Lincoln Electric Cross Country 300 Service Manual

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Cross Country ® 300

For use with machines having Code Numbers:

Cross Country ® 300: 12362, 12554, 12555

SERVICE MANUAL

SVM266

| Issue Date 18-Oct

Table of Contents

Troubleshooting

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Do you have a question about the Cross Country 300 and is the answer not in the manual?

Questions and answers

Paul Donahue

February 3, 2025

I have the Lincoln electric cross country 300 electric generator welder the 110 outlet is not working how do I reset it I've tried resetting it and it doesn't do anything can you please specify some options for me please thank you

Summary of Contents for Lincoln Electric Cross Country 300

Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
Page 6: Table Of Contents
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Cross Country™ 300 Service Manual Last update: 2018/10/01 CROSS COUNTRY™ 300 ..........................1 Service Manual ................................ 1 Theory of Operation .............................. 3 BATTERY, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION ..............3 WELD CONTROL BOARD ........................... 5 WELD WINDINGS, RECTIFIER, CHOPPER MODULE AND FEEDBACK ............6 INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION ..............7 PULSE WIDTH MODULATION ........................8 CHOPPER TECHNOLOGY FUNDAMENTALS ....................9 Troubleshooting & Repair ........................... 10 HOW TO USE TROUBLESHOOTING GUIDE ....................10 PC BOARD TROUBLESHOOTING PROCEDURES ..................11 Troubleshooting guide ............................12 Test Procedures ..............................26 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE ............... 26 CAPACITOR DISCHARGE PROCEDURE ...................... 29 BRUSH AND SLIP RING SERVICE PROCEDURE ..................33 ENGINE ALTERNATOR TEST PROCEDURE ....................35 STOP / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH TEST PROCEDURE ..........38 WELD MODE SELECTOR SWITCH TEST PROCEDURE ................. 41 IDLER SOLENOID TEST PROCEDURE ......................44 FUEL SHUTDOWN SOLENOID TEST PROCEDURE ..................46...
Page 7 LINCOLN ELECTRIC Cross Country™ 300 Service Manual REMOTE RECEPTACLE TEST PROCEDURE ....................47 FIELD BRIDGE RECTIFIER TEST PROCEDURE ..................... 49 CHOPPER MODULE FUNCTION TEST PROCEDURE ..................51 CHOPPER MODULE RESISTANCE TEST PROCEDURE ................. 55 CHOKE TEST PROCEDURE ........................58 WELD CONTROL FEEDBACK TEST PROCEDURE ..................60 WELD CONTROL BOARD PWM GATE SIGNAL TEST PROCEDURE .............. 64 WELD CONTROL BOARD VOLTAGE TEST PROCEDURE ................67 OUTPUT RECTIFIER BRIDGE TEST PROCEDURE ..................72 FLASHING VOLTAGE TEST PROCEDURE (ENGINE NOT RUNNING) ............76 ROTOR RESISTANCE AND GROUND TEST PROCEDURE (STATIC) ............... 80 ROTOR RESISTANCE AND GROUND TEST PROCEDURE (DYNAMIC) ............82 ROTOR VOLTAGE TEST PROCEDURE ......................84 STATOR SHORT CIRCUIT & GROUND TEST PROCEDURE ................87 STATOR VOLTAGE TEST PROCEDURE ....................... 90 Removal And Replacement Procedures ......................93 STOP / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH REMOVAL AND REPLACEMENT PROCEDURE ..93 WELD MODE SELECTOR SWITCH REMOVAL AND REPLACEMENT PROCEDURE ......... 96 FIELD BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE ............. 98 CHOPPER MODULE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE .
Page 8: Theory Of Operation
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Theory of Operation Figure E.1 – Battery, engine, rotor, stator and engine protection POSITIVE POSITIVE OUTPUT TERMINAL OUTPUT TERMINAL SHUNT SHUNT – – NEGATIVE CC NEGATIVE CC OUTPUT TERMINAL OUTPUT TERMINAL – – NEGATIVE CV NEGATIVE CV – – OUTPUT TERMINAL OUTPUT TERMINAL STATOR RECTIFIER RECTIFIER CHOPPER CHOPPER CHOKE CHOKE BRIDGE BRIDGE...
Page 9 LINCOLN ELECTRIC Cross Country™ 300 Service Manual engine protection/idle control board receives a signal from the weld control board that activates the idler solenoid that brings the engine to a low idle condition. When output current is sensed, either weld or auxiliary, the weld control board deactivates the idler solenoid and the engine returns to a high-speed condition.
Page 10: Weld Control Board
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure E.2 – Weld control board POSITIVE POSITIVE OUTPUT TERMINAL OUTPUT TERMINAL SHUNT – – NEGATIVE CC NEGATIVE CC OUTPUT TERMINAL OUTPUT TERMINAL – – NEGATIVE CV NEGATIVE CV – – OUTPUT TERMINAL OUTPUT TERMINAL STATOR STATOR RECTIFIER RECTIFIE CHOPPER CHOKE CHOKE BRIDGE BRIDGE BD IGBT ROTOR...
Page 11: Weld Windings, Rectifier, Chopper Module And Feedback
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure E.3 – Weld windings, rectifier, chopper module and feedback POSITIVE OUTPUT TERMINAL SHUNT – NEGATIVE CC OUTPUT TERMINAL – NEGATIVE CV – OUTPUT TERMINAL STATOR STATOR RECTIFIER CHOPPER CHOKE BRIDGE BD IGBT ROTOR ROTOR SLIP RINGS SLIP RINGS MECHANICAL MECHANICAL COUPLING COUPLING GLOW PLUG GLOW PLUG –...
Page 12: Insulated Gate Bipolar Transistor (Igbt) Operation
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure E.4 – Insulated gate bipolar transistor (IGBT) operation POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN A. PASSIVE A. PASSIVE Insulated Gate Bipolar Transistor (IGBT) Operation The IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, (zero volts relative to the source) and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the OFF position.
Page 13: Pulse Width Modulation
