below the allowable  
– 10% of rated voltage. This may damage appli-  
ances or other motor-driven equipment.  
WARNING  
Only a licensed, certified, trained electrician should  
install the machine to a premises or residential electri-  
cal system. Be certain that:  
• The installation complies with the National Electrical  
Code and all other applicable electrical codes.  
3. Install a 50 amp 120/240 volt plug (NEMA type 14-  
50) to a double pole circuit breaker using No. 8 or  
larger, 4 conductor cable of the desired length.  
(The 50 amp 120/240 volt plug is available in the  
optional power plug kit.)  
• The premises is isolated and no feedbacking into  
the utility system can occur. Certain state and local  
laws require the premises to be isolated before the  
generator is linked to the premises. Check your  
state and local requirements.  
4. Plug this cable into the 50 amp 120/240 volt  
receptacle on the RANGER 300 case front.  
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A-9  
A-9  
INSTALLATION  
FIGURE A.2  
CONNECTION OF RANGER 300 TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
COMPANY  
METER  
240 Volt  
60 Hz.  
3-Wire  
Service  
120 VOLT  
120 VOLT  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
GROUND  
50AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE  
SIZE RECOMMENDATIONS.  
WARNING  
Connection of Ranger 300 to premises wiring must  
be done by a licensed electrician and must comply  
with the National Electrical Code and all other  
applicable electrical codes.  
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NOTES  
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Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Safety Instructions......................................................................................................................B-2  
Additional Safety Precautions..............................................................................................B-2  
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  
Welding Operation ....................................................................................................................B-11  
General Information............................................................................................................B-11  
AC/DC Stick (Constant Current) Welding ..........................................................................B-11  
AC/DC TIG (Constant Current) Welding.............................................................................B-12  
DC Wire Feed Welding (CV) with Ranger 300 DLX............................................................B-13  
DC Wire Feed Welding (CV) with Ranger 300 D................................................................B-14  
Carbon Arc Gouging (Constant Current)............................................................................B-14  
Summary of Welding Processes and Machine Settings....................................................B-15  
Auxiliary Power ........................................................................................................................B-17  
Simultaneous Welding and Power Loads ..........................................................................B-17  
120/240 V Dual Voltage Receptacle ..................................................................................B-18  
120 V Duplex Receptacles.................................................................................................B-18  
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B-2  
B-2  
OPERATION  
WARNING  
OPERATING INSTRUCTIONS  
Read and understand this entire section before oper-  
ating your RANGER 300.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
SAFETY INSTRUCTIONS  
WARNING  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust to the outside.  
Do not attempt to use this equipment until you have  
thoroughly read all the operation and maintenance  
manuals supplied with your machine. They include  
important safety precautions; detailed engine starting,  
operating, and maintenance instructions; and parts  
lists.  
• Do not stack anything on or near the  
engine.  
MOVING PARTS can injure.  
• Do not operate this equipment with  
any of its doors open or guards off.  
ELECTRIC SHOCK can kill.  
• Stop the engine before servicing it.  
• Keep away from moving parts.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
• Insulate yourself from the work and  
ground.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
• Always wear dry insulating gloves.  
FUMES AND GASES can be dangerous.  
ADDITIONAL SAFETY PRECAUTIONS  
• Keep your head out of fumes.  
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.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
WELDING SPARKS can cause fire or  
explosion.  
• Keep flammable material away.  
• Do not weld on containers that have held  
combustibles.  
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B-3  
B-3  
OPERATION  
FOR AUXILIARY POWER  
GENERAL DESCRIPTION  
• 12,000 watts of 120/240 volt 60Hz AC auxiliary  
power.  
• Power for tools, lights, electric pumps and for  
standby emergency power.  
• Ability to drive a 2 HP motor (provided it is started  
under no load).  
• Two 15 amp industrial grade 120 volt duplex recep-  
tacles for up to 60 amps of 120 volt power.  
• One 50 amp 120/240 volt dual voltage receptacle  
for up to 50 amps of 240 volt auxiliary power.  
Allows easy connection to premises wiring.  
• Four 15 amp circuit breakers for 120V duplex  
receptacles and two 50 amp circuit breakers for  
240V receptacle.  
• Ability to weld and have AC power at the same time  
(within machine total capacity).  
• Compatible with GFCIs (ground fault circuit inter-  
rupters).  
The RANGER 300 is a diesel-engine driven, multi-  
process AC and DC arc welder and AC power gener-  
ator for commercial and residential 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 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. The RANGER 300 can also  
perform AC/DC TIG welding and DC semiautomatic  
wire feed welding.  
The engine used on the Ranger 300 machines is the  
Kubota "Super Five" water-cooled, 3 cylinder DH905  
engine. The DH905 has an offset piston design with  
built-in steel strut and a more rigid crankcase. The  
Kubota "Three Vortex Combustion System" gives  
higher power output, lower fuel consumption, lower  
noise, and cleaner exhaust. The "Super Glow System"  
gives rapid pre-heating for easy starting in cold weath-  
er. The large oil sump adds to the long life of this  
engine. The high capacity 30 amp alternator gives fast  
charging of the 495 CCA battery. The engine is  
extremely smooth and has very low vibration, even at  
low idle speed.  
OTHER FEATURES  
• Insonorized for extremely quiet operation [(99LW(A)  
and 74 db(A) @ 23 ft (7m)].  
• Kubota 3-cylinder, liquid cooled, diesel engine.  
Designed for long life, easy maintenance, excellent  
fuel economy and low noise.  
• Engine always starts in low idle for minimum engine  
wear in cold weather.  
• Manual operated lift pump for easy priming of  
engine if it runs out of fuel.  
• Engine protection system shuts engine down on low  
oil pressure or over temperature of coolant.  
• Indicator lights for low oil pressure, over tempera-  
ture and battery charger low output.  
The Ranger 300 machines are housed in a heavy  
gauge steel case that is protected by a durable pow-  
der paint finish. The case is completely insonorized for  
remarkably quiet operation. An easy to open hinged  
door allows access to the engine for single side ser-  
vice. The welder alternator has all copper windings  
and a high temperature insulation system that includes  
three coats of electrical grade varnish.  
• Engine Hour Meter standard on all models.  
• Engine coolant recovery bottle eliminates air in radi-  
ator and makes it easy to check coolant level.  
• Battery with 495 cold cranking amps.  
• Straight through ventilation - cooling air for welder  
alternator enters front of machine and is exhausted  
out rear.  
• Large capacity 10 gallon (38 l) fuel tank.  
• Automatic idler reduces engine speed when not  
welding or drawing auxiliary power. Machine  
always starts in low idle. Reduces fuel consumption  
and extends engine life.  
• Compact size fits many smaller trucks.  
• Single side engine service with easy to open access  
door.  
• Copper alternator windings and high temperature  
insulation for dependability and long life.  
• Powder painted case and base for outstanding cor-  
rosion protection.  
DESIGN FEATURES - ALL MODELS  
FOR WELDING  
• Excellent AC and DC constant current output for  
stick welding applications.  
• 40 to 300 amps constant current output with seven  
range settings.  
• Excellent semi-automatic wire feed welding on con-  
stant voltage output range(s).  
• TIG welding - full range on DC and up to 250 amps  
on AC.  
• 100% duty cycle rating on all output ranges.  
• Remote control capability standard on all models.  
Amphenol receptacle for easy connection of Lincoln  
remote control accessories.  
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B-4  
B-4  
OPERATION  
ADDITIONAL FEATURES  
RANGER 300 D (K1522-1)  
RECOMMENDED APPLICATIONS  
WELDER  
• One constant voltage wire-feed welding range - 80  
to 200 amps.  
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.  
The wire feed setting permits the Ranger 300D to be  
used with the LN-25 Wire Feeder and .035, .045 or  
.068 NR®-211-MP Innershield electrodes. Limited  
MIG (GMAW) welding can also be done with .030 or  
.035 L-50 and L-56 using blended Argon shielding  
gas. “Auto-Idle” functions when using an LN-25  
with an internal contactor.  
GENERATOR  
The RANGER 300 gives AC generator output for medi-  
um use demands.  
ADDITIONAL FEATURES  
RANGER 300 DLX (K1522-2)  
LIMITATIONS  
• Four constant voltage (CV) wire-feed welding  
ranges with fine control on each range for welding  
at 40 to 300 amps.  
• Excellent arc characteristics with MIG (GMAW) and  
recommended Innershield electrodes (FCAW).  
• Wire feeder amphenol receptacle (14-pin) for quick  
connection of control cable.  
• Voltmeter for reading CV wire-feed welding arc volt-  
age.  
• Built in contactor with front panel selection of  
“cold” or “hot” welding terminals.  
• Aluminum TIG welding when used with K930-1 TIG  
Module. Output contactor control with Amptrol.  
• Recommended wire feeders are the LN-25 with 42  
Volt Remote Output Control Module or with internal  
contactor and all models of the LN-7.  
• The Ranger 300 is not recommended for any  
processes besides those that are normally per-  
formed using stick welding (SMAW), TIG welding  
(GTAW), MIG (GMAW) welding and Innershield®  
(FCAW) welding.  
• The RANGER 300 D/DLX is not recommended for  
pipe thawing.  
• During welding, generator power is limited and out-  
put voltages can drop. Therefore, DO NOT OPER-  
ATE ANY SENSITIVE ELECTRICAL EQUIPMENT  
WHILE YOU ARE WELDING. See Table B.5 for  
permissible simultaneous welding and auxiliary  
power loads.  
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B-5  
B-5  
OPERATION  
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.  
FIGURE B.1  
OUTPUT PANEL CONTROLS  
3
4
2
5
1
6
14  
7
E
F
8
12  
13  
10  
9
11  
3. POLARITY SWITCH: Selects DC+, DC- or AC  
welding output. Color codings aid in the proper  
selection of stick (blue) or wire feed (red) polarity  
setting. On the RANGER 300 DLX the color setting  
of the polarity switch must match the color setting  
of the OUTPUT RANGE SELECTOR. Never  
change the polarity switch setting while welding  
since this could damage the switch.  
WELDER/GENERATOR CONTROLS  
See Figure B.1 for the location of the following fea-  
tures:  
1. OUTPUT RANGE SELECTOR: Selects continuous  
current output for constant current stick or TIG  
applications (blue settings) and constant voltage  
wire feed applications (red settings). The amper-  
ages on the dial correspond to the maximum  
amperages for each corresponding range setting.  
Never change the range switch setting while weld-  
ing, since this could damage the switch.  
4. CONTROL AT WELDER/REMOTE CONTROL  
SWITCH: Allows the operator to control welding  
output at the welding control panel or at a remote  
station. Remote connections are made at the 6 pin  
or 14 pin amphenol connector.  
2. FINE OUTPUT CONTROL: Allows fine adjustment  
of current or voltage within the selected output  
range.  
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B-6  
B-6  
OPERATION  
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” position, the contactor is closed at  
low and high idle.  
9. WELD OUTPUT TERMINAL (TO WORK) WITH  
FLANGE NUT: Provides the connection point for  
the work cable.  
10. WELD OUTPUT TERMINAL (TO ELECTRODE  
HOLDER) WITH FLANGE NUT: Provides the con-  
nection point for the electrode holder.  
11. GROUND STUD: Provides a connection point for  
connecting the machine case to earth ground for  
the safest grounding procedure.  
When a wire feeder or TIG Module control cable is  
attached to either the 6-pin or 14-pin amphenol  
connector and the Welding Terminals switch is in  
the “WELDING TERMINALS REMOTELY CON-  
TROLLED” position, the contactor is open in low  
idle and high idle until and the wire feeder trigger or  
Amptrol is closed. This closes the 2-4 circuit.  
When the gun trigger or Amptrol is released, the  
contactor opens and there is no voltage present at  
the electrode (300 DLX only).  
12. 6-PIN AMPHENOL: For attaching optional remote  
control equipment to the RANGER 300 D/DLX  
(Includes contactor closure circuit on the Ranger  
300 DLX and remote control circuit).  
13. 14-PIN AMPHENOL (DLX Model Only): For  
attaching wire feeder control cables to the  
RANGER 300 DLX (Includes contractor closure  
circuit, remote control circuit, wire feeder 115/42  
volt power source).  
6. WIRE FEEDER POWER CIRCUIT BREAKER:  
Opens the wire feeder circuit and disables the  
feeder if a fault is detected in the circuit (300 DLX  
only).  
14. VOLTMETER (DLX MODEL ONLY): Displays actu-  
al voltage at the output terminals when welding in  
CV-mode.  
7. 15 AMP, 120 VOLT DUPLEX RECEPTACLES:  
Connection point for supplying 120 volt power to  
operate one or two electrical devices.  
8. 50 AMP, 120/240 VOLT RECEPTACLE: Connection  
point for supplying 240 volt power to operate one  
electrical device.  
RANGER 300 D AND 300 DLX  
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B-7  
B-7  
OPERATION  
FIGURE B.2  
ENGINE CONTROLS  
5
4
6
8
1
9
2
E
F
3
7
Low idle and in the “WELDING TERMINALS  
REMOTELY CONTROLLED” mode - Pressing the  
gun trigger or Amptrol closes the Ranger 300 DLX  
output contactor and causes the engine to accel-  
erate to full speed.  
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.  
After the gun trigger or Amptrol is released and/or  
welding ceases (and no auxiliary power is being  
drawn), the engine will return to low idle after  
approximately 10 to 14 seconds.  
2. IDLER CONTROL SWITCH: The idler switch has  
two positions, “HIGH” and “AUTO”.  
When in “HIGH” (  
run continuously at high speed.  
) position, the engine will  
b) Auxiliary Power  
With the engine running at low idle and auxiliary  
power for lights or tools drawing approximately  
100-150 watts or greater from the receptacles, the  
engine will accelerate to high speed. If no power is  
being drawn from the receptacles (and not welding)  
for 10-14 seconds, the engine returns to low idle.  
When in “AUTO” (  
idler operates as follows:  
/
) idle position, the  
a) Welding  
Low idle with Ranger 300 DLX in the “WELDING  
TERMINALS ALWAYS ON” mode or with a Ranger  
300D - When the electrode touches work, the  
welding arc is initiated and the engine accelerates  
to full speed.  
RANGER 300 D AND 300 DLX  
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B-8  
B-8  
OPERATION  
3. START PUSHBUTTON: When the push-  
button is held, the starter motor cranks over  
the engine - release the button once the  
engine starts.  
It is normal for the light to go on when the “Engine”  
switch is switched to the “ON” position with the  
engine not running. It will go off after one minute  
to prevent discharging the battery if the engine is  
not started. If this happens, the engine protection  
circuit must be reset by turning the “Engine” switch  
to the “OFF” position and back to the “ON” posi-  
tion.  
NOTE: If you press the START 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 required  
maintenance.  
7. WATER TEMPERATURE LIGHT: Remains  
off under normal operating temperatures.  
If the red light turns on, the engine protec-  
5. BATTERY LIGHT: Is off when battery charging sys-  
tem is functioning normally. If the red light turns on  
while the engine is running, the fan belt may be  
broken or the alternator or the voltage regulator  
may be defective.  
tion system will stop the engine. The light will  
remain on when the engine is over temperature and  
the “Engine” switch is in the “ON” position (engine  
not running) but will go off as the engine cools.  
8. FUEL LEVEL GAUGE: Displays the level of diesel  
fuel in the 10-gallon fuel tank.  
It is normal for the light to go on when the “Engine”  
switch is switched to the “ON” position with the  
engine not running. It will go off after one minute  
to prevent discharging the battery if the engine is  
not started. If this happens, the engine protection  
circuit must be reset by turning the “Engine” switch  
to the “OFF” position and back to the “ON” posi-  
tion.  
9. ENGINE ON-OFF SWITCH: Energizes the fuel sole-  
noid in the “ON” position. In the STOP position,  
stops fuel flow to the injection pump and stops the  
engine.  
6. OIL PRESSURE LIGHT: Remains off  
with proper oil pressure. If the red light  
turns on while the engine is running, the engine  
protection system will stop the engine.  
RANGER 300 D AND 300 DLX  
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B-9  
B-9  
OPERATION  
NOTE: DO NOT allow the RANGER 300 to run out of  
fuel. If it does, you will have to bleed the injection sys-  
tem. See the Maintenance section of this manual and  
the Engine Operator’s Manual for instructions on  
bleeding the fuel injection system.  
ENGINE OPERATION  
WARNING  
DO NOT RUN THE ENGINE AT 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.  
CAUTION  
USE DIESEL FUEL ONLY  
Purchase diesel fuel in quantities that will be used  
within 30 days, to assure freshness.  
Read and understand all safety instructions included in  
the Kubota instruction manual that is shipped with your  
RANGER 300.  
STARTING THE ENGINE  
BEFORE STARTING THE ENGINE  
Check the engine oil level:  
CAUTION  
Remove all loads connected to the AC power recepta-  
cles and the welder before starting the diesel engine.  
See Figure D.1 for location of dipstick.  
1. Be sure the machine is on a level surface.  
2. Remove the engine oil dipstick and wipe it with a  
clean cloth. Reinsert the dipstick and check the  
level on the dipstick.  
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). See Figure B.3.  
3. Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill.  
FIGURE B.3  
4. Replace the dipstick.  
Check and fill the engine fuel tank:  
WARNING  
DIESEL fuel can cause fire or  
explosion.  
• Stop engine when fueling.  
• Do not smoke when fueling.  
• Do not overfill tank.  
• Keep sparks and flame away from tank.  
2. Check for proper level of coolant in the plastic  
reserve overflow tank. The level should be  
between the full and the low marks.  
1. Remove the fuel tank cap.  
3. Check for proper oil level on the oil dipstick. Close  
engine compartment door.  
2. Fill the tank approximately 4 inches (100 mm) from  
the top of the filler neck to allow for fuel expansion  
(observe the fuel gauge.) DO NOT FILL THE TANK  
TO THE POINT OF OVERFLOW.  
4. Set “IDLER” switch to “AUTO”.  
/
5. Set the “ENGINE” switch to “ON”. Observe that  
both the oil pressure light and battery charger light  
are on. Check the fuel gauge to make sure that  
there is an adequate fuel level. (NEVER ALLOW  
THE RANGER 300 D/DLX TO RUN OUT OF FUEL.)  
3. Replace the fuel tank cap and tighten securely.  
RANGER 300 D AND 300 DLX  
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B-10  
B-10  
OPERATION  
6. Press the “GLOW PLUG” button to pre-  
heat the cylinders per the following table:  
STOPPING THE ENGINE  
1. Remove all welding and generator power loads and  
let the engine cool by running it for several minutes  
at low idle.  
Pre-Heat Time  
Ambient Temperature  
Above 50°F (10°C)  
50°F (10°C) to 23°F(-5°C)  
Below 23°F (-5°C)  
2. Stop the engine by placing the Engine Switch in the  
“OFF” position. This turns off the fuel solenoid.  
You can also stop the engine by turning off the fuel  
valve located on the fuel filter housing.  
NOT REQUIRED  
Approximately 5 seconds  
Approximately 10 seconds  
BREAK-IN PERIOD  
Any engine will use a small amount of oil during its  
“break-in” period. For the diesel engine on the  
RANGER 300, break-in is about 50 running hours.  
CAUTION  
Check the oil every four hours during break-in.  
Change the oil after the first 50 hours of operation,  
every 100 hours thereafter. Change the oil filter at the  
second oil change.  
Never press the Glow Plug button continuously for  
more than 20 seconds.  
7. Release the “GLOW PLUG” button and  
press the “START” button to crank the  
engine. Release when the engine starts.  
During break-in, subject the RANGER 300 to moderate  
loads. Avoid long periods running at idle. Before  
stopping the engine, remove all loads and allow the  
engine to cool several minutes.  
8. Check that the indicator lights are off. If not, imme-  
diately stop the engine and investigate the indicat-  
ed problem.  
TABLE B.1  
TYPICAL RANGER 300 FUEL CONSUMPTION  
9. Allow the engine to warm up at low idle speed for  
several minutes before applying a load and/or  
switching to high idle. Allow a longer warm up time  
in cold weather.  