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure E.5 – Pulse width modulation MINIMUM OUTPUT (Dwell or Off Time) MAXIMUM OUTPUT (Dwell or Off Time) Pulse Width Modulation The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine. Minimum Output By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during a cycle. The top drawing shows the minimum output signal possible over a 50-microsecond time period. The positive portion of the signal represents one IGBT group conducting for 2 microsecond. The dwell time (off time) is 48 microseconds. Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized. Maximum Output By holding the gate signals on the 48 microseconds and allowing only 2 microseconds of dwell time (off time) during the 50-microseconds cycle, the output is maximized. The darkened area under the top curve can be compared to the area under the bottom curve. The more darkened area under the curve, the more power is present.
Page 14: Chopper Technology Fundamentals
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Chopper Technology Fundamentals The new era of welding machines such as the Cross Country 300, employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed though an inductor to control an arc. Hence the name “Chopper.” The biggest advantage of chopper technology is the high-speed control of the arc, similar to the inverter machines. A block diagram for this is as follows: EXTERNAL DC SOLID STATE INDUCTOR SOURCE SWITCH AND DIODE CONTROL In this system, the engine drives a three-phase alternator, which generates power that is rectified and filtered to produce approximately 85 VDC. The current is applied through a solid-state switch to an inductor. By turning on and off, current in the inductor and the arc can be controlled. The following diagram depicts the current flow in the system when the switch is open and closed. INDUCTOR SWITCH 70-80VDC DIODE CURRENT WITH SWITCH OPEN CURRENT WITH SWITCH CLOSED When the switch is closed, current is applied through the inductor to the arc. When the switch opens, current stored in the inductor sustains flow in the arc and through the diode. The repetition rate of switch closure is 200Khz, which allows ultra-fast control of the arc. By varying the ratio of on time versus off time of the switch (Duty Cycle), the current applied to the arc is controlled. This is the basis for chopper technology: controlling the switch in such a way as to produce superior welding.
Page 15: Troubleshooting & Repair
LINCOLN ELECTRIC Cross Country™ 300 Service Manual 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 Step 3. PERFORM COMPONENT TESTS. The last you locate and repair possible machine column, labeled “Recommended Course of malfunctions. Simply follow the three-step Action” lists the most likely components that may procedure listed below. have failed in your machine. It also specifies the appropriate test procedure to verify that the Step 1. LOCATE PROBLEM (SYMPTOM). Look subject component is either good or bad. If there under the column labeled “PROBLEM” are a number of possible components, check the (SYMPTOMS). This column describes possible components in the order listed to eliminate one symptoms that the machine may exhibit. Find the possibility at a time until you locate the cause of listing that best describes the symptom that the your problem. machine is exhibiting. Symptoms are grouped into four main categories: Output Problems, All of the referenced test procedures referred to Function Problems, Welding Problems and Engine in the Troubleshooting Guide are described in Problems. detail at the end of this section. Refer to the Troubleshooting and Repair Table of Contents to Step 2. PERFORM EXTERNAL TESTS. The second locate each specific Test Procedure. All of the column, labeled “POSSIBLE AREAS OF referred to test points, components, terminal MISADJUSTMENT(S)”, lists the obvious external strips, etc., can be found on the referenced possibilities that may contribute to the machine...
Page 16: Pc Board Troubleshooting Procedures
LINCOLN ELECTRIC Cross Country™ 300 Service Manual PC BOARD TROUBLESHOOTING PROCEDURES WARNING • If the PC board uses protective shorting jumpers, don’t ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment. Turn the input power OFF at the prevent further damage and allow proper failure analysis. fuse box before working on equipment. Do Test the machine to determine if the failure symptom not touch electrically hot parts. has been corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board CAUTION available for PC board troubleshooting. NOTE: Allow the machine to heat up so that all electrical Sometimes machine failures appear to be due to PC board components can reach their operating temperature. failures. These problems can sometimes be traced to poor Remove the replacement PC board and substitute it electrical connections. To avoid problems when with the original PC board to recreate the original troubleshooting and replacing PC boards, please use the problem. following procedure: a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Determine to the best of your technical ability that the Continue to look for bad connections in the control wiring PC board is the most likely component causing the harness, junction blocks and terminal strips. failure symptom. b.
Page 17: Troubleshooting Guide
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Troubleshooting guide Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical 1. Contact your local 1. Contact the Lincoln Electric damage is evident. authorized Lincoln Electric Service Department at 1-888- Service Facility. 935-3877. No welding output or auxiliary 1. Check for loose or faulty 1. Perform the Brush And Slip power. The engine operates connections in the auxiliary Ring Service Procedure. normally. circuit to the output 2. Check for flashing voltage at receptacles and/or the weld the slip rings (3-5 Volts DC @ .5 circuit to the output terminals. amp until generator builds up, 2. Check the brushes for wear the 160 Volts). and proper contact to the rotor 3. Perform the Flashing slip rings. Voltage Test Procedure. 4. Perform the Field Bridge Rectifier Test Procedure.
Page 18 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS No welding output in any 1. If the correct OCV is present 1. Check gate leads 23 and 25 mode. The auxiliary output is at the weld output terminals, and weld control board power normal. The engine operates check the welding cables, leads 13 and 14 for loose or normally. connectors, work clamp, faulty connections. See Wiring electrode holder, etc. for loose Diagram. or faulty connections. 2. Perform the Chopper 2. Check for damaged Module Function Test conductors or faulty Procedure. connections on the heavy 3. Perform the Stator Voltage current carrying leads that Test Procedure. connect the output studs to the 4. Perform the Stator Short chopper module and to the Circuit And Ground Test output rectifier bridge. Also Procedure.
Page 19 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The machine will weld but the 1. Make sure the machine is 1. Disconnect all external welding arc is “COLD”. The properly set for the electrode equipment and perform a engine runs normally and the and process being used. Check “load” test using a resistive auxiliary power is normal. electrode size, weld mode load bank and accurate meters. selector switch setting and Adjust the load for about 300 amps or voltage setting. If amps at 32 volts; check that the shielding gas is used make sure engine speed holds at 1800 of correct type and gas flow. RPM. If not perform engine 2. Make sure the process does maintenance. not demand more power than 2. Perform the Weld Control the machine can produce. Feedback Test Procedure. 3. If the current is correct try 3. If the maximum weld output increasing the “ARC CONTROL”...
Page 20 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The machine welds but it will 1. Check that the electrode is 1. If the engine will not not maintain a steady output. of good quality, dry and free maintain the correct load RPM, from contamination. Try using the engine may be in need of some Lincoln electrode and service. Air and fuel filters setting the machine per should be checked. Lincoln’s recommendation. 2. Check large current carrying 2. If shielding gas is used, check leads that connect to the that the gas and gas flow are stator, chopper module, shunt, correct. Check for damaged, choke and output terminals. pinched or leaking gas lines. See Wiring Diagram. Look for 3. Check for proper work and damaged conductors or faulty electrode leads and connections.
Page 21 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION FUNCTION PROBLEMS The weld output cannot be 1. Remote control devices 1. The output control adjusted with the front panel completely disable the front potentiometer may be output control knob in one or output in all modes except defective. Perform the Remote more weld modes. The weld ‘TOUCH START TIG’ mode. Receptacle Test Procedure. output terminals have normal *Make sure there is nothing 2. Perform the Weld Mode OCV (open circuit voltage). The plugged into the Amphenol Selector Switch Test Procedure. AC auxiliary power is normal receptacles. 3. Check the shunt and and the engine operates 2. Check for dirt or moisture associated leads and the normally.
Page 22 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION FUNCTION PROBLEMS The machine seems to be 1. Check the position of the 1. Check connector J7 on the locked into the ‘CC-stick’ mode weld mode selector switch. weld control board to see that of operation. The switch should positively it is properly seated and the snap into each mode position pins in both the plug and the and should not feel ‘gritty’ or board receptacle are in good get stuck between positions. condition. 2. Perform the Weld Mode Selector Switch Test Procedure. 3. The weld control board may be faulty. The arc quality is poor with 1. The ‘Arc Control’ may be set 1. Perform the Weld Mode excessive spatter. The arc heat too high. Selector Switch Test Procedure. can be controlled and 2. The output control may be 2. Perform the Output Rectifier maintained normally, the set too high for the electrode Bridge Test Procedure.
Page 23 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELDING PROBLEMS An across-the-arc type wire 1. Check that the weld mode 1. Use a voltmeter to check for feeder does not function when selector switch is in the correct the presence of about 58 VDC connected to the weld output position for the process being open circuit voltage (OCV) of the machine. The machine used, typically ‘CV-WIRE’ mode. across the output studs of the operates normally in the CC- 2. Check for poor weld cable machine. Stick mode and has normal AC connections between the 2. If the OCV is low, there may auxiliary output. feeder and the welder output be a problem with the mode terminal and between the work switch. piece and the other output 3. Perform the Weld Mode terminal. Selector Switch Test Procedure. 3. Check that the wire feeder’s work sensing lead is properly connected to work piece and is in good condition.
Page 24 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ENGINE PROBLEMS The engine will not crank when 1. Check the circuit breaker 1. Check the wiring and the the start button is pushed. (CB5). Reset if tripped. connections at the starter 2. Make sure the run/stop motor, glow plug button, circuit switch is in the ‘RUN’ position. breaker (CB5), run/stop switch 3. Check for loose or faulty and start button. See Wiring battery cable connections. Diagram. 4. The battery may be low or 2. Check the chassis ground faulty. If the battery will not connections between the accept a charge, replace it. engine block and the negative battery terminal. 3. Place the run/stop switch to the ‘Run’ position. Press the start button, while checking for voltage between a good clean chassis ground connection (-) and lead 231 (+) at the starter solenoid. See Wiring Diagram. 4. If battery voltage is present, the starter motor or solenoid may be defective or the engine...