.30 gallons/hour  
(1.0 liters/hour)  
Low Idle - No Load  
2000 RPM  
.60 gallons/hour  
(2.2 liters/hour)  
High Idle - No Load  
3700 RPM  
NOTE: If the engine fails to start in 60 seconds or  
stops running, the “ENGINE” switch must be  
switched to “OFF” and then switched back to “ON”  
before attempting to restart the engine. This resets  
the engine protection circuit.  
1.1 gallons/hour  
(4.2 liters/hour)  
AC CC Weld Output  
300 Amps @ 25 Volts  
1.2 gallons/hour  
(4.6 liters/hour)  
DC CC Weld Output  
300 Amps @ 25 Volts  
COLD WEATHER STARTING AND  
OPERATION  
.90 gallons/hour  
(3.6 liters/hour)  
DC CV Weld Output  
300 Amps @ 28 Volts*  
The Kubota engine used in the Ranger 300 can be  
started in temperatures as low as 5°F (-15°C). At tem-  
peratures below 23°F (-5°C), it is recommended that  
No. 1D diesel fuel be used in place of No. 2D. Allow  
engine to warm up before applying a load or switching  
to HIGH idle.  
1.3 gallons/hour  
(4.9 liters/hour)  
Auxiliary Power  
12,000 kVA  
* DLX model only  
RANGER 300 D AND 300 DLX  
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B-11  
B-11  
OPERATION  
WELDING OPERATION  
CAUTION  
GENERAL INFORMATION  
The RANGER 300 machines can deliver from 45 to 300  
amps of constant current for AC/DC stick welding.  
The Ranger 300 DLX can deliver 45 to 300 amps of  
constant voltage current for DC semiautomatic wire  
feed welding. The Ranger 300 D can deliver 45 to 200  
amps of constant voltage current for DC semiauto-  
matic wire feed welding. AC/DC constant current TIG  
welding is possible across the entire range from 45 to  
300 amps, although 250 amps is the maximum rec-  
ommended for AC TIG welding of aluminum.  
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.  
Output can be adjusted by setting the POLARITY  
SWITCH, the OUTPUT RANGE dial, and the FINE  
CONTROL dial on the output control panel to the set-  
tings that are best for your selected welding process.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and ground  
• Always wear dry insulating gloves.  
AC/DC STICK (CONSTANT CURRENT)  
WELDING  
FUMES AND GASES can be danger-  
ous.  
1. Remove the flange nuts from output terminals and  
place the work and electrode welding cables over  
the terminals. See Figure B.4. Replace and tight-  
en the flange nuts securely. Be sure the connec-  
tions are tight.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
2. Select the appropriate electrode. See “Welding  
Tips 1” included with your RANGER 300.  
MOVING PARTS can injure.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
3. Attach the work clamp securely to the work you are  
welding.  
4. Insert the electrode into the electrode holder.  
5. Set the IDLER CONTROL to AUTO and start the  
diesel engine.  
WELDING SPARKS can cause fire or  
explosion.  
6. Set the RANGE switch to a setting equal to or  
slightly lower than the welding current recom-  
mended for the electrode being used. For the best  
welding performance, always set the RANGE  
switch to the lowest CC-blue setting that will give  
the desired weld current. This will assure that the  
OUTPUT dial is set towards the high end of the  
dial. If the OUTPUT dial is set at 10 and the weld-  
ing current is set to low, move the RANGE switch  
to the next highest setting.  
• Keep flammable material away.  
ARC RAYS can burn.  
• Wear eye, ear and body protection.  
See additional warning information throughout this  
operator’s manual.  
7. Set the POLARITY switch to the desired polarity  
(CC-blue setting).  
8. Set the OUTPUT control. For stick welding, always  
use a setting between 5 and 10 on the dial (blue  
range).  
9. Strike an arc and begin welding. The OUTPUT  
control can be adjusted while welding.  
RANGER 300 D AND 300 DLX  
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B-12  
B-12  
OPERATION  
AFTER YOU FINISH WELDING:  
CAUTION  
1. Stop the engine.  
DO NOT change the RANGE switch setting while  
welding. This can result in damage to the switch.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
4. Remove any remaining piece of electrode from the  
electrode holder.  
RANGE SETTING  
ON MACHINE  
ACTUAL  
CURRENT RANGE  
5. If you are finished using the RANGER 300 for weld-  
ing, disconnect the welding cables from the weld  
output terminals. Reattach the flange nuts and  
leave them on the terminals.  
50  
75  
30 to 50 AMPS  
50 to 75 AMPS  
100  
140  
180  
225  
300  
70 to 100 AMPS  
95 to 140 AMPS  
110 to 180 AMPS  
130 to 225 AMPS  
160 to 300 AMPS  
AC/DC TIG (CONSTANT CURRENT)  
WELDING  
1. Connect the K930-1 TIG Module to the RANGER  
300. Follow the installation instructions provided  
with the kit.  
FIGURE B.4  
WELDING CIRCUIT CONNECTIONS  
2. Refer to the instruction manual with the TIG mod-  
ule (IM-528) for operation with a RANGER 300 and  
proper machine settings.  
1
3. Set the RANGE switch to the appropriate setting  
for the electrode you are using. Refer to IM-528  
with the TIG module or refer to Table B.2 for AC  
TIG welding.  
4. Set the POLARITY SWITCH to the desired polarity.  
5. Do not AC TIG weld on the 300 AC range setting.  
The output current may exceed the rating of the  
RANGER 300.  
E
F
6. Start the arc and begin welding.  
NOTE: When using the RANGER 300 for AC TIG weld-  
ing of aluminum, the TIG Module is to be set for CON-  
TINUOUS HF.  
5
AFTER YOU FINISH WELDING:  
1. Stop the engine.  
8
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
4
6
3
7
2
1. OUTPUT CONTROL PANEL  
2. ELECTRODE CABLE  
3. ELECTRODE HOLDER  
4. ELECTRODE  
5. OUTPUT TERMINALS  
6. WORK  
7. WORK CLAMP  
8. WORK CABLE  
RANGER 300 D AND 300 DLX  
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B-13  
B-13  
OPERATION  
TABLE B.2  
AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS  
Pure (EWP)  
“Range”  
Appropriate  
Tungsten Diameter  
Switch Settings  
75, 100 or 140(1)  
50, 75 or 100  
Welding Current  
100 - 200 amps  
50 - 100 amps  
45 - 150 amps  
1/8”  
3/32”  
1/16”  
50, 75 or 100  
1% Thoriated  
“Range”  
Appropriate  
Tungsten Diameter  
Switch Settings  
Welding Current  
1/8”  
3/32”  
1/16”  
100, 140 or 180  
50, 100 or 140  
50 or 100  
160 - 250 amps  
100 - 180 amps  
60 - 120 amps  
(1)  
The welding current will be approximately 200 amps with the range switch set at 120 and the OUTPUT CON-  
TROL set at 10. Do not use a range setting higher than 120 for AC TIG welding.  
4. Set the RANGE switch to either HIGH, MEDIUM  
DC WIRE FEED WELDING (CV) WITH  
RANGER 300 DLX  
HIGH, MEDIUM LOW, or LOW (CV-red) depending  
on your wire size and speed.  
1. Connect one of the following: the LN-25, LN-7 or  
5. Set the POLARITY SWITCH to either WIRE WELD-  
LN-8 Wire Feeder.  
ING DC+ or WIRE WELDING DC- depending on  
2. Some recommended Innershield electrodes are:  
.068 NR-211MP, .068 NR-232, NR-203 series, 5/64  
NR-311, and 5/64 NS-3M. Lincore® 33 and 55  
hardfacing electrodes can also be used. Cable  
length and other conditions can affect the ultimate  
results of this application. Request Lincoln publi-  
cation N-675 for additional information.  
the electrode.  
6. Set the OUTPUT control to a setting between 1 and  
10 that gives the most stable arc for the applica-  
tion. Try a higher RANGE switch setting if the arc  
is unstable.  
7. Strike an arc and begin welding. The OUTPUT  
control can be adjusted while welding. DO NOT  
change the RANGE switch setting while welding.  
This can result in damage to the switch.  
Recommended Outershield electrodes are .045  
(1.1 mm), .052 (1.3 mm), and 1/16 (1.6 mm)  
Outershield 71 and 1/16 (1.6 mm) Outershield 70.  
Request Lincoln publication GS-200 for additional  
information.  
AFTER YOU FINISH WELDING:  
1. Stop the engine.  
For MIG welding, the recommended electrodes are  
.030 (0.8 mm), .035 (0.9 mm) and .045 (1.1 mm) L-  
50 and L-56. You must use a blended shielding  
gas such as C25 (75% Argon, 25% CO2). Request  
Lincoln publication GS-100 for additional informa-  
tion.  
2. Allow the work to cool completely.  
3. Remove the work clamp from the work.  
3. Set the IDLER CONTROL to “AUTO” for the LN-25  
or “HIGH” for the LN-7 or LN-8 and start the diesel  
engine.  
RANGER 300 D AND 300 DLX  
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B-14  
B-14  
OPERATION  
AFTER YOU FINISH WELDING:  
1. Stop the engine.  
DC WIRE FEED WELDING (CV) WITH  
RANGER 300 D  
1. Connect an LN-25 with internal contactor to the  
Ranger 300 D.  
2. Allow the work to cool completely.  
3. Remove the work clamp from the work.  
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:  
CARBON ARC GOUGING  
(CONSTANT CURRENT)  
1. The recommended electrode is a 3/16” (4.8 mm)  
dia. carbon.  
Electrode  
Diameter  
Wire Speed  
in. / min.  
Approximate  
Current Range  
2 Set the RANGE switch to 300.  
3 Set the POLARITY switch to DC+ (cc - blue setting).  
4 Set the OUTPUT control to 10.  
.035”  
.045”  
.068”  
70 - 110  
70 - 130  
40 - 90  
60 - 120 amps  
120 - 170 amps  
125 - 210 amps  
5. Strike an arc and begin gouging.  
AFTER YOU FINISH GOUGING:  
The Ranger 300 D is recommended for limited "MIG"  
welding (GMAW - gas metal arc welding). The recom-  
mended electrodes are .030 and .035 L-50 and L-56.  
They must be used with a blended shielding gas such  
as C25 (75% Argon - 25% CO2). The .035 diameter  
electrode gives improved starting compared to .030  
diameter. The welding ranges that can be used with  
the Ranger 300 D are shown in the following table:  
1. Stop the engine.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
Electrode  
Diameter  
Wire Speed  
in. / min.  
Approximate  
Current Range  
.030”  
.035”  
150 - 450  
100 - 350  
80 - 170 amps  
80 - 190 amps  
3. Set the IDLER control to AUTO.  
4. Set the RANGE switch to WIRE FEED (CV-red set-  
ting).  
5. Set the POLARITY SWITCH to either WIRE WELD-  
ING DC+ (red) or WIRE WELDING DC- (red),  
depending on the electrode.  
6. Set the OUTPUT control to a setting between 1 and  
10 that gives the most stable arc for the applica-  
tion.  
7. Strike an arc and begin welding. The OUTPUT  
control can be adjusted while welding. DO NOT  
change the RANGE switch setting while welding.  
This can result in damage to the switch.  
RANGER 300 D AND 300 DLX  
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B-15  
B-15  
OPERATION  
SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS  
TABLE B.3  
SUMMARY OF WELDING PROCESSES FOR RANGER 300 DLX  
CONTROL  
CABLE &  
DIAGRAM  
IDLE  
MODE  
OUTPUT  
WELDING ELECTRODE  
CONTROL TERMINALS WHEN NOT  
SWITCH  
TO START WELDING  
PROCESS  
SWITCH  
WELDING  
STICK - CC  
CARBON ARC  
GOUGING - CC  
NO  
AUTO  
AT  
WELDER  
ALWAYS  
ON  
HOT  
Touch electrode to work.  
Welding starts immediately  
and engine goes to high idle.  
TIG - CC  
Press Amptrol. Welding  
starts immediately.  
K930-1 TIG MODULE /  
K936-1 CONTROL  
CABLE  
YES  
S23732-9  
AUTO  
AUTO  
REMOTE  
REMOTE  
REMOTE  
REMOTE  
COLD  
COLD  
WIRE FEED - CV,  
LN-25 WITH 42V RE-  
MOTE CONTROL KIT  
YES  
S23732-3  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately  
and engine goes to high idle.  
WIRE FEED - CV,  
LN-25 WITH  
INTERNAL  
NO  
S23732-1  
S23732-2  
AUTO  
AUTO  
AT  
WELDER  
ALWAYS  
ON  
COLD  
COLD  
Press gun trigger, LN-25  
contactor closes. Welding  
starts immediately and  
engine goes to high idle.  
CONTACTOR  
WIRE FEED - CV,  
LN-742  
YES  
S23732-5  
REMOTE  
REMOTE  
REMOTE  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately  
and engine goes to high idle.  
WIRE FEED - CV,  
LN-7 or LN-8  
YES  
S23732-4  
S23732-6  
HIGH  
HIGH  
REMOTE  
REMOTE  
COLD  
COLD  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately.  
K487-15 WIRE FEED-  
YES  
AT  
WELDER  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately.  
CV SPOOL GUN / K488 S23732-8  
CONTROL MODULE  
RANGER 300 D AND 300 DLX  
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B-16  
B-16  
INSTALLATION  
SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS, continued  
TABLE B.4  
SUMMARY OF WELDING PROCESSES FOR RANGER 300 D  
CONTROL  
CABLE &  
DIAGRAM  
IDLE  
MODE  
OUTPUT  
CONTROL  
SWITCH  
ELECTRODE  
WHEN NOT  
WELDING  
TO START WELDING  
PROCESS  
STICK - CC  
CARBON ARC  
GOUGING - CC  
NO  
AUTO  
AUTO  
AUTO  
AT  
WELDER  
HOT  
Touch electrode to work.  
Welding starts immediately  
and engine goes to high idle.  
TIG - CC  
K930-1 TIG MODULE /  
K936-1 CONTROL CABLE  
YES  
S23732-10  
REMOTE  
HOT  
Press Amptrol. Welding  
starts immediately.  
WIRE FEED - CV,  
LN-25 /  
INTERNAL  
NO  
S23732-1  
S23732-2  
AT  
WELDER  
COLD  
Press gun trigger, LN-25  
contactor closes. Electrode  
touches work, welding starts  
immediately and engine goes  
to high idle.  
CONTACTOR  
WIRE FEED - CV,  
LN-7 / K240  
CONTACTOR KIT  
YES  
S23732-11  
HIGH  
AT  
WELDER  
COLD  
Press gun trigger, K240  
contactor closes. Welding  
starts immediately.  
RANGER 300 D AND 300 DLX  
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B-17  
B-17  
OPERATION  
operated at 120 V or 9 to 11 amps when operated at  
240 V, it should be connected to the 120/240 dual volt-  
age receptacle. The full load current of a 1.5 HP motor  
is typically 15 to 17 amps when operated at 120 V or  
7.5 to 8.5 amps when operated at 240 V. It also should  
be connected to the 120/240 dual voltage receptacle.  
A 1.0 HP motor that draws less than 15 amps at 120 V  
can be plugged into one of the 120 V duplex recepta-  
cles.  
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. Do not connect  
any plugs that connect to the power receptacles in  
parallel.  
SIMULTANEOUS WELDING AND  
POWER LOADS  
Start the engine and set the “IDLER” control switch to  
the desired operating mode. Set the “CONTROL” to  
10. Voltage is now correct at the receptacles for aux-  
iliary power.  
Auxiliary power ratings are with no welding load.  
Simultaneous welding and power loads are permitted  
by the following table. The permissible currents shown  
assume that current is being drawn from either the  
120 V or 240 V supply (not both at the same time).  
Most single-phase motors through 2.0 HP can be  
started if there is no load on the motor or other load  
connected to the machine. Since the full load current  
of a 2.0 HP motor is typically 18 to 20 amps when  
TABLE B.5  
RANGER 300 SIMULTANEOUS WELDING AND POWER LOADS  
(OUTPUT CONTROL SET AT 10)  
Welding  
Output  
Amps  
Permissible  
Power Watts  
(Unity Power  
Permissible  
Auxiliary Current in Auxiliary Current in  
Amperes @ 120V  
Permissible  
Output  
Selector  
Setting  
Amperes @ 240V  
300  
225  
180  
140  
100  
75  
0
300  
225  
180  
140  
100  
75  
NONE  
3000  
4800  
6400  
8000  
0
13  
20  
27  
33  
38  
42  
25  
40  
53  
60  
60  
60  
9000  
10,000  
50  
50  
200  
60  
17  
40  
CV LOW (300 DLX)  
CV (300 D)  
4000  
9600  
33  
60  
225  
80  
13  
27  
CV MED. LOW  
(300 DLX)  
3000  
8800  
25  
60  
250  
100  
8
33  
CV MED. HIGH  
(300 DLX)  
2000  
8000  
17  
60  
300  
150  
0
25  
CV HIGH  
(300 DLX)  
0
6000  
0
50  
NOTE: Voltage and permissible watts decrease as “CONTROL” is adjusted to settings less than 10. It is recommended  
that at settings less than 10, only incandescent lighting loads be connected to the auxiliary power receptacles.  
RANGER 300 D AND 300 DLX  
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B-18  
B-18  
OPERATION  
MAXIMUM CURRENT DRAW FROM  
120 V DUPLEX RECEPTACLES - NO WELDING  
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). Do not connect the 115 V cir-  
cuits in parallel. Current sensing for the automatic idle  
feature is in both legs of the three wire circuit as shown  
below.  
EACH HALF OF TOTAL FROM  
TOTAL FROM  
BOTH 120 V  
DUPLEXES  
240 V LOAD FROM  
FULL KVA  
RECEPTACLE  
EACH 120 V  
DUPLEX  
ONE 120 V  
DUPLEX  
60 AMPS  
60 AMPS  
40 AMPS  
20 AMPS  
0
0
15 AMPS  
15 AMPS  
15 AMPS  
15 AMPS  
0
30 AMPS  
30 AMPS  
30 AMPS  
20 AMPS  
0
20 AMPS  
30 AMPS  
40 AMPS  
50 AMPS  
FIGURE B.5  
GND  
MAXIMUM CURRENT DRAW FROM OPTIONAL  
120 V GFCI DUPLEX RECEPTACLES - NO WELDING  
120 V  
240 V  
120 V  
EACH HALF OF TOTAL FROM  
TOTAL FROM  
BOTH 120 V  
DUPLEXES  
240 V LOAD FROM  
FULL KVA  
RECEPTACLE  
EACH 120 V  
DUPLEX  
ONE 120 V  
DUPLEX  
30 AMPS  
30 AMPS  
0
0
15 AMPS  
15 AMPS  
0
15 AMPS  
15 AMPS  
0
120 V DUPLEX RECEPTACLES  
35 AMPS  
50 AMPS  
The 120 V auxiliary power receptacles should only be  
used with three wire grounding type plugs or approved  
double insulated tools with two wire plugs.  
RANGER 300 D AND 300 DLX  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories...........................................................................................................................Section C  
General Options/Accessories.....................................................................................................C-2  
TIG Welding Options/Accessories..............................................................................................C-2  
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  
Connection of the LN-7 .......................................................................................................C-6  
Connection of the LN-8 Using the K867 Universal Adapter................................................C-7  
Connection of the K488 SG Control Module and K487-25 Spool Gun ..............................C-8  
Connection of the K930-1 TIG Module................................................................................C-9  
RANGER 300 D AND 300 DLX  
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C-2  
C-2  
ACCESSORIES  
K939-1 Docking Kit - For mounting the K930-1 TIG  
Module on top of the Ranger 300.  
GENERAL OPTIONS /  
ACCESSORIES  
K936-1 Control Cable - Control cable for connecting  
the K930-1 TIG Module to a RANGER 300 DLX.  
The following options/accessories are available for  
your RANGER 300 from your local Lincoln Distributor.  
K936-3 Control Cable - Control cable for connecting  
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.  
the K930-1 TIG module to a Ranger 300 D.  
K814 Arc Start Switch - A remote start switch used in  
conjunction with the K930-1 TIG Module to energize  
the RANGER 300 DLX output terminals via the TIG  
module.  
K802-R Power Plug Kit - Provides four 15 amp, 115  
volt plugs and one 50 amp, dual voltage (115/230V),  
full kVA plug.  