Page 25 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ENGINE PROBLEMS The battery does not stay 1. Check for loose, corroded or 1. Perform the Engine charged. faulty connections at the Alternator Test Procedure. battery. 2. There may be a defective 2. Check for loose or damaged component or faulty wiring alternator drive belt. causing a current draw when 3. The battery may be faulty. the run/stop switch is in the ‘Stop’ position. 3. Check the Run/Stop switch, the glow plug button, the alternator and the starter solenoid. Also check for damaged wiring and insulation. 4. If the engine charging system is operating properly but the battery is not staying charged, the battery is defective and should be replaced. The engine shuts down shortly 1. Try resetting the breaker. If 1. Examine the circuit breaker after starting and trips the it trips again do not attempt to...
Page 26 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ENGINE PROBLEMS The engine cranks when the 1. The battery voltage may be 1. The fuel filter may be start button is pressed but will low (normally results in slow clogged, replace if necessary. not start. cranking speed). The battery 2. Fuel pump may be faulty. should be checked and Check for fuel flow through recharged if it is not producing filters. Contact local authorized adequate voltage and replaced engine service shop. if it will not accept a full charge. 3. Check engine oil level. 2. Make sure the glow plug 4. The ON/OFF switch may be button is pressed while on for more than 60 seconds pressing the start button. See before starting. The ON/OFF the operator’s manual, for switch will need to be switched proper starting procedure. OFF and turned back ON again. 3. Make sure the fuel valve on 5. The fuel solenoid may be the fuel sediment filter is in the faulty or not operating...
Page 27 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ENGINE PROBLEMS The engine starts but shuts 1. Make sure the glow plug 1. The shut down fuel solenoid down immediately when the button is pressed while pushing may be faulty or not operating start button is released. the button (10 seconds properly. maximum after the engine 2. Check leads 233 and 262 and starts). See the operators perform the Fuel Shutdown manual for proper starting Solenoid Test Procedure. See procedure. Wiring Diagram. 2. Check the engine oil level. 3. Check for 12 volts at lead 3. Be certain that the engine is 233 when start button is not overheated. pushed. Check circuit breaker 4. Check that the machine has (CB5) and lead 231. an adequate supply of fresh, 4. The engine may have clean fuel. inadequate oil pressure.
Page 28 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION ENGINE PROBLEMS The engine will not idle down 1. Make sure the idle switch is 1. Perform the Idler Solenoid to low RPM. The machine has in the ‘Auto Idle’ position. Test Procedure. normal weld and auxiliary 2. Make sure there is no 2. Check for damaged wiring or output. external load on the weld faulty connections at the idle terminals or the auxiliary power solenoid, the engine protection receptacles. board, the run/stop switch and 3. Check for mechanical the start button. restrictions in the idler solenoid 3. Check for loose or damaged linkage. wiring or faulty connections at leads 405, 226, 227 and connections J/P-55-2 and J/P- 55-4, (control board J32-2, B3 and J31-8). See Wiring Diagram. 4. Perform the Weld Control Board Voltage Test.
Page 29 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE 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 1. The load on the auxiliary 1. Check that leads 3 and 6 are idle when using auxiliary receptacle may be too low. properly routed through the power. Auxiliary power is 2. The automatic idle system toroidal current sensor. Each normal when the idler switch is will not function reliably if the lead must have three turns and in the ‘High’ idle position, the load is less than 100 watts. must pass through the sensor automatic idle function works 3. The device connected to the in the opposite directions. See properly when welding. auxiliary power may be Wiring Diagram. The leads defective. Try another device. should be wrapped tightly and 4. Make sure the connections tie wrapped in place. to the auxiliary device are 2. Check the toroidal sensor for secure. any signs of damage.
Page 30 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE 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 1. Check that the welding 1. Check the leads and idle when striking arc. The cables are in good working connections at the shunt at the automatic idle system functions condition and the connections positive output stud. Check normally when using auxiliary are tight. Make sure the work lead 204S and 206S for power. Welding and auxiliary clamp is attached to clean, bare continuity from the shunt to J6- outputs are normal when the material. 1 and J6-2 on the weld control idle switch is in the ‘High Idle’ board. Check the pins and position. connections at J6. 2. Perform the Weld Control Board Voltage Test Procedure. The engine will not go to high 1. Check that the welding 1. Perform the Weld Control idle when attempting to strike cables and the auxiliary power Board Voltage Test Procedure.
Page 31: Test Procedures
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Test Procedures CASE COVER REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Case Covers. MATERIALS NEEDED 1/2” Nutdriver 1/2” Open-End Wrench...