K963 Hand Amptrol - Remote output control on  
RANGER 300 D/DLX and contactor control on Ranger  
300 DLX.  
K703 Accessory Kit - Includes the following:  
• Thirty-five feet (10.5 meters) of #1/0 AWG elec-  
trode cable.  
K870 Foot Amptrol - Remote output control on  
RANGER 300 D/DLX and contactor control on Ranger  
300 DLX.  
• Thirty feet (9.1 meters) of # 1/0 AWG work cable.  
• Headshield with No. 12 filter.  
SEMIAUTOMATIC FCAW AND MIG  
WELDING (RANGER 300 DLX)  
OPTIONS / ACCESSORIES  
• GC500 work clamp.  
• Cooltong® 300 insulated electrode holder.  
The cables are rated at 300 amps, 100% duty cycle.  
LN-25 Wire Feeder - This portable unit provides  
CC/CV for flux-cored arc welding (FCAW) and metal  
inert gas welding (MIG).  
K903-1 Spark Arrester Kit - A field-installed kit for the  
RANGER 300 engine muffler exhaust pipe (either  
engine option). Includes a heavy-gauge steel,  
approved spark arrester, mounting clamp and adapter.  
LN-7 or LN-8 Wire Feeder - Semiautomatic constant  
speed wire feeders.  
K857 Remote Control - Includes a control box with  
25 feet (7.5 meters) of 4 conductor cable. Allows out-  
put voltage to be controlled remotely.  
NOTE: Gas-shielded welding requires a Magnum Gun.  
Gasless welding requires an Innershield Gun.  
K487-25 Magnum Spool Gun - A lightweight, semi-  
automatic wire feeder for aluminum welding with  
argon gas. Has built-in remote wire speed control in  
the handle. Requires the K488 SG Control Module.  
Includes 50 feet (15.2 meters) of power cable.  
K896-1 GFCI Receptacle Kit - Includes two UL  
approved 120 volt ground fault circuit interrupter  
receptacles (duplex type) with covers and installation  
instructions. Each receptacle is rated 15 amps, but  
the maximum total current from each GFCI duplex is  
limited to 20 amps. The GFCI receptacles replace the  
two factory installed 120 volt duplex receptacles.  
K488 SG Control Module - Controls wire speed and  
gas flow. Provides the required control interface  
between the RANGER 300DLX and the K487-25  
Magnum Spool Gun.  
TIG WELDING OPTIONS /  
ACCESSORIES  
SEMIAUTOMATIC FCAW AND MIG  
WELDING (RANGER 300 D)  
OPTIONS / ACCESSORIES  
K930-1 TIG Module - The TIG Module is an accesso-  
ry that provides high frequency and shielding gas con-  
trol for AC and DC GTAW (TIG) welding applications. It  
provides contactor control of constant current welding  
power sources having an internal contactor.  
LN-25 Wire Feeder - The recommended wire feeder  
for use with the Ranger 300 D is the K449 LN-25. This  
portable unit provides CC/CV for flux-cored arc weld-  
ing (FCAW) and metal inert gas welding (MIG). For  
remote control use either a K857 Remote Control Kit  
(25 ft.) or a K444-1 Remote Voltage Control Kit (25 ft.),  
which mount inside the LN-25.  
The TIG Module is supplied without accessories. Arc  
Start switches, Amptrols, cables, torches and mount-  
ing brackets must be purchased separately.  
RANGER 300 D AND 300 DLX  
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C-3  
C-3  
ACCESSORIES  
NOTE: Figure C.1 shows the electrode connected for  
negative polarity. Use the Polarity switch on the  
Ranger 300 to select the desired electrode polarity.  
Change the LN-25 polarity switch.  
CONNECTION OF LINCOLN  
ELECTRIC WIRE FEEDERS  
WARNING  
3. Attach the single lead from the LN-25 to the work  
using the spring clip on the end of the lead. This is  
only a sense lead - it carries no welding current.  
ELECTRIC SHOCK can kill.  
• Do not operate with panels open.  
4. Place the IDLER switch in the “AUTO” or “HIGH”  
position, as desired.  
• Disconnect NEGATIVE (-) BATTERY  
LEAD before servicing.  
• Do not touch electrically live parts.  
CAUTION  
If you are using an LN-25 without an internal contac-  
tor, the electrode will be “HOT” when the Ranger 300  
is started.  
MOVING PARTS can injure.  
• Keep guards in place.  
• Keep away from moving parts.  
• Only qualified personnel should install,  
use or service this equipment.  
5. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
6. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS ALWAYS ON.”  
CONNECTION OF THE LN-25 TO THE  
RANGER 300 D AND DLX “ACROSS  
THE ARC” USING THE K857 REMOTE  
CONTROL (SEE FIGURE C.1.)  
7. Adjust wire feed speed at the LN-25.  
8. Set the LOCAL/REMOTE switch to “REMOTE” if a  
K857 remote control is used.  
1. Shut the welder off.  
CAUTION  
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.  
Electrode is always “HOT.”  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
FIGURE C.1  
RANGER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM –  
K857 REMOTE CONTROL  
14 PIN  
AMPHENOL  
OPTIONAL K857  
REMOTE CONTROL  
6 PIN  
AMPHENOL  
(RANGER 300 DLX  
ONLY)  
LN-25  
WIRE FEEDER  
WORK CLIP LEAD  
TO WORK  
ELECTRODE  
TO WORK  
TO WORK  
ELECTRODE CABLE  
RANGER 300 D AND 300 DLX  
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C-4  
C-4  
ACCESSORIES  
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.)  
CAUTION  
If you are using an LN-25 without an internal contac-  
tor, the electrode will be “HOT” when the Ranger 300  
is started.  
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.  
5. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
6. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS ALWAYS ON.”  
NOTE: Figure C.2 shows the electrode connected for  
negative polarity. Use the Polarity switch on the  
Ranger 300 to select the desired electrode polarity.  
Change the LN-25 polarity switch.  
7. Adjust wire feed speed at the LN-25.  
8. Set the LOCAL/REMOTE switch to “REMOTE” if a  
K444-1 remote control is used.  
3. Attach the single lead from the LN-25 to the work  
using the spring clip on the end of the lead. This is  
only a sense lead - it carries no welding current.  
CAUTION  
Electrode is always “HOT.”  
4. Place the IDLER switch in the “AUTO” or “HIGH”  
position as desired.  
FIGURE C.2  
RANGER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM –  
K444-1 REMOTE CONTROL  
14 PIN  
AMPHENOL  
(RANGER 300 DLX  
ONLY)  
6 PIN  
AMPHENOL  
OPTIONAL K444-1  
REMOTE CONTROL  
LN-25  
WIRE FEEDER  
WORK CLIP LEAD  
TO WORK  
ELECTRODE  
TO WORK  
TO WORK  
ELECTRODE CABLE  
RANGER 300 D AND 300 DLX  
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C-5  
C-5  
ACCESSORIES  
CONNECTION OF THE LN-25 TO THE  
RANGER 300 (DLX ONLY) USING  
THE K624-1 42V REMOTE CONTROL  
(SEE FIGURE C.3.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory - do not adjust above RPM  
specifications listed in this manual.  
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.  
5. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
Use the Polarity switch on the Ranger 300 to select the  
desired electrode polarity. Change the LN-25 polarity  
switch.  
6. Set the WELDING TERMINALS switch to  
“REMOTELY CONTROLLED.”  
3. Connect the K626-XX Control Cable to the 14-pin  
amphenol of the Ranger 300 DLX as indicated in  
Figure C.3. Make the proper connections for local  
or remote control according to Figure C.3.  
7 Adjust wire feed speed at the LN-25.  
8. Set the LOCAL/REMOTE switch to “REMOTE.”  
4. Connect the K626-XX Control Cable to the LN-25.  
FIGURE C.3  
RANGER 300 DLX/LN-25 WITH K624-1 42 VOLT REMOTE CONTROL  
TO LN-25 INPUT  
CABLE PLUG  
14 PIN  
AMPHENOL  
K626-XX INPUT CABLE ASSEMBLY  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
RANGER 300 D AND 300 DLX  
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C-6  
C-6  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
RANGER (300 DLX ONLY) USING K584  
CONTROL CABLE (SEE FIGURE C.4.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory - do not adjust above RPM  
specifications listed in this manual.  
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.  
NOTE: Figure C.4 shows the electrode connected for  
positive polarity. Use the Polarity switch on the Ranger  
300 DLX to select the desired electrode polarity.  
6. Set the LOCAL/REMOTE switch to “REMOTE” if a  
K857 remote control is used. Set the switch to  
“LOCAL” if no remote control is used.  
3. Connect the K584-XX Control Cable to the LN-7.  
7. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
4. Connect the K584-XX Control Cable to the 14-pin  
amphenol on the Ranger 300 DLX.  
8. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
5. Place the IDLER switch in the “HIGH” position.  
9. Adjust wire feed speed at the LN-7.  
NOTE: For remote control, a K857 remote control is  
required. Connect it to the 6-pin amphenol.  
FIGURE C.4  
RANGER 300 DLX/LN-7 WITH K584 CONTROL CABLE CONNECTION DIAGRAM  
TO LN-7 INPUT  
CABLE PLUG  
14 PIN  
AMPHENOL  
K584 CONTROL CABLE  
OPTIONAL K857  
REMOTE CONTROL  
6 PIN  
ELECTRODE  
TO WORK  
AMPHENOL  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
RANGER 300 D AND 300 DLX  
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C-7  
C-7  
ACCESSORIES  
5. Place the IDLER switch in the “HIGH” position.  
CONNECTION OF THE LN-8 TO THE  
RANGER 300 (DLX ONLY) USING K867  
UNIVERSAL ADAPTER (SEE FIGURE C.5.)  
CAUTION  
1. Shut the welder off.  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory - do not adjust above RPM  
specifications listed in this manual.  
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.  
NOTE: Figure C.5 shows the electrode connected for  
positive polarity. Use the Polarity switch on the  
Ranger 300 to select the desired electrode polarity.  
6. Set the LOCAL/REMOTE switch to “REMOTE.”  
7. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
3. Connect the K867 Universal Adapter to the K196  
input cable and the 14-pin amphenol of the Ranger  
300 DLX as indicated in Figure C.5. Make the  
proper connections for local or remote control  
according to Figure C.5.  
8. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
9. Adjust wire feed speed and voltage at the LN-8.  
4. Connect the K196 input cable to the LN-8.  
FIGURE C.5  
RANGER 300 DLX/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
82  
LN-8  
WIRE  
81  
42  
41  
INSULATE UNUSED  
FEEDER  
LEADS INDIVIDUALLY  
}
31  
32  
31  
32  
2
2
4
14 PIN  
AMPHENOL  
4
+
CV-  
21  
21  
GND  
K196  
INPUT CABLE  
K867 UNIVERSAL  
ADAPTER PLUG  
GND  
75  
76  
77  
A
ELECTRODE CABLE  
TO WIRE FEED UNIT  
B
C
TO WORK  
SPLICE LEADS  
AND INSULATE  
RANGER 300 D AND 300 DLX  
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C-8  
C-8  
ACCESSORIES  
5. Place the IDLER switch in the “HIGH” position.  
CONNECTION OF THE K488 SG  
CONTROL MODULE AND K487 MAGNUM  
SPOOL GUN TO THE RANGER 300  
(DLX ONLY) (SEE FIGURE C.6.)  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory - do not adjust above RPM  
specifications listed in this manual.  
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.  
6. Set the LOCAL/REMOTE switch to “REMOTE” if a  
K857 remote control is used. Set the switch to  
“LOCAL” if no remote control is used.  
NOTE: Figure C.6 shows the electrode connected for  
positive polarity. Use the Polarity switch on the Ranger  
300 DLX to select the desired electrode polarity.  
7. Set the OUTPUT RANGE switch to “WIRE WELD-  
ING CV.”  
3. Connect the K691-10 Input Cable as shown in  
Figure C.6.  
8. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
4. Set the slide switch on the SG Control Module to  
the “Lincoln” position.  
9. Adjust wire feed speed at the SG Control Module.  
CAUTION  
NOTE: For remote control, a K857 remote control is  
required. Connect it to the 6-pin amphenol.  
Be sure the switch is set to the “Lincoln” (contact clo-  
sure) position before attempting to operate the SG  
Control Module. Incorrect switch position could result  
in damage to the SG Control Module and/or the  
Ranger 300 DLX.  
FIGURE C.6  
RANGER 300 DLX/K691/K488/K487 SPOOL GUN CONNECTION DIAGRAM  
115V RECEPTACLE  
K488 SG  
CONTROL MODULE  
RANGER  
K487-25  
SPOOL GUN  
14 PIN WIRE FEEDER  
RECEPTACLE  
6 PIN REMOTE  
RECEPTACLE  
K691-10  
INPUT CABLE  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO CONTROL MODULE  
TO WORK  
RANGER 300 D AND 300 DLX  
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C-9  
C-9  
ACCESSORIES  
5. Place the IDLER switch in the “AUTO” or “HIGH”  
position as desired.  
CONNECTION OF THE K930-1 TIG  
MODULE TO THE RANGER 300 (DLX  
ONLY) USING K936 CONTROL CABLE  
(SEE FIGURE C.7.)  
CAUTION  
1. Shut the welder off.  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control  
circuits may be damaged. The engine governor set-  
ting is preset at the factory - do not adjust above RPM  
specifications listed in this manual.  
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.  
NOTE: Figure C.7 shows the electrode connected for  
positive polarity. Use the Polarity switch on the Ranger  
300 DLX to select the desired electrode polarity.  
6. Set the LOCAL/REMOTE switch to “REMOTE.”  
7. Set the OUTPUT RANGE switch to “STICK WELD-  
ING.”  
3. Connect the K936-1 Control Cable to the K930-1  
TIG Module and to the 14-pin amphenol on the  
Ranger 300 DLX.  
8. Set the WELDING TERMINALS switch to “WELD-  
ING TERMINALS REMOTELY CONTROLLED.”  
4. Connect the K870 Foot Amptrol or K963-1 Hand  
Amptrol or K814 Arc Start Switch to the K930-1  
TIG Module.  
FIGURE C.7  
RANGER 300 DLX/K930-1 TIG MODULE CONNECTION DIAGRAM  
REGULATOR  
FLOWMETER  
ARGON GAS  
CYLINDER  
TO GAS  
INPUT  
FITTING  
K870 FOOT AMPTROL  
-OR-  
K936-1  
CONTROL CABLE  
TO WORK  
K963-1 HAND AMPTROL  
-OR-  
14 PIN  
AMPHENOL  
K814 ARC START SWITCH  
ELECTRODE  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Kubota Engine Maintenance Schedule .....................................................................................D-2  
Kubota Engine Maintenance Components ...............................................................................D-2  
Routine and Periodic Maintenance ...........................................................................................D-3  
Engine Maintenance.............................................................................................................D-3  
Oil ..................................................................................................................................D-3  
Changing the Oil ............................................................................................................D-3  
Oil Filter..........................................................................................................................D-3  
Fuel.................................................................................................................................D-4  
Bleeding the Fuel System..............................................................................................D-4  
Air Cleaner......................................................................................................................D-4  
Tightening the Fan Belt .................................................................................................D-4  
Cooling System..............................................................................................................D-4  
Spark Arrester Screen....................................................................................................D-5  
Battery Maintenance............................................................................................................D-5  
Cleaning the Battery ......................................................................................................D-5  
Checking Specific Gravity..............................................................................................D-5  
Checking Electrolyte Level.............................................................................................D-5  
Charging the Battery......................................................................................................D-6  
Welder/Generator Maintenance ...........................................................................................D-6  
Storage...........................................................................................................................D-6  
Cleaning .........................................................................................................................D-6  
Brush Removal and Replacement ................................................................................D-6  
Nameplates ....................................................................................................................D-6  
Receptacles ...................................................................................................................D-6  
Cable Connections.........................................................................................................D-6  
Major Component Locations ...............................................................................................D-7  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
KUBOTA ENGINE MAINTENANCE  
SCHEDULE  
TABLE D.1  
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. Remove  
guards only when necessary and replace them when  
the maintenance requiring their removal is complete.  
Always use the greatest care when working near mov-  
ing parts.  
FREQUENCY  
MAINTENANCE REQUIRED  
Daily or Before  
Starting Engine  
• Fill fuel tank.  
• Check oil level.  
• Check air cleaner for dirty,  
loose, or damaged parts.  
• Check air intake and cooling  
areas, clean as necessary.  
Do not put your hands near the engine cooling blower  
fan. If a problem cannot be corrected by following the  
instructions, take the machine to the nearest Lincoln  
Field Service Shop.  
Every 50 Hours  
Every 100 Hours  
• Check fuel lines and clamps.  
(1)  
• Clean air filter element.  
• Check battery electrolyte level.  
• Check fan belt tightness.  
(2)  
ELECTRIC SHOCK can kill.  
Every 200 Hours  
Every 400 Hours  
• Change engine oil.  
(2)  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and ground  
• Always wear dry insulating gloves.  
• Replace oil filter cartridge.  
• Check radiator hoses.  
• Replace fuel filter element.  
(1) Replace air filter element after 600 hours of operation or sooner under  
dusty operating conditions.  
(2) If the engine is operated under heavy load, in high ambient temperatures,  
or under dusty conditions, change the oil and oil filter every 100 hours.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
Refer to your Kubota Engine Operator's Manual for  
periodic maintenance at 500 hours and beyond.  
MOVING PARTS can injure.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
KUBOTA ENGINE MAINTENANCE  
COMPONENTS  
See additional warning information throughout this  
operator’s manual and the Kubota Engine  
Operator’s Manual as well.  
TABLE D.2  
ITEM  
MAKE AND PART NUMBER  
Oil Filter Element  
Kubota 16271-32092  
Fram PH 3593A  
Air Cleaner Element Donaldson P148970  
Fuel Filter Element  
Kubota 15231-43560  
Fram C6921  
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D-3  
D-3  
MAINTENANCE  
4. Reinstall the oil fill cap and the dipstick and start  
the engine. Run for several minutes and stop  
engine. Wait 5 minutes to allow the oil to come  
down to the oil pan and check oil level again.  
ROUTINE AND PERIODIC  
MAINTENANCE  
ENGINE MAINTENANCE  
FIGURE D.1  
OIL COMPONENT LOCATIONS  
(Refer to Figure D.3 for the location of maintenance  
components.)  
OIL FILL CAP  
OIL LEVEL  
DIP STICK  
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. More frequent service may  
be required, depending on your specific application  
and operating conditions. See the Kubota Engine  
Operator's Manual for further information.  
OIL FILTER  
OIL  
Check the oil level before starting engine or  
daily. BE SURE TO MAINTAIN THE OIL  
LEVEL. Change the oil for the first time after 50 hours  
of operation. Then, under normal operating condi-  
tions, change the oil as specified in the maintenance  
schedule.  
OIL DRAIN PLUG  
OIL FILTER  
Change the oil filter the first time after 50 hours of  
operation. Then, under normal operating conditions,  
change the oil filter at every oil change. See Table D.2  
for recommended oil filters.  
CHANGING THE OIL  
Change the oil filter as follows:  
Change the oil, while the engine is still warm, as fol-  
lows:  
1. Drain the oil from the engine and allow the oil filter  
to drain.  
1. Drain the oil from the drain plug located on the  
engine bottom, as shown in Figure D.1.  
2. Remove the old filter (spin it off) and discard it.  
Wipe off the filter mounting surface and adapter.  
2. Replace the plug and tighten it securely.  
3. Apply a thin coat of new oil to the rubber gasket on  
the new oil filter.  
3. Remove the oil fill cap and add oil until the level  
reaches the full mark on the dipstick. The quantity  
of oil required for an oil and oil filter change is 5.4  
quarts (5.1 L). Use oil that is rated for diesel engine  
service (API classification CD/CE). Use SAE vis-  
cosity grades per Table D.3.  
4. Spin the new filter on to the mounting adapter until  
the gasket just touches the mounting surface, then  
turn it down another 1/2 to 3/4 turn. Do not over-  
tighten the new filter.  
5. Refill the engine with the proper amount and type  
of oil as described in the Changing the Oil section.  