Page 32 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 11. Carefully remove the exhaust rain cap from the exhaust pipe. See Figure F.1. 12. Using a 1/2” nutdriver, remove the ten screws securing the roof panel to the machine. See Figure F.1. 13. With the help of an assistant, carefully lift the roof panel off of the machine. 14. Place the previously removed fuel cap on to the fuel tank. REPLACEMENT PROCEDURE 1. Remove the fuel cap from the machine. 2. With the help of an assistant, carefully position the roof panel on to the machine. 3. Using a 1/2” nutdriver, attach the ten screws securing the roof panel to the machine. 4. Attach the exhaust rain cap to the exhaust pipe. 5. Attach the lift bail cover seal. 6. Attach the fuel trough and the fuel cap to the fuel tank. 7. Using a 1/2” nutdriver, attach the five screws securing the right case side to the machine. 8. Using a 3/8” nutdriver, tighten the two screws securing the right case side to the machine. 9. Using a 1/2” nutdriver, attach the five screws securing the left case side to the machine. 10. Using a 3/8” nutdriver, tighten the two screws securing the left case side to the machine. 11. Using a 1/2” nutdriver, attach eight (of the ten) screws securing the door slide rail to the machine. Repeat this step for each door slide rail. 12. Using a 1/2” nutdriver and a 1/2” open-end wrench, attach the two remaining bolts, nuts, flat washers and lock washers securing the door slide rail to the machine. Repeat this step for each door slide rail.
Page 33 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.1 – Fuel cap, lift bail cover seal, rain cap, door slide rail, engine service access door, roof panel and fuel trough locations RAIN CAP ROOF PANEL LIFT BAIL DOOR SLIDE COVER SEAL RAIL (ONE ON EACH SIDE) FUEL CAP ENGINE SERVICE ACCESS DOOR (ONE ON EACH SIDE) FUEL TROUGH Figure F.2 – Case side mounting hardware locations CASE SIDE SCREWS (FIVE ON EACH SIDE) CASE SIDE SCREWS (LOOSEN DO NOT REMOVE)
Page 34: Capacitor Discharge Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual CAPACITOR DISCHARGE PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will ensure that the Field Capacitor and the large Capacitors in the Chopper Module have been discharged. MATERIALS NEEDED Volt/Ohmmeter Resistor (25-1000 ohms and 25 watts minimum) Lincoln Part #S01404-114 works well for this purpose Electrically Insulated Gloves Electrically Insulated Pliers Jumper Leads Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the field capacitor. See Figure F.3. See Wiring Diagram. 4. Using a volt/ohmmeter, check the DC voltage at the terminals of the field capacitor. See Figure F.4. See Wiring Diagram. 5. If any voltage is present, discharge the capacitor using the high wattage resistor (25-1000 ohms @ 25 watts minimum), electrically insulated gloves and pliers. Hold the resistor on the capacitor terminals for ten seconds. See Figure F.4. See Wiring Diagram.
Page 35 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 9. If another type of resistors is used, jumper leads may need to be attached to the resistor. The leads can then be used to connect the resistor from terminals B1 to B2 and B4 to B5. See Figure F.6. See Wiring Diagram. 10. Using the volt/ohmmeter, check the voltage across terminals B1 and B2 then B4 and B5. It should be zero volts in both cases. See Figure F.6. See Wiring Diagram. If not, repeat the discharge procedure. 11. Perform the Case Cover Replacement Procedure. Figure F.3 – Field capacitor location FIELD CAPACITOR (LOCATED UNDER PROTECTIVE COVER)
Page 36 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.4 – Field capacitor terminal location and discharge components FIELD CAPACITOR TERMINALS RESISTOR INSULATED INSULATED PLIERS GLOVES Figure F.5 – Chopper module location CHOPPER MODULE POWER MODULE PANEL...
Page 37 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.6 – Chopper module terminal locations CHOPPER MODULE INSULATED INSULATED PLIERS GLOVES DISCHARGE RESISTOR...
Page 38: Brush And Slip Ring Service Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual BRUSH AND SLIP RING SERVICE PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure provides guidance in testing and maintaining the Brush and Slip Ring System. MATERIALS NEEDED Volt/Ohmmeter Miscellaneous Hand Tools 500 or 600 Grit Sand Paper 180 Grit Sand Paper 220 or 320 Grit Commutator Stone Low Pressure Compressed Air TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Examine brushes and slip rings. The slip rings, brush holder and brushes should be clean and free from oil or grease. The brushes should be making good, continuous contact with the slip rings. 5. The brushes should be of sufficient length and have adequate spring tension. Generally, the brushes should be replaced if either brush has less than 1/4” remaining before it reaches the end of its travel. Spring tension should be sufficient to hold the brushes firmly against the slip rings.
Page 39 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 9. If brushes have been replaced, repositioned or are not making full contact with the slip rings, it may be necessary to re-seat them. This can be done by placing a strip of 180 grit sandpaper between the slip rings and the brushes, with the abrasive side against the brushes. Pull the sandpaper strip around the circumference of the slip rings in the direction of rotor rotation only. Repeat this procedure until the surface of each brush is in full contact with its matching slip ring. 10.
Page 40: Engine Alternator Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual ENGINE ALTERNATOR TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Engine Alternator is properly charging the Battery. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Open the engine access door to gain access to the alternator. 3. Using a volt/ohmmeter, measure the voltage at the battery terminals. Normal voltage is approximately 12 VDC. See Wiring Diagram. 4. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch in the ‘High Idle/Run’ position. See Figure F.7. 5. Start the engine and allow it to run at high idle speed for approximately 15 to 30 seconds. 6. Using a volt/ohmmeter, measure the voltage at the battery terminals. Voltage should read approximately 13.7 to 14.2 VDC. See Wiring Diagram.
Page 41 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 14. If the voltage at both alternator test points reads the same as or less than battery voltage, the alternator is faulty and needs or be repaired or replaced. 15. If battery voltage is present at the positive terminal of the alternator, but not at the “IGN” terminal; check the Stop / (Auto Idle/Run) / (High Idle/Run) switch and the wiring connecting the “IGN” terminal to the switch. See Wiring Diagram.