Start the engine and check for leaks around the fil-  
ter element. Correct any leaks (usually by retight-  
ening the filter, but only enough to stop leaks)  
before placing the RANGER 300 back in service.  
TABLE D.3  
Viscosity Grades  
Ambient Temperature  
Above 25°C (77°F)  
0°C (32°F) to 25°C (77°F)  
Below 0°C (32°F)  
SAE 10W-30, SAE10W-40 or SAE30  
SAE 10W-30, SAE10W-40 or SAE20  
SAE 10W-30, SAE10W-40 or SAE10  
6. If there are no leaks, stop the engine and recheck  
the oil level. If necessary, add oil to bring the level  
up to the FULL mark, but do not overfill.  
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D-4  
D-4  
MAINTENANCE  
FUEL  
AIR CLEANER  
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.  
The Kubota diesel engine is equipped with a dry type air  
filter. Never apply oil to it. See Table D.2 for recom-  
mended air cleaner. Service the air cleaner as follows:  
1. Remove the dust cup from the bottom of the air  
cleaner housing. Clean out any accumulated dust.  
Use only fresh, No. 2 grade DIESEL fuel. Do not use  
kerosene.  
2. If dust is sticking to the element, blow compressed  
air through the element from the inside out. Turn  
the element as you apply air. Air pressure should  
be under 99 psi (68 newton/cm2). Replace the fil-  
ter if there is carbon or oil on the element.  
See the Kubota Engine Operator's Manual for instruc-  
tions on replacing the fuel filter. See Table D.2 for rec-  
ommended fuel filters.  
BLEEDING THE FUEL SYSTEM  
3. Replace the element at least every 600 hours of  
operation and sooner under dusty conditions.  
You will need to bleed air from the fuel system any  
time the fuel filter or fuel lines have been detached and  
refitted; after the fuel tank has been run out of fuel; or  
before using the engine after long storage. Bleed the  
fuel system as follows:  
TIGHTENING THE FAN BELT  
If the fan belt is loose, the engine can overheat and the  
battery lose its charge. Check tightness by pressing  
on the belt midway between the pulleys. It should  
deflect about .25 in. (6 mm) under a load of 20 lbs.  
(9 Kg).  
WARNING  
To avoid personal injury, do not bleed a hot engine.  
This could cause fuel to spill onto a hot exhaust man-  
ifold, creating a danger of fire.  
COOLING SYSTEM  
WARNING  
Refer to Figure D.2  
HOT COOLANT can burn skin.  
1. Fill the fuel tank. Open the fuel cock.  
• Do not remove cap if radiator is  
hot.  
2. Open the air vent plug on the fuel injection pump  
two turns using a 10mm wrench.  
3. Move the fuel feed pump lever by hand until fuel  
flows out of the air vent plug.  
4. Tighten the air vent plug.  
Check the coolant level by observing the level in the  
plastic reserve overflow tank. Add 50/50 antifreeze/  
water solution if the level is close to or below the  
“LOW” mark. Do not fill above the “FULL” mark.  
Remove radiator cap and add coolant to radiator if  
overflow tank is empty.  
FIGURE D.2  
FUEL BLEEDING COMPONENT LOCATIONS  
AIR VENT PLUG  
To drain the coolant, open the petcock at the bottom  
of the radiator. Open the radiator cap to allow com-  
plete drainage. (Tighten the petcock and refill with a  
50/50 antifreeze/water solution.) Use an automotive  
grade (low silicate) ethylene glycol antifreeze. The  
cooling system capacity is 5.4 quarts (5.1l.). Replace  
and tighten the radiator cap.  
FUEL FEED PUMP LEVER  
FUEL FEED PUMP LEVER  
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D-5  
D-5  
MAINTENANCE  
BATTERY ACID can burn eyes and skin.  
CAUTION  
• Wear gloves and eye protection and  
be careful when working near battery.  
Always premix the antifreeze 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 proper cooling  
during hot weather and freezing protection to -34°F  
(-37°C).  
• Follow instructions printed on battery.  
To prevent ELECTRICAL DAMAGE when:  
a) Installing a battery.  
Cooling solution exceeding 50% ethylene glycol can  
result in engine overheating and damage to the  
engine. Coolant solution must be premixed before  
adding to radiator.  
b) Using a booster.  
Use correct polarity - Negative Ground.  
To prevent BATTERY DISCHARGE, if you have an igni-  
tion switch, turn it off when engine is not running.  
Periodically remove the dirt from the radiator fins.  
Periodically check the fan belt and radiator hoses.  
Replace if signs of deterioration are found.  
CLEANING THE BATTERY  
Keep the battery clean by wiping it with a damp cloth  
when dirty. If the terminals appear corroded, discon-  
nect the battery cables and wash the terminals with an  
ammonia solution or a solution of 1/4 pound (0.1113  
kg) of baking soda and 1 quart (0.946 l) of water. Be  
sure the battery vent plugs (if equipped) are tight so  
that none of the solution enters the cells.  
SPARK ARRESTER SCREEN  
If the muffler has the optional spark arrester, remove it  
every 50 hours or once a year, whichever comes first,  
and inspect it. Clean the arrester. Replace it if you find  
any damage.  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clean  
water. Coat the battery terminals lightly with petrole-  
um jelly or a non-conductive grease to retard corro-  
sion.  
BATTERY MAINTENANCE  
CAUTION  
Keep the battery clean and dry. Moisture accumulation  
on the battery can lead to more rapid discharge and  
early battery failure.  
GASES FROM BATTERY can explode.  
• Keep sparks, flame and cigarettes  
away from battery.  
CHECKING SPECIFIC GRAVITY  
Check each battery cell with a hydrometer. A fully  
charged battery will have a specific gravity of 1.260.  
Charge the battery if the reading is below 1.215.  
To prevent EXPLOSION when:  
•
INSTALLING A NEW BATTERY – disconnect neg-  
ative cable from old battery first and connect to  
new battery last.  
NOTE: Correct the specific gravity reading by adding  
four gravity points (0.004) for every five degrees the  
electrolyte temperature is above 80°F (27°C). Subtract  
four gravity points (9.004) for every five degrees the  
electrolyte temperature is below 80°F (27°C).  
•
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.  
CHECKING ELECTROLYTE LEVEL  
If battery cells are low, fill them to the neck of the filler  
hole with distilled water and recharge. If one cell is low,  
check for leaks.  
•
USING A BOOSTER – connect positive lead to  
battery first then connect negative lead to negative  
battery lead at engine foot.  
The battery is a group 45, with a rating of 495 cold  
cranking amps.  
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D-6  
D-6  
MAINTENANCE  
CHARGING THE BATTERY  
NAMEPLATES  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is  
correct. Improper polarity can damage the charging  
circuit. The RANGER 300 positive (+) battery terminal  
has a red terminal cover.  
Whenever routine maintenance is performed on this  
machine - or at least yearly - inspect all nameplates  
and labels for legibility. Replace nameplates that are  
no longer clear. Refer to the parts list for the replace-  
ment item number.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
after the battery is charged, reconnect the positive  
battery cable first and the negative cable last. Failure  
to do so can result in damage to the internal charger  
components.  
RECEPTACLES  
Keep the electrical receptacles in good condition.  
Remove any dirt, oil, or other debris from their sur-  
faces and holes.  
CABLE CONNECTIONS  
Follow the instructions of the battery charger manu-  
facturer for proper charger settings and charging time.  
Check the welding cable connections at the weld out-  
put terminals often. Be sure that the connections are  
always firm.  
WELDER / GENERATOR  
MAINTENANCE  
STORAGE  
Store the RANGER 300 in clean, dry protected areas.  
CLEANING  
Blow out the generator and controls periodically with  
low pressure air. Do this at least once a week in par-  
ticularly dirty areas.  
BRUSH REMOVAL AND REPLACEMENT  
It is normal for the brushes and slip rings to wear and  
darken slightly. Inspect the brushes when a generator  
overhaul is necessary.  
WARNING  
Do not attempt to polish slip rings while the engine is  
running.  
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D-7  
D-7  
MAINTENANCE  
FIGURE D.3  
MAJOR COMPONENT LOCATIONS  
1. OUTPUT TERMINALS  
2. ENGINE CONTROLS  
11. CAPACITOR BANK (RANGER 300 DLX ONLY)  
12. RADIATOR ASSEMBLY  
3. AUXILIARY POWER RECEPTACLES  
4. OUTPUT CONTROL PANEL  
5. REACTOR ASSEMBLY  
6. FUEL TANK  
13. CHOKE ASSEMBLY  
14. LIFT BAIL WELDED ASSEMBLY  
15. CASE BACK ASSEMBLY  
16. FIELD CAPACITOR AND  
RECTIFIER BRIDGE  
7. DIESEL ENGINE  
8. ROTOR/STATOR ASSEMBLY  
9. BASE WELDED ASSEMBLY  
10. P.C. BOARD COVER  
17. CONTACTOR (RANGER 300 DLX ONLY)  
18. FUEL SHUTOFF & IDLER ASSEMBLY  
19. CASE TOP  
20. DOOR ASSEMBLY  
19  
6
12  
7
15  
18  
10  
17  
8
14  
5
20  
16  
13  
4
11  
3
9
2
1
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
-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  
FIGURE E.1  
RANGER 300 BLOCK LOGIC DIAGRAM  
RANGE  
SWITCH  
RANGER 300 DLX  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
RECTIFIER  
BRIDGE  
SWITCH  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
OIL &  
WATER  
SENSORS  
IDLER  
SOLENOID  
ALTERNATOR  
BATTERY  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2  
BATTERY, STARTER, ENGINE, GLOW PLUGS,ENGINE PROTECTION,  
ROTOR, STATOR AND IDLER SOLENOID  
RANGE  
SWITCH  
RANGER 300 DLX  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
RECTIFIER  
BRIDGE  
SWITCH  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
OIL &  
WATER  
SENSORS  
IDLER  
SOLENOID  
ALTERNATOR  
BATTERY  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
feedback winding and the auxiliary power winding for  
wire feeders. The field feedback winding provides  
rotor current during machine operation. The output of  
the Ranger 300 is dependent on two criteria, the  
engine RPM and the amount of current in the rotor  
winding.  
BATTERY, STARTER, ENGINE,  
GLOW PLUGS, ENGINE  
PROTECTION, ROTOR, STATOR  
AND IDLER SOLENOID  
The 12VDC battery powers the starter motor and glow  
plugs. The glow plugs are used to preheat the diesel  
engine to enhance starting. When the engine is start-  
ed and running, the battery circuit voltage is fed  
through the printed circuit board to the rotating field  
coil in the rotor via a brush and slip ring configuration.  
This excitation (“flashing”) voltage magnetizes the  
rotor lamination. The rotor is mechanically coupled to  
the engine. This rotating magnet induces a voltage in  
the stationary windings of the main alternator (stator).  
There are four separate and isolated windings incorpo-  
rated in the stator lamination assembly. Each set has  
a different number of turns producing different magni-  
tudes of AC output voltages. These four windings are  
the weld winding, the auxiliary power winding, the field  
The engine alternator supplies “charging” current for  
the battery circuit. The battery circuit provides power  
for the printed circuit board and also for the idler sole-  
noid. The idler solenoid is mechanically connected to  
the engine's throttle linkage. If welding or auxiliary  
current is being drawn from the Ranger 300, the print-  
ed circuit board activates the idler solenoid, which  
then brings the engine to the high RPM state. When  
no output current is sensed, either weld or auxiliary,  
the printed circuit board deactivates the idler solenoid  
and the engine returns to low RPM.  
The engine protection circuit shuts the engine off in the  
event of low oil pressure or engine coolant over-tem-  
perature.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3  
ROTOR FIELD FEEDBACK, AUXILIARY AND WIRE FEEDER POWER  
RANGE  
SWITCH  
RANGER 300 DLX  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
RECTIFIER  
BRIDGE  
SWITCH  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
OIL &  
WATER  
SENSORS  
IDLER  
SOLENOID  
ALTERNATOR  
BATTERY  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
When full field voltage is applied to the rotor and the  
engine is running at high speed (3600 RPM), a 230VAC  
voltage is developed in the stator auxiliary winding.  
This winding is tapped to provide 115VAC. The two  
voltages (115VAC and 230VAC), are connected to the  
appropriate receptacles and offer 12,000 watts (total)  
of AC power.  
ROTOR FIELD FEEDBACK,  
AUXILIARY 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 controlled  
by the printed circuit board according to the setting of  
the machine’s output control or remote control. This  
filtered and controlled voltage is fed to the rotor wind-  
ing via the brush and slip ring configuration. As the  
feedback voltage is increased or decreased, the out-  
puts of the weld and auxiliary windings are increased  
or decreased.  
The auxiliary wire feeder winding offers 115VAC and is  
tapped to also provide 42VAC. The current draw from  
this winding should be limited to 8 amps. These volt-  
ages and remote control signals are fed through the  
by-pass (filter) board to the amphenol receptacles.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E-4  
WELD WINDING, REACTOR AND RANGE SWITCH  
RANGE  
SWITCH  
RANGER 300 DLX  
WORK  
TERMINAL  
AC  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
RECTIFIER  
BRIDGE  
SWITCH  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
OIL &  
WATER  
SENSORS  
IDLER  
SOLENOID  
ALTERNATOR  
BATTERY  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
the current path. As more turns of reactor are brought  
into the circuit, the more impedance there is to current  
flow. Simply stated, the more reactor in the circuit, the  
lower the welding current.  
WELD WINDING, REACTOR AND  
RANGE SWITCH  
The stator weld winding is connected to the reactor  
and range switch. The inductance in the reactor offers  
an impedance to current flow. The reactor coil is  
tapped at various points. As the range switch is rotat-  
ed, different amounts of reactor coil are brought into  
If a constant voltage is desired for wire feeding, then  
the reactor is bypassed, and the range switch is con-  
nected to one of four taps on the stator weld winding  
to provide a lower but “stiffer” output voltage.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, OUTPUT CONTACTOR  
AND OUTPUT TERMINALS  
RANGE  
SWITCH  
RANGER 300 DLX  
WORK  
TERMINAL  
AC  
CHOKE  
PART OF  
RANGE  
OUTPUT  
RECTIFIER  
BRIDGE  
SWITCH  
AC  
CAPACITORS  
REACTOR  
ELECTRODE  
TERMINAL  
cv  
output  
contactor  
SHUTDOWN  
SOLENOID  
STATOR  
ROTOR  
GLOW PLUGS  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
SLIP  
RINGS  
STARTER  
MOTOR  
OIL &  
WATER  
SENSORS  
IDLER  
SOLENOID  
ALTERNATOR  
BATTERY  
115 & 230VAC  
RECEPTACLES  
FIELD  
BRIDGE  
PRINTED  
CIRCUIT  
BOARD  
FIELD  
CAPACITOR  
BY-PASS  
BOARD  
CONTACTOR CLOSURE  
CONTACTOR CLOSURE  
OUTPUT  
CONTROL  
REMOTE  
SWITCH  
42VAC  
115VAC  
6 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
where the AC voltage is rectified to a DC voltage; and  
then to the choke, where the DC output is filtered. The  
filtered DC current path is through the polarity switch  
and output contactor to the output terminals.  
OUTPUT BRIDGE, CHOKE,  
POLARITY SWITCH, OUTPUT  
CONTACTOR AND OUTPUT  
TERMINALS  
When a CV (constant voltage) is desired, the reactor is  
passed by. The range switch applies a lower AC volt-  
age to the rectifier bridge. The DC output of the bridge  
is filtered and “stiffened” by the capacitors. This lower  
but “stiffer” DC output is passed through the tapped  
portion of the choke, the polarity switch, and output  
contactor to the output terminals.  
The AC voltage developed in the stator weld winding  
is delivered, through 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 AC output is selected, the current path is from the  
stator weld winding through the reactor, range switch,  
and polarity switch; through the output contactor to  
the output terminals. If a DC output is called for, the  
current path is through the output rectifier bridge,  
In the Ranger 300DLX machines, the output contactor  
is in series with the electrode terminal and must be  
energized (closed) to provide welding voltage at the  
output terminals.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
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NOTES  
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Section F-1  
Section F-1  
TABLE OF CONTENTS  
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  
Auxiliary and Field Winding Test ...................................................................................F-33  
Rotor Voltage Test ........................................................................................................F-37  
Charging Circuit Test.....................................................................................................F-39  
Oscilloscope Waveforms.....................................................................................................F-41  
Normal Open Circuit Voltage Waveform (115 VAC Supply) .........................................F-41  
Typical DC Weld Output Voltage Waveform (CV Mode High Tap)................................F-42  
Typical DC Weld Output Voltage Waveform..................................................................F-43  
Typical AC Weld Output Voltage Waveform..................................................................F-44  
Abnormal Open Circuit DC Weld Voltage Waveform....................................................F-45  
Abnormal Open Circuit Weld Voltage Waveform (High CV Mode) ...............................F-46  
Normal Open Circuit Weld Voltage Waveform (High CV Mode) ...................................F-47  
Normal Open Circuit DC Weld Voltage Waveform .......................................................F-48  
Normal Open Circuit AC Weld Voltage Waveform .......................................................F-49  
Replacement Procedures ....................................................................................................F-50  
Brush Removal and Replacement ...............................................................................F-50  
Field Capacitor and/or Rectifier Bridge Removal and Replacement ...........................F-53  
Control Board Removal and Replacement ..................................................................F-56  
Output Rectifier Bridge Removal and Replacement.....................................................F-59  
Output Capacitor Bank Removal and Replacement.....................................................F-62  
Output Contactor Removal and Replacement..............................................................F-64  
Stator and/or Rotor Removal and Replacement .........................................................F-67  
Retest After Repair ..............................................................................................................F-72  
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F-2  
F-2  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure list-  
ed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the sub-  
ject component is either good or bad. If there are  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM” (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into four main categories: Output Problems,  
Engine Problems Function Problems, and  
Welding Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this section.  
Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 1-800-833-9353.  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- Remove the PC board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC board on or near paper, plastic or cloth which  
could have a static charge. If the PC board can’t be  
installed immediately, put it back in the static-shield-  
ing bag.  
WARNING  
ELECTRIC SHOCK  
can kill.  
•
Have an electrician install and  
service this equipment. Turn the  
input power OFF at the fuse box  
before working on equipment. Do  
not touch electrically hot parts.  
- 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.  
CAUTION  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure  
symptom has been corrected by the  
replacement PC board.  
NOTE: It is desirable to have a spare (known good)  
PC board available for PC board troubleshooting.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static  
electrical damage and electrical shock. Read  
the warning inside the static resistant bag and  
perform the following procedures:  
a. If the original problem does not reappear by  
substituting the original board, then the PC  
board was not the problem. Continue to look  
for bad connections in the control wiring  
harness, junction blocks, and terminal strips.  
PC board can be damaged by static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the PC  
board was the problem. Reinstall the  
replacement PC board and test the machine.  
- Remove your body’s static  
charge before opening the static-  
shielding bag. Wear an anti-static  
wrist strap. For safety, use a 1  
Meg ohm resistive cord connected  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
to  
a
grounded part of the  
equipment frame.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
- If you don’t have a wrist strap,  
touch an un-painted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent  
static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Workstations  
- Tools which come in contact with the PC board must  
be either conductive, anti-static or static-dissipative.  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical dam- 1. Contact your local Lincoln 1. Contact The Lincoln Electric  
age is evident.  
Authorized  
Facility.  
Field  
Service  
Service Dept. 1-800-833-9353  
(WELD).  
No weld output and no auxiliary 1. Make sure the REMOTE switch 1. Perform the Rotor Voltage  
power. Engine operates normally.  
(S8) is in the proper position –  
“MACHINE CONTROL” – if a  
remote control unit is NOT con-  
nected to the machine.  
Test.  
2. If the Rotor Voltage Test is nor-  
mal, perform the Rotor  
Resistance Test.  
2. Check the brushes for wear and  
proper contact to the rotor slip  
rings.  
3. If the Rotor Voltage Test is NOT  
normal, perform the Auxiliary  
and Field Winding Voltage  
Test. Then check the field  
diode bridge (D2), the field  
capacitor (C1), and the Output  
Control (R3). Replace if neces-  
sary.  
4. The control board may be  
faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No weld output, the auxiliary power 1. On DLX machines, the output 1. On DLX machines, the output  
(230-115VAC) is operating normal-  
ly. Engine operates normally.  
contactor must be activated  
(closed).  
contactor or associated leads  
may be faulty. See the Wiring  
Diagram. The output contactor  
coil is energized by 12VDC. If  
the coil is not receiving 12VDC  
when the Welding Terminals  
Switch is in the “Always ON”  
position, the control board may  
be faulty. Also check associat-  
ed leads #224 and #232.  
2. Normal AC open circuit voltage  
is approximately 70 to 80 volts.  
Normal DC is 64 to 74VDC. If  
the open circuit voltage is NOT  
present at the welder output  
terminals, contact your local  
Lincoln  
Authorized  
Field  
Service Facility.  
2. If OCV is absent in both modes  
(CV & CC), disconnect lead W1  
from the output bridge (D1).  
With the engine at high idle and  
the output control at maximum,  
check for 70 to 76VAC from  
lead W1 to lead W2 on the main  
stator winding. See the Wiring  
Diagram. If the AC voltage is  
NOT present, the winding may  
be faulty. Check the winding for  
continuity and test to be sure it  
is NOT grounded to the stator  
iron. Replace if necessary. If  
the voltage is present, proceed  
to step #3.  
3. If normal open circuit voltage is  
present at the output terminals,  
check the welding cables,  
clamps, and electrode holder  
for loose or broken connec-  
tions.  
(continued on page F-6)  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
(continued from page F-5)  
3. Check the reactor, range switch  
(S2) and associated wires for  
loose or faulty connections.  
Check the reactor winding for  
continuity and test to be sure it  
is NOT grounded to the reactor  
iron.  
4. Check the choke (L1), polarity  
mode switch (S1), and associ-  
ated wires for loose or faulty  
connections. Check the choke  
winding for continuity and test  
to be sure it is NOT grounded to  
the choke iron.  
5. Check the weld output termi-  
nals and associated wires for  
loose or faulty connections.  
6. Perform the Output Rectifier  
Bridge Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
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F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No auxiliary power at receptacles 1. If the machine is equipped with 1. Check the auxiliary power  
- welding output is normal - engine  
runs normally.  
circuit breakers, check circuit  
breakers. Reset if tripped.  
receptacles and associated  
wires for loose or faulty con-  
nections.  
2. Make sure the output control  
(R1) is set at the maximum 2. Perform the Auxiliary and  
position.  
Field Winding Voltage Test.  
3. Check for a loose or faulty  
plug(s) at the power recepta-  
cles.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
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F-8  
F-8  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Machine has low welding output 1. If a remote control unit is NOT 1. If the engine high idle RPM is  
and low auxiliary output.  
connected to the machine,  
make sure the REMOTE switch  
is in the proper position -  
“MACHINE CONTROL.”  
low, perform the Engine  
Throttle Adjustment Test.  
2. Perform the Rotor Voltage  
Test.  
2. The brushes may be worn.  
Contact your local Lincoln  
3. If the rotor voltage is low, the  
field capacitor (C1) or the field  
bridge (D2) may be faulty. Test  
and replace if necessary.  
Authorized  
Facility.  
Field  
Service  
3. The Engine RPM may be low.  
4. Check the output control poten-  
tiometer (R3). Normal resis-  
tance is 10,000 ohms. Also  
check associated wiring for  
loose or faulty connections.  
5. The rotor may be faulty.  
Perform the Rotor Resistance  
Test.  
6. The control board may be faulty.  
Replace.  
7. If the engine high idle RPM is  
OK, the engine may have lost  
horsepower and be in need of  
major repair.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
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F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No DC welding output. AC welding 1. Make sure the polarity mode 1. Perform the Output Rectifier  
output and auxiliary power are nor-  
switch (S1) is in the proper posi-  
Bridge Test.  
mal.  
tion and is “seated” correctly.  
2. Check the choke (L1), the polar-  
ity mode switch (S1) and asso-  
ciated wires for loose or faulty  
connections. Check the choke  
winding for continuity and test  
to be sure it is NOT grounded to  
the choke iron.  
2. Make sure the electrode and  
polarity are correct for the  
process being used.  
No AC welding output. DC welding 1. Make sure the polarity mode 1. Check the operation of the  
output and auxiliary power are nor-  
mal.  
switch (S1) is in the proper posi-  
tion and is “seated” correctly.  
polarity switch (S1). Also check  
the associated wires for loose  
or faulty connections. See the  
Wiring Diagram.  
2. Make sure the electrode is cor-  
rect for the process being used.  
2. Check for continuity from lead  
“A1” to lead “A2.” See the  
Wiring Diagram.  
3. Make sure the welding cables  
are not coiled or too long.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
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F-10  
F-10  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No constant voltage (CV) welding 1. Make sure the range switch (S2) 1. Check the operation of the  
output. Constant current (CC) and  
auxiliary power are operating nor-  
mally.  
is in the proper position and  
“seated” correctly.  
range switch (S2) and check the  
associated wires for loose or  
faulty connections. See the  
Wiring Diagram.  
2. Make sure the wire feeder and  
welding cables are connected  
correctly.  
2. Check the continuity from leads  
C1 to lead W1 located in the  
main stator. See the Wiring  
Diagram. On DLX machines,  
also check leads C2, C3, and  
C4 to lead W1.  
3. On DLX machines, check the  
capacitors and associated  
leads. See the Wiring Diagram.  
The constant voltage (CV) welding 1. Make sure the range switch and 1. Check the operation of the  
output is low or unstable.  
Constant current (CC) and auxiliary  
power are operating normally.  
polarity switch are in the correct  
position (CV) and “seated” cor-  
rectly.  
range switch (S2) and check the  
associated wires for loose or  
faulty connections. See the  
Wiring Diagram.  
2. Make sure the wire feeder and  
welding cables are connected 2. On DLX machines the capacitor  
correctly.  
bank (C2, C3, C4, and C5) may  
be faulty. Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-11  
F-11  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not idle down to low 1. Make sure the idler switch (S5) 1. With the idler switch (S5) in the  
speed. Machine has normal weld  
output and auxiliary power.  
is in the “Auto” position.  
“Auto” position, no external  
load connected to the machine  
and the engine running, check  
the DC voltage at leads #222J  
to #214 located at the idler  
solenoid. Also check from  
leads #222H to #213. No (zero)  
volts is normal. If 12VDC IS  
present, the control board may  
be faulty. If no voltage is indi-  
cated and the solenoid is keep-  
ing the engine in a high speed  
condition, the idler solenoid  
may be faulty. Also check for a  
mechanical restriction in the  
throttle linkage.  
2. Make sure there is NOT an  
external load on the weld termi-  
nals nor the auxiliary power  
receptacles.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
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F-12  
F-12  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not go to high idle when 1. Make sure the welding cables 1. Check for broken or faulty con-  
attempting to weld. Welding out-  
put is normal when idler switch is  
in “HIGH” position. Automatic idle  
function works properly when the  
auxiliary power is loaded.  
and connections are tight.  
nections in the sensing leads  
#254 and #254 A & B). Make  
sure their connections are tight  
at the work output terminal and  
polarity mode switch. See the  
Wiring Diagram.  
2. If welding without a control  
cable connected to the DLX  
machine, the welding terminals  
switch (S7) must be in the  
“Always On” position.  
2. Make sure leads #254 and  
#254C are looped three times  
through the current sensor on  
the control board. See the  
Wiring Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
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F-13  
F-13  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not go to high idle 1. Check circuit breaker CB8. 1. Check for broken or faulty con-  
when attempting to weld or when  
the auxiliary power is loaded.  
Reset if tripped.  
nections in the sensing leads  
(#254, #254A, and lead #3 and  
#6). Make sure leads #3 and #6  
are looped through the AC cur-  
rent sensor.  
2. Make sure the welding cables  
and auxiliary power lead con-  
nections are tight.  
3. Automatic idler may not func-  
tion if the auxiliary power is  
loaded to less than 150 watts.  
2. The control board may be  
faulty. Replace.  
3. Perform the High Speed  
Solenoid Resistance Test.  
4. Check the leads and associat-  
ed connections between the  
high speed solenoid and the  
control board.  
The engine will not crank or cranks 1. Check for loose or faulty battery 1. If the battery is replaced or  
very slowly.  
cable connections.  
tests good, the charging circuit  
may be faulty. Perform the  
Charging Circuit Test.  
2. The battery may be faulty.  
2. The starter motor or starter  
solenoid may be faulty.  
3. The engine may be hard to  
crank due to a mechanical fail-  
ure in the engine.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine cranks but will not 1. The engine may be low on or 1. The fuel solenoid may be faulty.  
start.  
out of fuel.  
Perform the Fuel Shutdown  
Solenoid Resistance Test.  
2. Make sure the on/off switch  
(S6) is in the “ON” position.  
2. The engine may be faulty.  
3. The oil level or pressure may be 3. The control board may be faulty.  
low, causing the engine protec-  
tion system to shut off fuel flow  
to the engine. Check the oil  
pressure light.  
4. The engine coolant may be  
overheated, causing the engine  
protection system to shut off  
fuel flow to the engine. Check  
the water temperature light.  
5. The engine “glow” plugs may  
not be operating correctly.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine shuts off shortly after 1. The oil level or pressure may be 1. The fuel shutdown solenoid  
starting.  
low, causing the engine protec-  
tion system to shut off fuel flow  
to the engine. Check the oil  
pressure light.  
may be faulty. Perform the Fuel  
Shutdown Solenoid Resis-  
tance Test.  
2. The control board may be  
faulty.  
2. Check for adequate fuel supply.  
3. Circuit breaker CB9, located in  
the engine compartment, may  
be open. If CB9 is tripped, the  
oil pressure and charging indi-  
cator lights will not be on when  
the engine switch is in the “ON”  
position and the engine is not  
running.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
Output control on welder not func- 1. Make sure the REMOTE switch 1. Check the output control (R3).  
tioning.  
(S8) is in the MACHINE CON-  
TROL position.  
Normal resistance is 10,000  
ohms. Replace if defective.  
2. The output control (R3) may be 2. Check the REMOTE switch (S8)  
defective.  
and associated wiring. See the  
Wiring Diagram (leads #75, #76  
and #77).  
3. The control board may be  
faulty. Replace.  
Remote output control not func- 1. Make sure the remote switch 1. Check the remote switch (S8)  
tioning.  
(S8) is in the REMOTE position.  
and associated wiring. See the  
Wiring Diagram (leads #75, #76  
and #77).  
2. The remote control unit may be  
faulty. Repair or replace.  
2. The RF bypass board may be  
defective. Check or replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-17  
F-17  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The wire feeder does not work 1. Check circuit breaker CB1. 1. Check for the presence of  
when connected to the welder 14-  
pin amphenol (DLX machines  
only).  
Reset if tripped.  
115VAC at leads #31A and 32.  
See the Wiring Diagram.  
2. The wire feeder control cable  
may be faulty.  
replace.  
Check or 2. Check for the presence of  
42VAC at leads #31B to #42.  
See the Wiring Diagram.  
3. The wire feeder may be faulty.  
Check or replace.  
3. If any of the above voltages are  
missing or low, check the circuit  
breaker CB1 for proper opera-  
tion.  
4. The RF bypass board may be  
faulty. Check or replace.  
5. Perform the Auxiliary and  
Field Winding Voltage Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-18  
F-18  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
With the engine running, the output 1. Make  
sure  
the  
Welding 1. With Welding Terminals switch  
contactor does not pull in when  
using a wire feeder with a control  
cable connected to the RANGER  
300 DLX amphenol.  
Terminals switch (S8) is in the  
“Welding Terminals Remotely  
Controlled” position.  
(S8) in the “Welding Terminals  
Always On” position, check for  
12VDC from leads #224(+) to  
#232(-) at the output contactor.  
If 12VDC is present and the  
contactor does NOT activate,  
the contactor may be defective.  
See the Wiring Diagram.  
2. If the output contactor activates  
(closes) when switch S8 is in  
the “Welding Terminals Always  
On” position, the contactor and  
control PC board are function-  
ing.  
2. If the correct voltage is NOT  
present in Step #1, check from  
lead #224 to ground (lead #5)  
for the presence of 12VDC. If  
12VDC IS present, check the  
continuity of lead #232 to 9J2  
on the control board. See the  
Wiring Diagram.  
3. Install a jumper wire from pins  
“D” to “C” on the 14-pin am-  
phenol. If the output contactor  
activates, the problem is exter-  
nal to the RANGER 300 DLX.  
The wire feeder or control cable  
may be faulty.  
3. If 12VDC is NOT present from  
lead #224 to ground (lead #5),  
check the continuity of lead  
#224 to 1J1 on the control  
board. See the Wiring Diagram.  
4. The control board may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-19  
F-19  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The battery does not stay charged. 1. Check for loose or faulty con- 1. Perform the Charging Circuit  
nections at the battery and  
Test.  
engine charging system.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-20  
F-20  
TROUBLESHOOTING & REPAIR  
OBSERVE SAFETY GUIDELINES  
DETAILED IN THE BEGINNING OF THIS MANUAL.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
The welding arc is “cold.” The 1. Check for loose or faulty con- 1. Check for the correct open cir-  
engine runs normally (3700 RPM  
no load). The auxiliary power is  
functioning normally.  
nections at the weld output ter-  
minals and welding cable con-  
nections.  
cuit voltage (OCV) at the weld-  
ing output terminals. If the cor-  
rect voltage is present at the  
output terminals, check for  
loose connections on the heavy  
current carrying leads inside the  
Ranger 300 D. See the Wiring  
Diagram.  
2. The welding cables may be too  
long or coiled, causing an  
excessive voltage drop.  
2. If the OCV is low at the welder  
output terminals, perform the  
Engine Throttle Adjustment  
Test.  
3. Perform the Output Rectifier  
Bridge Test.  
4. Check for shorted or grounded  
windings in the reactor and also  
in the main stator. See the  
Wiring Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 300 D AND 300 DLX  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
Need nose pliers  
Wiring Diagram  
This procedure requires approximately 20 minutes to perform.  
RANGER 300 D AND 300 DLX  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.1 – ROTOR BRUSH LEADS REMOVED  
5. Measure the resistance to ground. Set the  
meter on the high scale (X100,000). Place  
one meter probe on either of the slip rings.  
Place the other probe on any good  
unpainted ground. The resistance should  
be very high, at least 500,000 ohms.  
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). See Figure  
F.1. This will electrically isolate the rotor  
windings.  
6. If the test does not meet the resistance  
specifications, then the rotor may be faulty.  
7. Connect the leads previously removed  
from the brush assembly. Make sure the  
leads are connected to the proper brushes  
- lead #219 to the negative brush, lead  
#200A to the positive brush.  
4. Using the volt/ohmmeter, check the rotor  
winding resistance across the slip rings.  
Set the meter on the low scale (X1).  
Normal resistance is approximately 5 or 6  
ohms.  
8. Replace the right front case side previous-  
ly removed.  
RANGER 300 D AND 300 DLX  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there are faulty diodes in the output rectifier bridge.  
MATERIALS NEEDED  
Volt/Ohmmeter (Diode Tester)  
5/16” Nut driver  
3/8” Nut driver  
1/2” Wrench  
Wiring Diagram  
This procedure requires approximately 35 minutes to perform.  
RANGER 300 D AND 300 DLX  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.2 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS  
Left side (–)  
Right side (+)  
6. Electrically isolate the diode pigtail leads  
by carefully bending them out into “free  
air.”  
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.  
7. With an ohmmeter or diode tester, check  
each of the four diodes from their pigtails  
to their respective heat sinks.  
3. Carefully remove the right and left front  
case sides.  
8. Reverse the tester leads and check the  
diodes again. Diodes should have a low  
resistance in one polarity and a very high  
resistance in the opposite polarity.  
4. Locate the two halves of the output rectifi-  
er. The negative plate is located on the  
lower left side of the machine behind the  
case front. The positive plate is located on  
the lower right side of the machine behind  
the case front. See Figure F.2.  
9. Replace any “shorted” or “open” diode as  
the tests indicate.  
See the Diode  
Removal and Replacement Procedure.  
10. Replace the pigtails and heavy leads onto  
the correct studs. Assemble the washers  
and nuts.  
5. Using the 1/2” wrench, remove the nuts and  
washers holding the diode pigtails and the  
heavy current-carrying leads to the studs  
on the rectifier plates. Note leads and pig-  
tail placement for reassembly.  
11. Replace the left and right front case sides.  
RANGER 300 D AND 300 DLX  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
FUEL SHUTDOWN SOLENOID RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the shutdown solenoid coil resistances are normal.  
MATERIALS NEEDED  
Ohmmeter  
Wiring Diagram  
This procedure requires approximately 25 minutes to perform.  
RANGER 300 D AND 300 DLX  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
FUEL SHUTDOWN SOLENOID RESISTANCE TEST (continued)  
FIGURE F.3 – PLUG J12 LOCATION  
PLUG J12  
LOCATION  
3. Locate and disconnect plug J12. See  
Figure F.3. Also see the Wiring Diagram.  
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 #237  
LEAD #224B  
LEAD #5K  
4. Using the ohmmeter, check the resistance  
from lead #237 to lead #5K. See Figure F.4.  
Normal resistance of the “pull-in” coil is  
approximately 0.5 ohms.  
NOTE: This solenoid is activated with 12VDC.  
The “hold-in” voltage is derived from the con-  
trol board. The “pull-in” voltage is derived  
from the starter contactor. See the Wiring  
Diagram. If the 12VDC is not present, check  
the leads and associated connections.  
5. Using the ohmmeter, check the resistance  
from lead #224B to lead #5K. See Figure  
F.4. Normal resistance of the “hold-in” coil  
is approximately 11.5 ohms.  
6. Reassemble plug J12 and close and latch  
the engine access door.  
RANGER 300 D AND 300 DLX  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
HIGH SPEED SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the solenoid coil resistance is normal and also if the solenoid is  
capable of functioning when it is energized with 12VDC.  
MATERIALS NEEDED  
External 12VDC supply (30 amps)  
Wiring Diagram  
Volt/Ohmmeter  
This procedure requires approximately 35 minutes to perform.  
RANGER 300 D AND 300 DLX  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
HIGH SPEED SOLENOID TEST (continued)  
FIGURE F.5 – SOLENOID LEADS  
PULL-IN COIL  
(LARGER TERMINALS  
TOP AND BOTTOM  
#222H AND #213A)  
HOLD-IN COIL  
(SMALLER TERMINALS  
TOP AND BOTTOM  
#222J AND #214A)  
TEST PROCEDURE  
CAUTION  
1. Turn the engine off.  
When the solenoid activates, remove the volt-  
age immediately. Do not leave the external  
supply connected to terminals #222H and  
#213A for longer than three seconds.  
Component damage could result.  
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). See Figure F.5 and the Wiring  
Diagram. Remove any necessary wire  
wraps.  
8. If the solenoid does not operate properly,  
check for a mechanical restriction in the  
linkage.  
4. Check the pull-in coil resistance (larger ter-  
minals #222H and #213A). The normal  
resistance is approximately 0.4 ohms.  
9. Using the external 12VDC supply, apply  
12VDC to the smaller solenoid terminals  
for the hold-in coil (#222J+ to #214A-).  
Push in the solenoid plunger. With the  
12VDC applied to the hold-in coil, the  
plunger should stay in until the 12VDC is  
removed.  
Check the hold-in coil resistance (smaller  
terminals #222J and #214A). The normal  
resistance is approximately 20 ohms).  
If either coil resistance is not correct, the  
solenoid may be faulty. Replace.  
10. If the linkage is intact and the solenoid  
does not operate correctly when the  
12VDC is applied, the solenoid may be  
faulty. Replace.  
5. Using the external 12VDC supply, apply  
12VDC to the larger solenoid terminals  
(#222H+ to #213A-). The solenoid should  
activate. The solenoid should deactivate  
when the 12VDC is removed.  
11. Replace the harness leads to the correct  
terminals. See Figure F.5 and the Wiring  
Diagram. Replace any previously re-  
moved wire wraps.  