Page 42 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.8 – Engine alternator terminal locations 232M...
Page 43: Stop / (Auto Idle/Run) / (High Idle/Run) Switch Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual STOP / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Stop / (Auto Idle/Run) / (High/Idle/Run) Switch is functioning properly. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Disconnect the lead from the negative battery terminal. 5. Locate the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch. See Figure F.9. See Wiring Diagram. 6. Label and disconnect leads 5R, 256, 257, 232A, 232B and 236A from terminals 7, 5, 6, 3, 2 and 8 of the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch. See Figure F.10. See Wiring Diagram. 7. Using a volt/ohmmeter, perform the resistance tests outlined in Table F.1. See Figure F.10. See Wiring Diagram.
Page 44 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Table F. 1 – Stop / (auto idle/run) / (high idle/run) switch resistance tests TEST POINT (+) TEST POINT (–) EXPECTED READING POSITION LESS THAN ONE OHM TERMINAL 2 TERMINAL 3 HIGH IDLE/RUN (LOW RESISTANCE) LESS THAN ONE OHM TERMINAL 5 TERMINAL 6 HIGH IDLE/RUN (LOW RESISTANCE) LESS THAN ONE OHM TERMINAL 2 TERMINAL 3 AUTO IDLE/RUN (LOW RESISTANCE) AT LEAST 500K OHMS TERMINAL 5 TERMINAL 6 AUTO IDLE/RUN (HIGH RESISTANCE) AT LEAST 500K OHMS TERMINAL 2 TERMINAL 3 STOP/OFF (HIGH RESISTANCE) AT LEAST 500K OHMS TERMINAL 5 TERMINAL 6 STOP/OFF (HIGH RESISTANCE) Table F. 2 – Stop / (auto idle/run) / (high idle/run) switch diode test TEST POINT (+) TEST POINT (–) EXPECTED READING TERMINAL 8 TERMINAL 7...
Page 45 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.10 – Stop / (auto idle/run / (high idle/run) switch terminal and lead locations 232A 236A 232A 232B START / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH (VIEWED FROM THE REAR)
Page 46: Weld Mode Selector Switch Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual WELD MODE SELECTOR SWITCH TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Weld Mode Selector Switch is functioning properly. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the weld mode selector switch. See Figure F.11. See Wiring Diagram. 5. Using a volt/ohmmeter, perform the voltage tests outlined in Table F.3. See Figures F.12. See Wiring Diagram.
Page 47 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Table F. 3 – Weld mode selector switch tests TEST POINT (+) TEST POINT (–) EXPECTED READING POSITION LESS THAN ONE OHM TERMINAL 2 TERMINAL 3 STICK (LOW RESISTANCE) LESS THAN ONE OHM TERMINAL 5 TERMINAL 6 STICK (LOW RESISTANCE) AT LEAST 500K OHMS TERMINAL 5 TERMINAL 4 STICK (HIGH RESISTANCE) LESS THAN ONE OHM TERMINAL 2 TERMINAL 3 TIG (LOW RESISTANCE) LESS THAN ONE OHM TERMINAL 5 TERMINAL 4 TIG (LOW RESISTANCE) AT LEAST 500K OHMS TERMINAL 5 TERMINAL 6 TIG (HIGH RESISTANCE) LESS THAN ONE OHM TERMINAL 1 TERMINAL 2 (LOW RESISTANCE) LESS THAN ONE OHM TERMINAL 5...
Page 48 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.12 – Weld control board terminal and lead locations 222A 222A WELD MODE SELECTOR SWITCH (VIEWED FROM THE REAR)
Page 49: Idler Solenoid Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual IDLER SOLENOID TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Idler Solenoid resistance values are normal and also determine if it will function normally when it is energized with 12 VDC. MATERIALS NEEDED External 12 VDC Supply (30 Amps) (Automotive Battery Works Well) Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Open the right side engine service door. 3. Locate the idler solenoid, mounted on the fuel injection pump. See Wiring Diagram. 4. Locate and unplug harness connection P55/J55. Cut cable ties as necessary. See Wiring Diagram. 5. Using a volt/ohmmeter, check the pull-in coil resistance, pins 3 and 4 (black wire to white wire). The normal resistance is less than 0.2 ohms. Check the hold-in coil resistance, pins 3 and 2 (black wire to red wire). The normal resistance is approximately 11 ohms. Check the resistance between pin 3 (black wire) and a clean, unpainted chassis ground. See Figure F.13. The resistance should be very high 500,000 Ohms or more. If any of the above resistance values are incorrect, the solenoid may be faulty. Replace.
Page 50 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.13 – Idler solenoid terminal locations P-55 J-55 232L COMMON 12 VOLT + RUN BLACK WHITE ENGINE PROTECTION ENGINE PROTECTION PULL HOLD IDLE CONTROL P.C.B. IDLE CONTROL P.C.B. IDLE SOLENOID IDLE SOLENOID WIRING HARNESS CONNECTOR CONNECTOR (LEAD ENTRY VIEW) (LEAD ENTRY VIEW)
Page 51: Fuel Shutdown Solenoid Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual FUEL SHUTDOWN SOLENOID TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Fuel Shutdown Solenoid resistance values are normal. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Open the right side engine service door. 3. Locate the fuel shutdown solenoid, on the right side of the engine behind the idle solenoid. See Wiring Diagram. 4. Locate harness connection P54/J54. Cut cable ties as necessary. See Wiring Diagram. 5.
Page 52: Remote Receptacle Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual REMOTE RECEPTACLE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if there is a problem with the Remote Receptacle control wiring relating to electrical tracking between other control conductors, power conductors or ground. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Locate the 6-pin remote receptacle on the front panel. See Figure F.14. See Wiring Diagram. 3. Make sure there are no devices plugged into the 6-pin Amphenol. 4. Using a volt/ohmmeter, perform the test outlined on Table F.4. See Figures F.14 and F.15. See Wiring Diagram.
Page 53 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.14 – Remote receptacle location 6-PIN REMOTE RECEPTACLE Figure F.15 – Remote receptacle pin locations...