12. Close and secure the right side engine  
service access door.  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
If the machine output is low or high, this test will determine whether the engine is operating  
at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjust-  
ing the throttle to the correct RPM are given.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
10mm Wrench  
7/16” Wrench  
White or red marking pencil  
Strobe-tach, frequency counter, or oscilloscope  
This procedure requires approximately 30 minutes to perform.  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.6 – STROBE MARK LOCATION  
FLYWHEEL  
CHALK MARK  
4. Connect the strobe-tach according to the  
manufacturer’s instructions.  
TEST PROCEDURE  
1. Conduct this procedure with the engine  
5. Start the engine and direct the strobe-tach  
light on the flywheel bolt. Synchronize it to  
the rotating mark.  
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.  
With the machine at HIGH IDLE the tach  
should read between 3650 and 3700 RPM.  
3. With a white or red marking pencil, place a  
mark on one of the flywheel bolts. See  
Figure F.6 for location.  
With the machine at LOW IDLE the tach  
should read between 2150 and 2220 RPM.  
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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  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
6. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust LOW IDLE: First make sure there is  
NOT a load on the machine. Set the IDLER  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 10mm  
wrench to loosen the lock nut on the low  
speed set screw. See Figure F.8. Adjust  
the set screw until the frequency is 37 Hz.  
Tighten the lock nut.  
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. Using the 7/16” wrench,  
adjust the high speed solenoid linkage to  
lengthen the linkage until the engine speed  
starts to decrease. See Figure F.7. Adjust  
the linkage in the opposite direction until  
the engine speed is within limits (3650 -  
3700 RPM). Tighten the locking nut. The  
high speed set screw is preset and sealed  
by the engine manufacturer and normally  
should not be adjusted.  
Oscilloscope Method  
1. Connect the oscilloscope to the 115 VAC  
receptacle, according to the manufacturer’s  
instructions. At HIGH IDLE (3700 RPM), the  
waveform should exhibit a period of 15.8  
milliseconds. At LOW IDLE (2220 RPM), the  
waveform should exhibit a period of 27.02  
milliseconds. Refer to the NORMAL OPEN  
CIRCUIT VOLTAGE WAVEFORM (115VAC  
SUPPLY) HIGH IDLE - NO LOAD in this  
section of the manual.  
Adjust LOW IDLE: First make sure there is  
NOT a load on the machine. Set the IDLER  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 10mm  
wrench to loosen the lock nut on the low  
speed set screw. See Figure F.8. Adjust  
the set screw until the engine speed is  
between 2150 and 2220 RPM. Tighten the  
lock nut.  
2. If either of these waveform periods is incor-  
rect, 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. Using the 7/16” wrench,  
adjust the high speed solenoid linkage to  
lengthen the linkage until the engine speed  
starts to decrease. See Figure F.7. Adjust  
the linkage in the opposite direction until  
the period is 15.8 milliseconds. Tighten the  
locking nut. The high speed set screw is  
preset and sealed by the engine manufac-  
turer and normally should not be adjusted.  
Frequency Counter Method  
1. Plug the frequency counter into one of the  
115 VAC receptacles.  
2. Start the engine and check the frequency  
counter. At HIGH IDLE (3700 RPM), the  
counter should read 63 Hz. At LOW IDLE  
(2220 RPM), the counter should read 37 Hz.  
Note that these are median measurements;  
Hertz readings may vary slightly above or  
below.  
Adjust LOW IDLE: First make sure there is  
NOT a load on the machine. Set the IDLER  
switch to AUTO and wait for the engine to  
change to low idle speed. Use the 10mm  
wrench to loosen the lock nut on the low  
speed set screw. See Figure F.8. Adjust  
the set screw until the period is 27.02 mil-  
liseconds. Tighten the lock nut.  
3. 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. Using the 7/16” wrench,  
adjust the high speed solenoid linkage to  
lengthen the linkage until the engine speed  
starts to decrease. See Figure F.7. Adjust  
the linkage in the opposite direction until  
the frequency is 63 Hz. Tighten the locking  
nut. The high speed set screw is preset and  
sealed by the engine manufacturer and nor-  
mally should not be adjusted.  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct AC voltages are being generated from the stator wind-  
ings.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
This procedure requires approximately 45 minutes to perform.  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.9 – LOCATION OF LEADS #3A AND #3B  
15 AMP  
CB LEADS  
#3A AND #3B  
LOCATED ON  
REAR OF PANEL  
To test the 230 VAC winding:  
TEST PROCEDURE  
1. With the 5/16” and 3/8” nut drivers, remove  
the case left side.  
To test the 115 VAC winding:  
1. With the 5/16” and 3/8” nut drivers, remove  
the case left side.  
2. Set the voltmeter to the AC volts position.  
3. Connect the volt/ohmmeter probes to leads  
#6 and #3 where they connect to the 50  
amp circuit breakers. See the Wiring  
Diagram.  
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.  
NOTE: It is easier to insert the probes directly  
into the receptacle to perform this test.  
However, the probes may not reach in far  
enough to make or keep a good connection.  
4. Connect the volt/ohmmeter probes to leads  
#3A and #3B where they connect to the 15  
amp circuit breakers. See Figure F.9.  
5. Start the engine and run it at high idle (3700  
RPM).  
4. Start the engine and run it at high idle (3700  
RPM).  
6. Set the output control to the maximum  
position (position 10).  
5. Set the output control to the maximum  
position (position 10).  
7. Check the AC voltage reading. It should be  
approximately 125 VAC.  
6. Check the AC voltage reading. It should be  
approximately 240 VAC.  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.10 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER  
201  
201A  
7
_
AC  
200  
200A  
200B  
+
9
AC  
Field  
Bridge  
Rectifier  
Cable  
Tie  
Retaining  
Tab  
9
201  
201A  
Capacitor  
7
200  
200A  
200B  
To test the field winding:  
5. Check the AC voltage reading. It should be  
between 40 and 47 VAC.  
1. With the 5/16” and 3/8” nut drivers, remove  
the case right side.  
If the reading is missing or not within spec-  
ifications, check for loose or broken wires  
between the test points and the stator  
windings. See the Wiring Diagram. Make  
sure that the windings are NOT grounded  
internally to the stator iron. If the leads are  
intact, then the stator may be faulty. Re-  
place the stator. If the voltage reading is  
within specifications, the windings are good  
and functioning properly.  
2. Connect the volt/ohmmeter probes to leads  
#7 and #9 where they connect to the Field  
Bridge Rectifier. See Figure F.10.  
3. Start the engine and run it at high idle (3700  
RPM).  
4. Set the output control to the maximum  
position (position 10).  
6. Reinstall the right case side.  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
AUXILIARY AND FIELD WINDING TEST (continued)  
FIGURE F.11 – 14-PIN AMPHENOL PIN ASSIGNMENTS  
C
B
D
L
E
K
A
M
J
N
F
I
G
H
To test the feeder winding:  
Ranger 300 DLX Models  
7. Connect the volt/ohmmeter probes to  
leads #31 and #42 where they connect to  
15 amp circuit breaker CB1 and the 14-pin  
amphenol. See the Wiring Diagram.  
1. With the 5/16” and 3/8” nut drivers, remove  
the case left side.  
NOTE: It is possible to check this voltage read-  
ing at the amphenol by inserting the test  
probes at pin K (for lead #42) and pin I (for lead  
#31B). See Figure F.11. However, if you use  
this method and get no voltage reading, it  
could mean there is a break or loose connec-  
tion in the leads between the circuit breaker  
and the amphenol. Check the reading again  
with one probe at the circuit breaker connec-  
tion for lead #31 and the other probe at amphe-  
nol pin K.  
2. Set the voltmeter to the AC volts position.  
3. Connect the volt/ohmmeter probes to leads  
#31 and #32 where they connect to 15 amp  
circuit breaker CB1 and the 14-pin amphe-  
nol. See the Wiring Diagram. See Figure  
F.11.  
NOTE: It is possible to check this voltage read-  
ing at the amphenol by inserting the test  
probes at pin A (for lead #32) and pin J (for lead  
#31A). See Figure F.11. However, if you use  
this method and get no voltage reading, it  
could mean there is a break or loose connec-  
tion in the leads between the circuit breaker  
and the amphenol. Check the reading again  
with one probe at the circuit breaker connec-  
tion for lead #31 and the other probe at amphe-  
nol pin A.  
8. Set the output control to the maximum  
position (position 10).  
9. Check the AC voltage reading. It should  
be between 43 and 50 VAC.  
If the voltage readings are within specifications,  
then the windings are good and functioning  
properly.  
4. Start the engine and run it at high idle (3700  
RPM).  
If any one or more of the readings are missing or  
not within specifications, check for loose or bro-  
ken wires between the test points and the stator  
windings. See the Wiring Diagram. Make sure  
that the windings are NOT grounded internally to  
the stator iron. If the leads are intact, then the  
stator may be faulty. Replace the stator.  
5. Set the output control to the maximum  
position (position 10).  
6. Check the AC voltage reading. It should be  
between 115 and 126 VAC.  
10. Reinstall the right case side.  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
ROTOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the rotor at maximum  
engine speed (3700 RPM - high idle). This information will aid the technician in determining  
if the generator field is operating properly.  
MATERIALS NEEDED  
Volt/Ohmmeter (Multimeter)  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
This procedure requires approximately 20 minutes to perform.  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
ROTOR VOLTAGE TEST (continued)  
FIGURE F.12 – LOCATION OF LEADS 200A AND 219 FOR ROTOR VOLTAGE TEST  
TEST PROCEDURE  
6. Check the voltage reading on the voltmeter.  
It should read approximately 37-40 VDC.  
1. With the 5/16” and 3/8” nut drivers, remove  
the right case side.  
7. If the voltage reading is low or not present,  
the generator field is not functioning proper-  
ly. Perform the Rotor Resistance Test.  
The Field Diode Bridge (D2), the Field  
Capacitor (C1), and/or the control board  
may be faulty.  
2. Set the volt/ohmmeter to the DC volts posi-  
tion.  
3. Connect the positive meter probe to the  
brush nearest the rotor lamination (lead  
#200A). See Figure F.12 for location.  
8. If the voltage reading is normal, the field cir-  
cuit is functioning properly. Install the right  
case side.  
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).  
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F-39  
F-39  
INSTALLATION  
CHARGING CIRCUIT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the engine alternator and associated circuitry are functioning prop-  
erly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
3/8” Nut driver  
Wiring Diagram  
This procedure requires approximately 20 minutes to perform.  
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F-40  
F-40  
INSTALLATION  
CHARGING CIRCUIT TEST (continued)  
FIGURE F.13 – VOLTAGE REGULATOR LEADS  
ALTERNATOR  
222D  
224A  
227  
B
IG  
L
TEST PROCEDURE  
4. If the DC voltages are correct, the engine  
alternator is operating normally.  
1. With the 5/16” and 3/8” nut drivers, remove  
the right case side.  
If any of the voltage readings are missing or  
not normal, the engine alternator or associ-  
ated wiring may be faulty. See the Wiring  
Diagram.  
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.  
CHARGING CIRCUIT TEST CHART  
TEST CONDITIONS  
Ignition Switch Off  
TEST POINTS  
TYPICAL VOLTAGE  
12 VDC  
Lead 222D to Frame Ground  
Lead 224A to Frame Ground  
Lead 227 to Frame Ground  
Lead 222D to Frame Ground  
Lead 224A to Frame Ground  
Lead 227 to Frame Ground  
Lead 222D to Frame Ground  
Lead 224A to Frame Ground  
Lead 227 to Frame Ground  
Ignition Switch Off  
0 VDC  
Ignition Switch Off  
0 VDC  
Ignition Switch On  
12 VDC  
Ignition Switch On  
12 VDC  
Ignition Switch On  
0.7 VDC  
Engine running at 3700 RPM  
Engine running at 3700 RPM  
Engine running at 3700 RPM  
14.5 VDC  
14.3 VDC  
14.3 VDC  
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F-41  
F-41  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
15.8 ms  
0 volts  
5 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.  
Note: Scope probes connected at  
machine 115VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-42  
F-42  
TROUBLESHOOTING & REPAIR  
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM (CV MODE HIGH TAP)  
MACHINE LOADED  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 250 AMPS AT 30VDC  
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. The machine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-43  
F-43  
TROUBLESHOOTING & REPAIR  
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM  
MACHINE LOADED  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 250 AMPS AT 25 VDC  
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. The machine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
TYPICAL AC WELD OUTPUT VOLTAGE WAVEFORM  
MACHINE LOADED  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 250 AMPS AT 25VDC  
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. The machine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM  
HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM  
ONE OUTPUT DIODE NOT FUNCTIONING  
0 volts  
5 ms  
50 volts  
This is NOT the typical DC (+) output  
voltage waveform. One output diode  
is not functioning. Note the “gap” in  
the waveform. One output diode was  
disconnected to simulate an open or  
non-functioning output diode. Each  
vertical division represents 50 volts  
and each horizontal division repre-  
sents 5 milliseconds in time.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM  
(HIGH CV MODE)  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
OUTPUT CAPACITOR BANK NOT FUNCTIONING  
0 volts  
5 ms  
50 volts  
This is NOT the typical CV output  
voltage waveform. The capacitor  
bank is not functioning. Note the  
“ripple” in the waveform. The capac-  
itor bank was disconnected to simu-  
late an open or non-functioning  
capacitor bank. Each vertical divi-  
sion represents 50 volts and each  
horizontal division represents 5 mil-  
liseconds in time.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
RANGER 300 D AND 300 DLX  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM (HIGH CV MODE)  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
0 volts  
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.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
0 volts  
5 ms  
50V  
This is the typical DC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 50 volts and that  
each horizontal division represents 5  
milliseconds in time.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT AC WELD VOLTAGE WAVEFORM  
HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM  
0 volts  
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.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in accessing the generator brushes for main-  
tenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
5/16” Wrench  
7/16” Wrench  
Slot head screwdriver  
Needle nose pliers  
This procedure requires approximately 35 minutes to perform.  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
FIGURE F.14 – BRUSH LEADS/BRUSHES RETAINED WITH CABLE TIE  
219  
200A  
1. BRUSHES  
2. CABLE TIE  
3. RETAINER CLIP  
1. BRACKET MOUNTING HOLES  
7. Remove the old brushes and insert the  
new ones. One corner of the terminal clip  
is beveled so that the brush can go in only  
one way.  
PROCEDURE  
1. Conduct this procedure with the engine  
OFF.  
2. With the 5/16” and 3/8” nut drivers, remove  
the right case side.  
8. Snap the plastic retainer back onto the  
brush holder. The brushes may need  
some repositioning; wiggle them slightly to  
help them seat properly on the slip rings.  
3. With the needle nose pliers, gently remove  
the red and white wires from the brushes.  
See Figure F.14.  
9. To reinstall the brushes, depress the  
spring-loaded brushes into the holder and  
slip a suitable non-metallic, fairly stiff  
retainer through the slots at the top and  
bottom of the holder. A cable tie works  
well; see Figure F.14. This will hold the  
brushes up so that you can easily install  
the holder.  
4. With the 7/16” wrench, remove the brush  
holder assembly bracket from the stator  
frame.  
5. With the 5/16” wrench, remove the two  
screws that secure the brush holder assem-  
bly to the bracket. Slide the brush holder  
assembly out of the bracket.  
10. Slide the brush holder assembly back into  
the bracket and, with the 5/16” wrench,  
install the two screws that hold it in place.  
6. To change the brushes, use the slot head  
screw driver to pop off the plastic retainer  
on the back of the brush holder assembly.  
11. With the 7/16” wrench, attach the brush  
holder assembly bracket to the stator  
frame.  
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F-52  
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.  
NOTE: A slight amount of darkening and wear  
of the slip rings and brushes is normal.  
Brushes should be inspected when a general  
overhaul is necessary. If brushes are to be  
replaced, clean the slip rings with a fine emery  
paper.  
13. With the needle nose pliers, connect the  
red and the white wires to the appropriate  
terminals on the brushes. The red wire is  
nearest to the rotor lamination.  
CAUTION  
14. Check the wire connections for clearance  
and tightness.  
Do not attempt to polish slip rings while engine  
is running.  
15. Install the right case side.  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the field capacitor and rectifier  
bridge for maintenance or replacement of either component.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
Jumper wire with alligator clips on each end for discharging the field capacitor  
Slot head screw driver  
Needle nose pliers  
Diagonal cutters  
Wiring Diagram  
This procedure requires approximately 35 minutes to perform.  
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F-54  
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  
201  
201A  
7
_
AC  
200  
200A  
200B  
+
9
AC  
Field  
Bridge  
Rectifier  
Cable  
Tie  
Retaining  
Tab  
9
201  
201A  
Capacitor  
7
200  
200A  
200B  
5. Both the capacitor and the rectifier bridge  
are mounted in a molded plastic holder. To  
remove it, pull the assembly away from the  
metal baffle and slide the assembly out-  
ward.  
PROCEDURE  
1. Conduct this procedure with the engine  
OFF.  
2. With the 5/16” and 3/8” nut drivers, remove  
the right case side.  
6. With the diagonal cutters, cut the wire wrap  
from around the capacitor. Snap the  
capacitor out of the assembly. Slide the  
rectifier bridge out of its part of the plastic  
holder.  
3. Discharge the field capacitor by connecting  
the jumper wire clips on the white and the  
red wire terminals on the top of the capac-  
itor. See Figure F.15. Leave the clips on for  
at least 5 seconds, then remove.  
7. Install the new capacitor and rectifier  
bridge by inserting them into the plastic  
holder. Replace the wire wrap that secures  
the capacitor to the holder. Slide the hold-  
er back into position in the panel.  
4. With the needle nose pliers, gently remove  
the seven wires from the field rectifier  
bridge. Label the wires for reassembly.  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
FIELD CAPACITOR AND/OR RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT (continued)  
8. Connect the wires to the proper terminals  
on the rectifier bridge. See Figure F.15  
and the Wiring Diagram.  
The two leads #7 and #9 are the AC side  
of the bridge and attach to the other two  
corners of the rectifier. Either lead can go  
on either terminal.  
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.  
9. Check that the leads are not grounded and  
also check for clearance and tightness.  
10. Install the right case side.  
Leads #201 and #201A are located on the  
negative (-) terminal, which will always be  
located diagonally across from the posi-  
tive (+) terminal.  
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F-56  
F-56  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this man-  
ual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the control board for maintenance  
or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
1/4” Nut driver  
1/2” Wrench  
3/8” Wrench  
Slot head screw driver  
Diagonal cutters  
Wiring Diagram  
This procedure requires approximately 45 minutes to perform.  
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F-57  
F-57  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.16 – PRINTED CIRCUIT BOARD LOCATION  
B213  
B5A  
CONTROL  
BOARD  
COVER  
B222  
J1  
J2  
J3  
CONTROL  
7. Remove the case top and door assembly,  
PROCEDURE  
then reinstall the fuel cap.  
Before starting the following procedure, refer to  
the topic “PC Board Troubleshooting  
Procedures” at the beginning of this section.  
8. With the 5/16” nut driver, remove the con-  
trol board cover. See Figure F.16.  
9. Remove the three molex plugs from the  
control board (J1, J2, J3). Also remove the  
three individual leads #213, #222, and  
#5A. See Figure F.16. Note lead place-  
ment.  
1. Conduct this procedure with the engine  
OFF.  
2. With the 5/16” and 3/8” nut drivers, remove  
screws from the case top.  
3. With the 1/2” wrench, remove the exhaust  
pipe from the muffler.  
10. Cut the wire ties and disconnect the bolt-  
ed connections from the current sensing  
leads (#254, #254A and #254B - see the  
Wiring Diagram). Count the turns in the  
current sensor and note for reassembly.  
4. Remove the rubber gasket (cover seal) from  
the lift bail.  
5. Remove the fuel cap and the rubber gasket  
for the fill tube.  
CAUTION  
6. Unlatch the double door assembly and use  
the slot head screw driver and 3/8” wrench  
to remove the door support rod from the  
door assembly.  
Be sure to follow the recommended static-free  
methods for handling printed circuit boards.  
Failure to do so can result in permanent dam-  
age to the equipment.  
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F-58  
F-58  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
11. With the 1/4” nut driver, remove the  
screws holding the control board.  
14. Connect the three molex plugs.  
15. Connect the three individual leads #213,  
#222, and #5A.  
12. Replace the old control board with a new  
one.  
16. Replace any wire ties that were cut during  
the removal procedure.  
13. Connect current sensing leads #254 and  
#254A. Thread the leads through the cur-  
rent sensor the same number of turns  
noted during removal. Connect the leads  
and install new wire ties. See the Wiring  
Diagram for the proper connections.  
17. With the 5/16” nut driver, install the control  
board cover.  
18. Install the case top, gaskets, and double  
door support rod.  
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F-59  
F-59  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE REMOVAL  
AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output rectifier bridge for  
maintenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
1/2” Wrench  
7/16” Wrench  
Penetrox A-13  
Wiring Diagram  
This procedure requires approximately 50 minutes to perform.  
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F-60  
F-60  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)  
FIGURE F.17 – OUTPUT RECTIFIER CONNECTIONS  
Left Side (–)  
Right Side (+)  
5. With the 7/16” wrench, remove the nut and  
washers holding the top stud assembly to  
the rectifier mounting bolts.  
PROCEDURE  
1. Conduct this procedure with the engine  
OFF.  
6. With the 7/16” wrench, remove the nuts, lock  
washers, and flat washers from the two top  
mounting bolts. Note insulator placement.  
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. The positive portion is located on the  
lower right side and the negative portion on  
the lower left side of the machine.  
7. With the 3/8” nut driver, remove the two bot-  
tom mounting screws. Note the placement  
of the nylon and Nomex insulators. These  
must be in place when you reinstall the  
rectifier bridge assembly in order to elec-  
trically insulate the bridge from the frame.  
For the remaining steps, refer to Figure F.17.  
3. With the 1/2” wrench, remove the diode pig-  
tails and heavy leads from the terminal studs.  
Note lead and washer placement: nut, split  
washer, flat washer, leads. Label leads for  
reassembly. See the Wiring Diagram.  
8. Clear the leads and carefully remove the heat  
sink assembly.  
9. Repeat the above procedure to remove the  
other half of the output rectifier.  
4. With the 1/2” wrench, remove the two heavy  
leads and one small lead from the rectifier  
heat sink plate. Note that the small lead is  
always on top for reassembly.  
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F-61  
F-61  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)  
Reassembly:  
12. With the 7/16” wrench, install the flat  
washers, lock washers, and nuts to the  
two top mounting bolts. Install insulators  
as previously removed.  
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.  
13. With the 1/2” wrench, install the two heavy  
leads and one small lead to the heat sink  
plate. The small lead goes on top.  
NOTE: Use Penetrox A-13 on aluminum elec-  
trical connection surfaces.  
14. With the 1/2” wrench, reattach the diode  
pigtails and heavy leads to the terminal  
studs. Placement is: leads, flat washer,  
split washer, nut.  
10. With the 3/8” nut driver, install the two  
bottom mounting screws. Note the place-  
ment of the nylon insulators. These must  
be in place when you install the rectifi-  
er bridge assembly in order to electri-  
cally insulate the bridge from the frame.  
15. Install the case sides.  
11. With the 7/16” wrench, install the washers  
and nuts to hold the top stud assembly to  
the rectifier mounting bolts. Install insula-  
tors as previously removed.  
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F-62  
F-62  
TROUBLESHOOTING & REPAIR  
OUTPUT CAPACITOR BANK REMOVAL AND REPLACEMENT  
(RANGER 300 DLX ONLY)  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output capacitor bank for  
maintenance or replacement. Ranger 300 D models do not have the capacitor bank.  
MATERIALS NEEDED  
Volt/Ohmmeter  
25-watt resistor  
5/16” Nut driver  
3/8” Nut driver  
1/2” Wrench  
Wiring Diagram  
This procedure requires approximately 25 minutes to perform.  
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F-63  
F-63  
TROUBLESHOOTING & REPAIR  
OUTPUT CAPACITOR BANK REMOVAL AND REPLACEMENT  
(RANGER 300 DLX ONLY) (continued)  
FIGURE F.18 - OUTPUT CAPACITOR BANK  
CAPACITOR (4)  
BUSS BAR (2)  
5. With the 5/16” nut driver, remove the four  
mounting screws holding the capacitor bank  
assembly to the base of the machine.  
PROCEDURE  
1. Conduct this procedure with the engine  
OFF.  
6. Carefully remove the capacitor bank assem-  
bly.  
2. With the 5/16” and 3/8” nut drivers, remove  
the right case side.  
7. To replace the capacitor bank assembly,  
mount the assembly to the base of the  
machine with the four screws previously  
removed.  
3. With the voltmeter, check the voltage across  
each of the four output capacitors. If a volt-  
age is present, use a 25-watt resistor to dis-  
charge each capacitor. See Figure F.18.  
8. With the 1/2” wrench, attach the two heavy  
leads and small lead previously removed to  
the positive and negative capacitor buss  
bars. Observe capacitor polarity.  
4. With the 1/2” wrench, remove the two nuts,  
bolts, and washers holding the two heavy  
leads (W14 and W3) and the two small leads  
(#236A negative and #245 red, positive) to  
the capacitor bank buss bars. Note lead  
placement.  
9. Install the right case side.  
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F-64  
F-64  
TROUBLESHOOTING & REPAIR  
OUTPUT CONTACTOR REMOVAL AND REPLACEMENT  
(RANGER 300 DLX ONLY)  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the Ranger 300 DLX output con-  
tactor for maintenance or replacement. Ranger 300 D models do not have the contactor.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
3/8” Wrench  
1/2” Wrench  
Slot head screw driver  
Needle nose pliers  
Wiring Diagram  
This procedure requires approximately 35 minutes to perform.  
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F-65  
F-65  
TROUBLESHOOTING & REPAIR  
OUTPUT CONTACTOR REMOVAL AND REPLACEMENT  
(RANGER 300 DLX ONLY) (continued)  
FIGURE F.19 – OUTPUT CONTACTOR LOCATION  
1. CONTACTOR  
2. COIL LEAD CONNECTIONS  
3. HEAVY LEAD CONNECTIONS  
4. MOUNTING HARDWARE  
5. VERTICAL BAFFLE  
3
2
4
1
5
5. With the slot head screw driver and the 3/8”  
nut driver, remove the three mounting screws,  
nuts, and washers that hold the contactor to  
the vertical baffle. The contactor can now be  
removed.  
PROCEDURE  
1. Conduct this procedure with the engine  
OFF.  
2. With the 5/16” and 3/8” nut drivers, remove  
the left case side.  
6. To reinstall the output contactor, use the slot  
head screw driver and 3/8” nut driver to  
attach the mounting screws, nuts, and wash-  
ers to the vertical baffle.  
3. With the needle nose pliers, remove the three  
small leads connected to the output contac-  
tor coil (leads #232, #224, and #224C). Note  
lead placement. See Figure F.20.  
7. With the 1/2” wrench, attach the heavy leads  
(W8 and W9) to the output contactor.  
4. With the 1/2” wrench, remove the nut, bolt,  
and washers holding the heavy leads (W8 and  
W9) to the output contactor. See the Wiring  
Diagram.  
8. With the needle nose pliers, attach the three  
small leads to the contactor coil. See the  
Wiring Diagram and Figure F.20.  
9. Install the left case side.  
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F-66  
F-66  
TROUBLESHOOTING & REPAIRs  
OUTPUT CONTACTOR REMOVAL AND REPLACEMENT  
(RANGER 300 DLX ONLY) (continued)  
FIGURE F.20 – CONTACTOR COIL LEAD PLACEMENT  
W8  
W9  
224  
224C  
232  
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F-67  
F-67  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing and replacing the Ranger 300 sta-  
tor and rotor for maintenance or replacement. The key to successful stator removal is to free  
all stator connections in order to be able to pivot the machine case front to the side. This  
allows the stator to be pulled straight out from the engine.  
MATERIALS NEEDED  
5/16” Nut driver  
3/8” Nut driver  
Needle nose pliers  
Diagonal cutters  
3/8” Wrench  
7/16” Wrench  
1/2” Socket wrench  
Hoist  
Slot head screw driver  
Phillips head screw driver  
Gear puller (small)  
Socket wrench extension (8”)  
Feeler gauge (for air gap check)  
This procedure requires approximately 51⁄2 hours to perform.  
RANGER 300 D AND 300 DLX  
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F-68  
F-68  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.21 – COMPONENT LOCATIONS, STATOR/ROTOR REMOVAL  
11  
10  
9
8
7
13  
5
12  
4
1. STATOR MOUNTING BRACKET  
2. MOUNTING BRACKET BOLT (2)  
3. ROTOR BEARING SCREWS (2)  
4. BLOWER  
5. TOLERANCE RING  
6. BRUSH ASSEMBLY BRACKET  
7. STATOR MOUNTING BOLT (8)  
8. ROTOR BEARING  
6
3
2
1
9. ROTOR  
10. FLEX PLATE  
11. ENGINE  
12. ROTOR BOLT (6)  
13. CLAMPING BAR (3)  
RANGER 300 D AND 300 DLX  
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F-69  
F-69  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR REMOVAL AND REPLACEMENT (continued)  
15. Remove all stator leads from connection  
points on the front panel. See the Wiring  
Diagram. Remove lead #6 from circuit  
breaker CB2. Note that it passes through  
the idler current sensor. Remove lead #3  
from circuit breaker CB3. Note that it  
passes through the idler current sensor.  
Disconnect the in-line connector on leads  
#42 and #32 located between the stator  
and the 14-pin amphenol.  
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” socket wrench to remove the  
exhaust pipe from the muffler.  
3. Remove the right and left case sides.  
Then remove the negative (-) and positive  
(+) cables from the battery.  
Disconnect lead #E from the common  
ground screw. Remove lead W1 (heavy  
stator lead) from the top left side of the  
negative (-) output rectifier assembly.  
Untape and disconnect W2 from lead R at  
the 1/2” bolted connection to separate the  
stator from the reactor. Disconnect heavy  
lead A1 from the bottom of the negative  
(-) output rectifier to the reactor.  
4. Remove the rubber gasket (cover seal)  
from the lift bail.  
5. Remove the fuel cap and the rubber gas-  
ket for the fill tube.  
6. Unlatch the double door assembly and  
use the slot head screw driver and 3/8”  
wrench to remove the door support rod  
from the door assembly.  
16. Using the 3/8” nut driver, remove the four  
screws (2 on each side) holding the output  
rectifier assemblies to the base of the  
machine.  
7. Remove the case top and door assembly,  
then reinstall the fuel cap.  
17. Using the 1/2” wrench, remove the four  
choke mounting bolts from the base of the  
machine. Push the choke forward, toward  
the front of the machine.  
8. With the 1/2” socket wrench and exten-  
sion, remove the fuel tank. (Four bolts  
hold the fuel tank.) With the 3/8” nut dri-  
ver, remove leads #226 and #5W from the  
fuel gauge. Label the leads for reassem-  
bly.  
18. Ranger 300 DLX machines only: perform  
the  
Output  
Contactor  
Removal  
Procedure. This is required in order to  
remove the choke, step 20.  
9. Perform the Field Capacitor and Field  
Rectifier Bridge Removal Procedure.  
NOTE: If the front of the machine is loose,  
it may not be necessary to remove the  
output contactor. The choke may be able  
to slide past the contactor if the front of  
the machine can be pulled forward.  
10. Perform the Output Capacitor Bank  
Removal Procedure. (Ranger 300 DLX  
only.)  
11. Perform the Brush Removal Procedure.  
19. Using the 1/2” wrench, remove heavy lead  
W4 from the choke to the center of the  
positive (+) output rectifier. On Ranger  
300 DLX machines, also remove heavy  
leads W5 and W6 from the choke to the  
S2 range switch. See the Wiring Diagram.  
12. Cut the cable ties from the reactor to the  
range switch.  
13. Remove the fiber insulator plate from the  
hole in the vertical baffle.  
14. Remove the four stator leads C1, C2, C3,  
C4 connected to the S2 range switch.  
Use care; excessive force will break the  
terminals away from the rivets. (DLX only.  
“D” machines have only one lead.)  
20. Slide the choke assembly out of the  
machine.  
RANGER 300 D AND 300 DLX  
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F-70  
F-70  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.22  
MACHINE FRONT COMPONENTS PIVOTED TO SIDE  
21. Using the 1/2” wrench, remove the three  
reactor mounting bolts from the machine  
base.  
27. Remove the blower (fan) by turning it coun-  
terclockwise to unscrew it from the rotor  
shaft. Prevent engine rotation as you turn  
the blower.  
22. Using the 5/16” wrench, remove the three  
screws holing the front vertical baffle to the  
machine base.  
28. Remove the two 3/8” screws that hold the  
rotor bearing in place.  
23. Using the 1/2” wrench, remove the two  
screws holding the front vertical baffle to  
the fuel tank rails.  
29. Support the engine. Remove the eight  
9/16” bolts that mount the stator to the  
engine.  
24. Using the 5/16” wrench, remove the three  
screws holding the front panel to the base  
of the machine. Clear all stator leads and  
cut any necessary cable ties.  
30. Using a gear puller, carefully remove the  
stator.  
ROTOR REMOVAL PROCEDURE  
25. Carefully lift and pivot the front panel  
assembly, along with the reactor, around to  
the right side of the machine. See Figure  
F.22. Support the unit with a box or large  
pan.  
1. Support the rotor. See Figure F.21.  
2. Using the 1/2” wrench, remove the six 1/2”  
rotor bolts, lock washers, and three clamp-  
ing bars. Caution: the rotor will be free to  
fall when the bolts are removed.  
26. Remove the two 1/2” nuts and bolts that  
hold the stator mounting bracket to the  
base of the machine. See Figure F.21.  
3. Remove the rotor bearing. It must be  
removed before the stator can be rein-  
stalled.  
RANGER 300 D AND 300 DLX  
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F-71  
F-71  
TROUBLESHOOTING & REPAIR  
STATOR AND/OR ROTOR REMOVAL AND REPLACEMENT (continued)  
REASSEMBLY NOTES  
LEAD RECONNECTION  
CHECKLIST  
1. Be sure to remove the rotor bearing from  
the stator frame before reinstalling the  
rotor/stator Also remove the tolerance  
ring.  
ENGINE  
■ Lead #226 and #5W to fuel gauge  
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.  
FRONT PANEL  
■ Lead #E to common ground screw  
4. Install a new tolerance ring and press in a  
new rotor bearing.  
■ Lead #6 to CB2 (note that it passes through  
the idler current sensor)  
5. Tighten stator bolts.  
■ Lead #3 to CB3 (note that it passes through  
6. Check the air gap for .015” (minimum).  
the idler current sensor)  
7. Position the front panel and the reactor in  
place.  
■ Stator leads C1, C2, C3, and C4 to the S2  
range switch (DLX machines)  
8. Perform the Brush Replacement Pro-  
■ In-line connectors #32 and #42 to the 14-  
cedure.  
pin amphenol  
9. Perform the Field Capacitor and Field  
Rectifier Bridge Replacement Pro-  
cedure. (Ranger 300 DLX only.)  
■ Lead W1 to the top of the negative (–) out-  
put rectifier (left side)  
10. Perform the Output Capacitor Bank  
■ Lead W4 to the center of the positive (+)  
Replacement Procedure.  
output rectifier (right side)  
11. After installing the choke, perform the  
Output Contactor Replacement Pro-  
cedure (Ranger 300 DLX only, if  
removed).  
■ Lead W2 at lead R bolted connection (tape  
the connection)  
■ Leads W5 and W6 between the choke and  
polarity switch S1 (Ranger 300 DLX only)  
12. Mount the choke, reactor, front panel,  
and vertical baffle.  
■ Lead A1 between the reactor and the bot-  
tom of the negative (–) output rectifier (left  
side)  
13. Replace insulation and wire ties previous-  
ly removed.  
14. Mount the output rectifier assemblies.  
RANGER 300 D AND 300 DLX  
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F-72  
F-72  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Retest a machine:  
•
If it is rejected under test for any reason that requires you to remove any mechanical part which could affect  
the machine’s electrical characteristics.  
OR  
•
If you repair or replace any electrical components.  
ENGINE OUTPUT  
Mode  
Low Idle  
High Idle  
No Load RPM  
2150 - 2220  
3700 - 3650  
Load RPM  
NA  
3450-3670  
WELDER DC OUTPUT  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
64 - 74  
25 - 35  
295 - 325  
WELDER AC OUTPUT  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
70 - 79  
27 - 35  
295 - 325  
WELDER CV OUTPUT  
Output Control  
Range Switch  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Maximum  
Maximum  
Maximum  
Wire Feed CV High  
Wire Feed CV Med HI  
Wire Feed CV Med LO  
Wire Feed CV Low  
62 - 71  
46 - 53  
46 - 53  
46 - 53  
27 - 34  
25 - 30  
20 - 25  
15 - 20  
295 - 325  
220 - 240  
155 - 170  
135 - 155  
AUXILIARY POWER OUTPUT  
230 Volt Receptacle  
115 Volt Receptacle  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
245 - 260  
210 - 245  
48 - 53  
120 - 127  
106 - 121  
58 - 63  
AMPHENOL AUXILIARY OUTPUT  
42 Volt Auxiliary  
Load Volts  
115 Volt Auxiliary  
Open Circuit  
Voltage  
115 - 128  
Open Circuit  
Load Volts  
114 - 126  
Voltage  
40 - 46  
38 - 42  
RANGER 300 D AND 300 DLX  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G  
WIRING DIAGRAM RANGER 300 D (CODE 10399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2  
WIRING DIAGRAM RANGER 300 DLX (CODE 10400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3  
WIRING DIAGRAM RANGER 300 DLX (CODE 10850) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4  
CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5  
CONTROL PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6  
BYPASS PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7  
BYPASS PC BOARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8  
RANGER 300 D AND 300 DLX  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - RANGER 300 D (CODE 10399)  
WIRING DIAGRAM - RANGER 300 D  
254B  
254A  
CB8  
15A  
3
TURNS  
254  
BLACK  
L1  
BLACK  
222E  
254C  
(CHOKE)  
W6  
W4  
S1  
ELECTRODE POLARITY  
SWITCH  
IDLER WELD  
CURRENT  
SENSOR  
222F  
L2  
222J  
PC  
222K  
HIGH  
5
10  
BOARD  
PCB1  
222H  
SPEED  
240  
W7  
PULL  
COIL  
HOLD  
COIL  
SOLENOID  
W11  
DC+  
239  
236  
J2  
254  
AC  
4J10  
WHITE  
76  
250  
213B  
RED  
214A  
77  
213A  
222  
213  
214B  
5J10  
1
6
DC-  
J11  
DC-  
AC  
75  
220  
239  
221  
DC+  
8
4
5F  
200B  
W4  
OUTPUT  
214  
221  
220  
RECTIFIER  
(+)  
D1  
(-)  
4
2
1
J1  
235  
5G  
W7  
W1  
201A  
W16  
W15  
A1  
254B  
J3  
5A  
-
11J10  
224  
W12  
A2  
1
5
3
224F  
W10  
222  
12J10  
224E  
W11  
236  
224  
+
219  
5F  
A2  
224F  
201A  
REACTOR  
ENGINE  
HOUR METER  
254A  
240  
R2  
224D  
A1  
BATTERY  
CHARGER  
214  
200B  
77  
R
R6  
C1  
R4  
R2  
W12  
R1  
R3  
W9  
R5  
R7  
W10  
235  
25 OHM  
IDLER AC  
CURRENT  
SENSOR  
OUTPUT  
R
50  
W
RHEOSTAT  
224  
75  
RANGE  
"SIG" TERMINAL  
W2  
W1  
SWITCH  
S2  
10K POT  
MAX  
241  
250  
R3  
75A  
15A  
CB9  
S5  
CW  
77D  
76D  
226  
IDLER  
AUTO  
FUEL  
SENDER  
WORK  
FUEL  
ELECTRODE  
5A  
SWITCH  
GAUGE  
GND  
76A  
S8  
235B  
6
5F  
S
+
227A  
8J10  
77  
76  
SHOWN IN  
"HIGH"  
POSITION  
5W  
C1  
HIGH  
3
5G  
235A  
STATOR  
7
21A  
67  
5B  
REMOTE SWITCH  
(SHOWN IN  
6
3
9
76D  
GLOW PLUG  
S6  
S3  
REMOTE POSITION)  
5
SWITCH  
GND-E  
ON/OFF  
SWITCH  
224H  
75A  
224G  
235B  
76A  
222G  
223A  
77A  
77A  
221C  
222  
224E  
S4  
222C  
OIL  
WATER  
TEMP.  