Page 54: Field Bridge Rectifier Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual FIELD BRIDGE RECTIFIER TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Input Rectifier is receiving AC input voltage and is converting it to the correct DC output voltage. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the field bridge rectifier. See Figure F.16. See Wiring Diagram. 5. Label and disconnect leads 200, 200A, 5H, 201A and 6A from the field bridge rectifier. See Figure F.17. See Wiring Diagram. 6. Using a volt/ohmmeter, perform the forward voltage drop tests outlined in Table F.5. See Figure F.17. See Wiring Diagram. 7. If any of the tests fail, the field bridge rectifier may be faulty. 8. If faulty, perform the Field Bridge Rectifier Removal And Replacement Procedure. 9. Connect the previously removed leads 200, 200A, 5H, 201A and 6A to the field bridge rectifier. See Wiring Diagram. 10. Perform the Case Cover Replacement Procedure. Table F. 5 – Field bridge rectifier forward voltage drop tests TEST POINT (POS) TEST POINT (NEG) EXPECTED READING...
Page 55 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.16 – Field bridge rectifier location CONTROL PANEL (VIEWED FROM THE REAR) FIELD BRIDGE RECTIFIER Figure F.17 – Field bridge rectifier lead locations FIELD BRIDGE RECTIFIER – 201A 200A...
Page 56: Chopper Module Function Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual CHOPPER MODULE FUNCTION TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Chopper Module is functioning properly and receiving the correct input from the Output Rectifier and Weld Control PC Board. This test can only provide meaningful results if the machine is producing normal AC auxiliary output. MATERIALS NEEDED Frequency Counter or Digital Multimeter With Frequency Counter Function Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Make sure there is nothing plugged into the Amphenol receptacle. 4. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch in the ‘High Idle/Run’ position. See Figure F.18. 5. Place the weld mode selector switch in the ‘CC-Stick’ position. See Figure F.18. 6. Start the engine and allow it to stabilize at high idle RPM. 7. Locate the chopper module board. See Figure F.19. See Wiring Diagram. 8. Visually verify the LED’s on the board are illuminated according to Table F.6. See Figure F.20. See Wiring Diagram. 9. Check for 80 to 100 VDC at terminals B1- to B2+ and B4- to B5+ of the chopper module. See Figure F.20. See Wiring Diagram. 10. If the correct DC voltage is not present at terminals B1- to B2+ and B4- to B5+, check for damaged conductors or faulty connections between the chopper module, the output rectifier and stator weld winding. See Wiring Diagram. Perform the Stator Voltage Test Procedure and the Output Rectifier Bridge Test Procedure.
Page 57 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 12. If the voltage drops to 0 VDC after the leads 23 and plug J3 have been disconnected, the weld control board is driving the chopper module when it should not be doing so. Reconnect lead 23 and plug J3 and perform the Weld Control Board PWM Gate Signal Test Procedure. 13. Reconnect leads 23 and plug J3. See Wiring Diagram. 14. Check for about 58 VDC between chopper module terminals B2+ to B3- and B5+ to B6 and across the welder output terminals. See Figure F.20. See Wiring Diagram. 15. If about 58 VDC is present at chopper module terminals B2+ to B3- and B5+ to B6-, but not at the weld output terminals, there is a problem between the chopper module and one of the output terminals. Check for damaged conductors or faulty connections. Also check the shunt, the choke and the connections at the back of the output terminals. See Wiring Diagram.
Page 58 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.18 – Stop / (auto idle/run) / (high idle/run) switch and weld mode selector switch locations WELD MODE STOP / (AUTO IDLE/RUN) SELECTOR / (HIGH IDLE/RUN) SWITCH SWITCH Figure F.19 – Chopper module board location CHOPPER MODULE POWER MODULE PANEL...
Page 59 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.20 – Chopper module board terminal locations (LEAD 23) LED 1 LED 2 LED 1 LED 2 LED 3 LED 3...
Page 60: Chopper Module Resistance Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual CHOPPER MODULE RESISTANCE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Chopper Module is shorted. This test can only detect some problems in the “Power” section of the module. Problems in some other PC board components may not be detected. MATERIALS NEEDED 7/16”Nutdriver Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the chopper module PC board. See Figure F.21. See Wiring Diagram. 5. Using a 7/16” nutdriver, remove the six screws, lock washers and flat washers securing the heavy leads to terminals B1, B2, B3, B4, B5 and B6 of the chopper module PC board. See Figure F.22. See Wiring Diagram. Label leads for reassembly. 6. Using a volt/ohmmeter, perform the wide diode tests outlined in Table F.7. See Figures F.21 and F.22. See Wiring Diagram. 7. If any of the tests fail, the chopper module pc board may be faulty. 8. If faulty, perform the Chopper Module PC Board Removal And Replacement Procedure. 9. Using a 7/16” nutdriver, attach the six screws, lock washers and flat washers securing the heavy leads to terminals B1, B2, B3, B4, B5 and B6 of the chopper module PC board. See Wiring Diagram.
Page 61 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Table F. 7 – Chopper module diode tests OHMMETER OHMMETER READING (+) PROBE (–) PROBE EXPECTED READING 0.3 – 0.5 mv 1.50 – 1.90 0.5 mv 0.3 – 0.5 mv 1.5 – 1.90 0.5 mv Figure F.21 – Chopper module board location CHOPPER MODULE POWER MODULE PANEL...
Page 62 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.22 – Chopper module board terminal locations...