START  
R
R
PRESSURE  
SWITCH  
5A  
SHOWN IN  
"ON" POSITION  
3J10  
GND-E  
GND-G  
220C  
GROUND SCREW  
BLOWER BAFFLE  
5E  
5E  
220A  
225  
223  
221A  
222B  
GND-C  
10J10  
5B  
5H  
9J10  
GND-D  
GLOW PLUGS  
7J10  
6J10  
220B  
221B  
3
OIL PRESSURE  
SWITCH  
WATER  
TEMP.  
125/250V. SINGLE  
RECEPTACLE  
201  
201A  
SWITCH  
PCB2  
BYPASS PC  
BLACK  
BLACK  
222D  
222B  
222E  
3E  
3F  
7
3
6
219  
(-)  
SLIP  
RINGS  
6
75B  
D2  
CB2  
50A  
GND-D  
9
AC  
AC  
222A  
120  
V
(+)  
GND-G  
5
CB4  
15A  
CB6  
15A  
200B  
1J10  
77B  
76B  
J5  
225  
J8  
J9  
REMOTE CONTROL  
A
120/240V  
3C  
3D  
200A  
RED  
77B  
76B  
75B  
224B  
STARTER  
(+)  
200  
RED  
(+)  
SILVER  
76A  
STARTER  
1
5D  
4
SOLENOID  
B
C
COLORED  
3G  
5L  
CONTACTOR  
2J10  
12  
3H  
5M  
COIL  
BLACK  
TERMINALS  
(+)  
(-)  
BLACK  
11  
(+)  
(-)  
2
1
4
BLACK  
11  
5H  
76A  
800 MFD  
201  
RED  
C1  
GND-C  
CB5  
15A  
120  
V
CB7  
15A  
WHITE  
J6  
J7  
ROTOR FIELD  
5D  
F
GND-B  
75A  
77A  
3
CB3  
50A  
237  
3D  
77A  
J10  
SILVER  
(-)  
12 VOLT  
GROUND  
3C  
227  
3A  
3B  
3
COLORED  
TERM.  
POSITIVE SLIP  
RING NEAREST  
LAMINATION  
BATTERY  
3A  
3B  
SILVER  
PULL  
HOLD  
COIL  
AMPHENOL  
5
COLORED  
TERMINALS  
67  
COIL  
5L  
CRANK  
MOTOR  
21A  
B
IG  
L
222D  
224A  
ENGINE HARNESS CONNECTOR  
TO PANEL HARNESS  
L3  
5M  
WHITE  
5K  
FUEL  
5E  
FRAME  
BLACK  
ALTERNAT0R  
CONNECTION  
BLOCK  
SHUTDOWN  
SOLENOID  
FUEL SHUTDOWN  
SOLENOID  
GROUND SCREW  
ABOVE AMPHENOL HOLE  
J10  
5K  
J13  
GROUND  
9
5
1
10  
6
11  
7
12  
8
IDLER SOLENOID  
J12  
(HARNESS LEAD END)  
(HARNESS LEAD END)  
ALTERNATOR  
ENGINE  
5H  
1J10  
(HARNESS LEAD END)  
224A  
GROUND  
222F  
213  
2
3
4
237  
NOTES:  
ELECTRICAL SYMBOLS PER E1537  
ALL CASE FRONT COMPONENTS VIEWED FROM REAR.  
5K  
INDICATES JACK NUMBER  
INDICATES CAVITY NUMBER  
224B  
227  
J13  
214  
222G  
J12  
J11  
9-12-97A  
L10556  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER 300  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - RANGER 300 DLX (CODE 10400)  
WIRING DIAGRAM - RANGER 300 DLX  
254B  
254A  
CB8  
15A  
3
TURNS  
210  
254  
BLACK  
L1  
BLACK  
222E  
254C  
(CHOKE)  
W6  
W4  
S1  
(-)  
IDLER WELD  
CURRENT  
SENSOR  
ELECTRODE POLARITY  
222F  
SWITCH  
W7  
L2  
222J  
PC  
VM  
222K  
232  
232  
HIGH  
5
10  
BOARD  
PCB1  
222H  
SPEED  
(+)  
PULL  
COIL  
HOLD  
COIL  
W5  
240  
SOLENOID  
240  
236  
239  
211  
2C  
J2  
224  
CV-  
247  
250  
4J10  
W3  
245  
RED  
WHITE  
213A  
76  
CV+  
213B  
RED  
214A  
77  
+
_
222  
213  
214B  
1
6
100  
25W  
C3  
C4  
C5  
DC+  
C2  
J11  
75  
5J10  
W3  
DC-  
AC  
220  
239  
221  
236A  
4
8
5F  
247  
200B  
W4  
W11  
31,000 MFD  
OUTPUT  
214  
WELDING TERMINAL  
CONTROL SWITCH  
SHOWN IN  
254B  
221  
220  
254  
RECTIFIER  
CAPACITORS  
(+)  
D1  
4
2
1
J1  
235  
5G  
W7  
W1  
201A  
224  
ON  
W14  
W16  
W15  
A1  
J3  
"ALWAYS ON"  
POSITION  
210  
5A  
-
11J10  
A2  
W10  
S7  
W12  
236  
S2A (CLOSED  
WITH S2 IN  
1
3
(-)  
5
224F  
C1, C2, C3 OR C4  
POSITION)  
12J10  
224E  
222  
+
5F  
219  
W13  
R4  
5C  
W8  
A2  
224F  
201A  
REACTOR  
ENGINE  
HOUR METER  
OUTPUT  
254A  
224D  
CONTACTOR  
232  
240  
A1  
BATTERY  
CHARGER  
214  
200B  
77  
R
R6  
C1  
C3  
25 OHM  
50W  
R2  
W12  
R1  
R3  
R5  
R7  
C2  
C4  
CR1  
235  
IDLER AC  
CURRENT  
SENSOR  
OUTPUT  
R
224  
224C  
241  
RHEOSTAT  
W10  
75  
RANGE  
"SIG" TERMINAL  
W2  
W1  
SWITCH  
S2  
10K POT  
MAX  
W9  
W9  
250  
R3  
75A  
15A  
CB9  
224C  
5G  
S5  
CW  
77D  
76D  
226  
IDLER  
AUTO  
FUEL  
SENDER  
FUEL  
GAUGE  
WORK  
ELECTRODE  
5A  
SWITCH  
C4  
GND  
76A  
S8  
235B  
6
C3  
5C  
S
+
227A  
C2  
8J10  
77  
76  
SHOWN IN  
"HIGH"  
POSITION  
5W  
C1  
HIGH  
3
21  
235A  
STATOR  
7
21A  
67  
5B  
REMOTE SWITCH  
(SHOWN IN  
3
6
32  
9
31  
42  
76D  
GLOW PLUG  
S6  
2C  
S3  
REMOTE POSITION)  
5
GND-E  
SWITCH  
ON/OFF  
SWITCH  
224H  
75A  
224G  
235B  
76A  
CB1  
222G  
77A  
77A  
221C  
222  
224E  
AMPHENOL  
1
223A  
S4  
2C  
222C  
(15AMP)  
OIL  
WATER  
TEMP.  
START  
J
115VAC  
A
31A  
31A  
R
R
PRESSURE  
224C  
SWITCH  
SHOWN IN  
3J10  
32  
4A  
2A  
21  
5A  
GND-E  
GND-G  
"ON" POSITION  
220C  
GROUND SCREW  
BLOWER BAFFLE  
5E  
D
5E  
220A  
225  
223  
PCB2  
221A  
CONTACTOR  
BYPASS PC  
222B  
5A  
GND-C  
C
10J10  
5B  
5H  
9J10  
4
8
GND-D  
GLOW PLUGS  
7J10  
6J10  
WORK  
H
220B  
221B  
2A  
3
REMOTE CONTROL  
E
4C  
77C  
77C  
OIL PRESSURE  
SWITCH  
WATER  
J4  
76C  
4A  
F
TEMP.  
76C  
75C  
125/250V. SINGLE  
RECEPTACLE  
201  
201A  
SWITCH  
75C  
G
1
3
5
BLACK  
BLACK  
31B  
42  
I
222D  
222B  
222E  
3E  
3F  
7
42VAC  
219  
(-)  
SLIP  
6
K
6
75B  
2B  
D2  
CB2  
50A  
GND-D  
9
AC  
AC  
B
GND-A  
222A  
120  
V
(+)  
GND-G  
5
CB4  
15A  
GROUND  
CB6  
15A  
200B  
1J10  
2J10  
77B  
76B  
J5  
225  
J8  
J9  
REMOTE CONTROL  
A
120/240V  
RINGS  
3C  
3D  
200A  
RED  
77B  
224B  
STARTER  
(+)  
200  
RED  
(+)  
SILVER  
76A  
STARTER  
1
2
5D  
4
SOLENOID  
B
C
D
76B  
75B  
2B  
COLORED  
3G  
5L  
4B  
CONTACTOR  
12  
3H  
COIL  
BLACK  
TERMINALS  
(+)  
(-)  
BLACK  
11  
(+)  
(-)  
4
BLACK  
11  
5H  
CONTACTOR  
76A  
2C  
75A  
800 MFD  
201  
RED  
C1  
GND-C  
E
CB5  
15A  
120  
V
4B  
CB7  
15A  
J6  
J7  
WHITE  
ROTOR FIELD  
5D  
F
GND-B  
3
CB3  
50A  
237  
3D  
77A  
SILVER  
J10  
12 VOLT  
(-)  
GROUND  
3C  
77A  
227  
3A  
3
COLORED  
TERM.  
1
POSITIVE SLIP  
RING NEAREST  
LAMINATION  
BATTERY  
3A  
3B  
SILVER  
3B  
PULL  
HOLD  
COIL  
5
AMPHENOL  
2
COLORED  
67  
21A  
COIL  
5L  
TERMINALS  
4C  
CRANK  
MOTOR  
B
IG  
L
222D  
224A  
ENGINE HARNESS CONNECTOR  
TO PANEL HARNESS  
L3  
WHITE  
5K  
FUEL  
5E  
5A  
FRAME  
ALTERNAT0R  
CONNECTION  
BLOCK  
FUEL SHUTDOWN  
SOLENOID  
SHUTDOWN BLACK  
SOLENOID  
J10  
5K  
GROUND SCREW  
ABOVE AMPHENOL HOLE  
J13  
GROUND  
IDLER SOLENOID  
9
5
1
10  
6
11  
7
12  
8
J12  
(HARNESS LEAD END)  
(HARNESS LEAD END)  
ALTERNATOR  
ENGINE  
5H  
1J10  
(HARNESS LEAD END)  
222F  
213  
GROUND  
2
3
4
237  
NOTES:  
ELECTRICAL SYMBOLS PER E1537  
ALL CASE FRONT COMPONENTS VIEWED FROM REAR.  
224A  
5K  
INDICATES JACK NUMBER  
INDICATES CAVITY NUMBER  
224B  
227  
J13  
214  
222G  
J11  
J12  
6-20-97  
L10262  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER 300  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - RANGER 300 DLX (CODE 10850)  
WIRING DIAGRAM - RANGER 300 DLX  
254B  
254A  
CB8  
25A  
3 TURNS  
254C  
210  
254  
L1  
(CHOKE)  
BLACK  
BLACK  
222K  
222E  
W6  
W4  
S1  
ELECTRODE POLARITY  
SWITCH  
222F  
(-)  
IDLER WELD  
CURRENT  
SENSOR  
222W  
222X  
L2  
HIGH  
SPEED  
SOLENOID  
W7  
222J  
PC  
222Z  
VM  
222Y  
232  
232  
5
10  
BOARD  
PCB1  
CR  
222H  
213Z  
5Z  
213X  
(+)  
213Y  
W5  
PULL  
COIL  
HOLD  
COIL  
240  
240  
236  
214Z  
239  
211  
2C  
214B  
J2  
224  
213B  
CV-  
247  
250  
4J10  
W3  
245  
RED  
WHITE  
213A  
76  
CV+  
DC+  
DC-  
RED  
214A  
77  
+
_
222  
213  
1
6
100 W  
25W  
C3  
C4  
C5  
C2  
J11  
75  
5J10  
W3  
220  
239  
221  
236A  
4
8
AC  
5F  
247  
200B  
W4  
W11  
31,000 MFD  
CAPACITORS  
OUTPUT  
RECTIFIER  
214  
WELDING TERMINAL  
CONTROL SWITCH  
SHOWN IN  
"ALWAYS ON"  
POSITION  
254B  
221  
220  
254  
(+)  
(-)  
4
2
1
J1  
235  
5G  
W7  
201A  
224  
ON  
W14  
W16  
W12  
W15  
A1  
D1  
J3  
210  
5A  
-
11J10  
A2  
W10  
S7  
W1  
S2A (CLOSED  
WITH S2 IN  
1
5
3
224F  
C1, C2, C3 OR C4  
POSITION)  
12J10  
236  
222  
+
5F  
219  
W13  
5C  
W8  
A2  
224F  
201A  
REACTOR  
ENGINE  
HOUR METER  
OUTPUT  
CONTACTOR  
254A  
224D  
232  
240  
A1  
BATTERY  
CHARGER  
214  
224E  
200B  
77  
R
R6 C1  
R5 R7 C2  
R4  
R3  
C3  
25 OHM  
50W  
R2  
W12  
R1  
CR1  
C4  
235  
IDLER AC  
CURRENT  
SENSOR  
OUTPUT  
RHEOSTAT  
R
224  
224C  
241  
W10  
75  
RANGE  
SWITCH  
S2  
"SIG" TERMINAL  
W2  
W1  
10K POT  
MAX  
W9  
W9  
250  
R3  
75A  
15A  
CB9  
S5  
IDLER  
224C  
CW  
77D  
76D  
226  
FUEL  
AUTO  
FUEL  
WORK  
ELECTRODE  
5A  
SWITCH  
C4  
C3  
GAUGE  
GND  
SENDER  
76A  
S8  
235B  
8J10  
235A  
6
5C  
S
+
227A  
C2  
77  
76  
SHOWN IN  
"HIGH"  
POSITION  
5W  
C1  
HIGH  
3
21  
5G  
STATOR  
7
21A  
67  
5B  
REMOTE SWITCH  
(SHOWN IN  
REMOTE POSITION)  
6
32  
3
9
31  
42  
76D  
GLOW PLUG  
SWITCH  
S6  
ON/OFF  
SWITCH  
2C  
S3  
5
GND-E  
224H  
75A  
224G  
235B  
76A  
CB1  
222G  
223A  
77A  
77A  
221C  
222  
224E  
AMPHENOL 1  
S4  
START  
SWITCH  
2C  
222C  
(15AMP)  
OIL  
PRESSURE  
WATER  
TEMP.  
J
115VAC  
A
31A  
31A  
R
R
224C  
SHOWN IN  
"ON" POSITION  
3J10  
32  
4A  
2A  
21  
5A  
GND-E  
220C  
GROUND SCREW  
BLOWER BAFFLE  
5E  
D
5E  
220A  
225  
223  
GLOW PLUGS  
PCB2  
221A  
GND-G  
GND-D  
CONTACTOR  
C
BYPASS PC  
5A  
222B  
GND-C  
10J10  
220B  
5B  
5H  
9J10  
221B  
4
8
7J10  
6J10  
WORK  
H
2A  
4C  
77C  
3
REMOTE CONTROL  
E
77C  
OIL PRESSURE  
SWITCH  
WATER  
TEMP.  
J4  
76C  
4A  
75C  
F
76C  
75C  
31B  
42  
125/250V. SINGLE  
RECEPTACLE  
201  
201A  
SWITCH  
G
1
3
5
BLACK  
BLACK  
I
42VAC  
K
222D  
222B  
222E  
3E  
3F  
7
6
219  
(-)  
SLIP  
6
75B  
2B  
D2  
CB2  
50A  
GND-D  
9
AC  
AC  
B
GND-A  
222A  
120 V  
(+)  
GND-G  
5
CB4  
15A  
GROUND  
CB6  
15A  
200B  
1J10  
2J10  
77B  
76B  
J5  
225  
J8  
120/240V  
J9  
REMOTE CONTROL  
A
RINGS  
3C  
3D  
200A  
RED  
77B  
76B  
75B  
2B  
224B  
STARTER  
SOLENOID  
(+)  
200  
RED  
(+)  
SILVER  
76A  
STARTER  
1
2
5D  
4
B
C
D
COLORED  
TERMINALS  
3G  
BLACK  
5L  
4B  
CONTACTOR  
12  
3H  
BLACK  
COIL  
(+)  
(-)  
11  
(+)  
(-)  
4
BLACK  
11  
5H  
CONTACTOR  
E
76A  
2C  
75A  
800 MFD  
201  
RED  
C1  
GND-C  
CB5  
15A  
120 V  
4B  
CB7  
15A  
J6  
WHITE  
5D  
SILVER  
COLORED  
TERM.  
ROTOR FIELD  
F
GND-B  
3
CB3  
50A  
237  
3D  
77A  
J10  
12 VOLT  
BATTERY  
(-)  
GROUND  
3C  
77A  
227  
3A  
3
1
POSITIVE SLIP  
RING NEAREST  
LAMINATION  
3A  
3B  
SILVER  
COLORED  
TERMINALS  
3B  
PULL  
COIL  
HOLD  
COIL  
5
AMPHENOL 2  
67  
5L  
4C  
CRANK  
MOTOR  
21A  
J7  
B
IG  
L
222D  
224A  
ENGINE HARNESS CONNECTOR  
TO PANEL HARNESS  
L3  
FUEL  
WHITE  
5K  
5E  
5A  
FRAME  
GROUND  
ALTERNAT0R  
CONNECTION  
BLOCK  
FUEL SHUTDOWN  
SOLENOID  
SHUTDOWN BLACK  
SOLENOID  
J10  
5K  
GROUND SCREW  
J13  
IDLER SOLENOID  
(HARNESS LEAD END)  
9
5
1
10  
6
11 12  
J12  
ABOVE AMPHENOL HOLE  
(HARNESS LEAD END)  
7
3
8
4
ALTERNATOR  
ENGINE  
GROUND  
5H  
1J10  
(HARNESS LEAD END)  
222F  
213  
5Z  
2
237  
NOTES:  
ELECTRICAL SYMBOLS PER E1537  
ALL CASE FRONT COMPONENTS VIEWED FROM REAR.  
224A  
5K  
INDICATES JACK NUMBER  
INDICATES CAVITY NUMBER  
224B  
227  
J13  
214  
222G  
J11  
J12  
5-4-2001B  
L11702  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD  
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 300  
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G-6  
G-6  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CONTROL BOARD  
ITEM  
REQ D.  
PART No.  
IDENTIFICATION  
N.J.  
N.G.  
2
1
~.04  
6.00  
5.80  
xxxxxxxxxx  
xxxxxxxxxx  
2
2
xxxx  
xxxx  
3.13  
xxxxxxxxxxxxxx  
xxxxxxxxxxxxxx  
xxxxxx  
xxxxxx  
xxxx  
xxxx  
N.J.  
.20  
0
N.K.  
11.30  
.20  
5.75  
0
11.50~.04  
N.J.  
2-16-2001B  
ENGINE WELDER  
CONTROL P.C. BOARD ASSEMBLY  
3132-2  
G
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 troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
RANGER 300  
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G-7  
G-7  
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  
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G-8  
G-8  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - BYPASS BOARD  
~.04  
4.00  
X
X
X
X
X
X
X
X
X
2.83  
CAPACITORS = MFD/VOLTS  
X
X
X
X
X
X
X
X
X
X
X
1.18  
X
X
XXXXXX XXXXXX  
X
ENGINE WELDERS  
BYPASS P.C. BD. ASSEMBLY  
11-20-98E  
18733-1B  
M
0
~.04  
1.75  
0
.75  
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 troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
RANGER 300  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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