Page 63: Choke Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual CHOKE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Choke is shorted turn to turn or grounded. MATERIALS NEEDED 7/16” Nutdriver Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the chopper module board. See Figure F.23. See Wiring Diagram. 5. Using a 7/16” nutdriver, remove the bolt, lock washer and flat washer securing the heavy lead to terminal B6 of the chopper module. See Figure F.23. See Wiring Diagram. 6. Open: No weld output. Using a volt/ohmmeter, measure the resistance from the heavy lead to the negative CV output terminal. See Figure F.24. See Wiring Diagram. Resistance should be very low (less than one ohm). Using a volt/ohmmeter, measure the resistance from the heavy lead to the negative CC output terminal. See Figure F.24. See Wiring Diagram. Resistance should be very low (less than one ohm).
Page 64 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.23 – Chopper module board and B6 terminal locations CHOPPER MODULE POWER MODULE PANEL Figure F.24 – Negative CC & CV output terminal locations NEGATIVE (-) CC OUTPUT TERMINAL NEGATIVE (-) CV OUTPUT TERMINAL...
Page 65: Weld Control Feedback Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual WELD CONTROL FEEDBACK TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Weld Control PC Board is receiving accurate current and voltage feedback from the Weld Circuit. This test will only yield usable information if the machine is producing some weld output. MATERIALS NEEDED Digital Multimeter Suitable For Accurate Readings In Both The Millivolt And Normal Weld Voltage Ranges Resistive Load Bank Ammeter Suitable For Accurate Readings Of Normal Welding Current (Often Built Into The Load Bank) Wiring Diagram TEST PROCEDURE 1. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch in the “High Idle/Run” position. See Figure F.25. 2. Place the weld mode selector switch in the “CC-STICK” position. See Figure F.25. 3. Make sure that nothing is plugged into the Amphenol receptacle. 4. Connect the resistive load bank and the ammeter to the weld output terminals per the equipment manufacturer’s instructions; also connect the voltmeter probes across the weld output terminals. See Figure F.25.
Page 66 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 11. Locate plugs J3 and J6 on the weld control board. See Figure F.26. Remove the plugs and check for dirt, corrosion, damaged, expanded or incorrectly positioned terminals. Repair or replace wiring components as needed and reconnect the plugs to the control board. 12. Restart the machine and apply a load across the weld terminals that measures about 200 amps. If the machine will not produce 200 amps of current, apply as much load as you can. 13. Using the voltmeter, measure and note the DC voltage at the weld output terminals. 14. Check the voltage between lead 204S+ (J6-1) and lead 208A- (J3-15) at the weld control board Molex plugs. The voltage should be the same as was measured at the weld terminals. See Figures F.26 and F.27.
Page 67 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.25 – Stop / (auto idle/run) / (high idle/run) switch and weld mode selector switch locations WELD MODE STOP / (AUTO IDLE/RUN) SELECTOR / (HIGH IDLE/RUN) SWITCH SWITCH WELD OUTPUT TERMINALS Figure F.26 – Weld control board and plug locations CONTROL PANEL (VIEWED FROM THE REAR) WELD CONTROL BOARD...
Page 68 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.27 – Weld control board lead locations 206S 204S 208A...
Page 69: Weld Control Board Pwm Gate Signal Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual WELD CONTROL BOARD PWM GATE SIGNAL TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Weld Control PC Board is able to produce the PWM (Pulse Width Modulated) gate signal needed to control the IGBTs (Insulated Gate Bipolar Transistor) on the Chopper Module. This test will also verify that the Weld Control PC Board can turn the PWM gate signal on and off properly. MATERIALS NEEDED Frequency Counter, or Multimeter With Frequency Counter Function Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch in the ‘High Idle/Run’ position. See Figure F.28. 4. Place the weld mode selector switch in the ‘CC-Stick’ position. See Figure F.28. 5. Start the engine and let it run and stabilize at high idle. 6. Locate the weld control board. See Figure F.29. See Wiring Diagram. 7. Locate plug J3 on the weld control board. See Figure F.29. See Wiring Diagram. 8. Using a frequency counter, test for the presence of the 20kHz PWM gate signal between leads 23+ (J3-10) and lead 25- (J3-9). See Figure F.30. See Wiring Diagram. 9. If the 20 kHz gate signal is present, the test is complete. 10. If there is no 20 kHz gate signal, test for the presence of 80 to 100 VDC at leads 13+ (J3-8) to lead 14- (J3-16) of the weld control board. See Figure F.30. See Wiring Diagram.
Page 70 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 14. If about 15 VDC is detected, the welding terminal control circuit is open. Check for damaged leads for faulty connections at leads 2 and 4. See Wiring Diagram. 15. If the wiring and components are undamaged and functioning properly, the weld control board is defective and should be replaced. 16. Perform the Case Cover Replacement Procedure. Figure F.28 – Stop / (auto idle/run) / (high idle/run) switch and weld mode selector switch locations WELD MODE STOP / (AUTO IDLE/RUN) SELECTOR / (HIGH IDLE/RUN) SWITCH SWITCH...
Page 71 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.29 – Weld control board and plug locations CONTROL PANEL (VIEWED FROM THE REAR) WELD CONTROL BOARD Figure F.30 – Weld control board lead locations...
Page 72: Weld Control Board Voltage Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual WELD CONTROL BOARD VOLTAGE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Weld Control Board is functioning properly. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the weld control board. See Figure F.31. See Wiring Diagram. 4. Using a volt/ohmmeter, perform the tests outlined in Table F.8. See Figures F.32 and F.33. See Wiring Diagram.
Page 73 LINCOLN ELECTRIC Cross Country™ 300 Service Manual AT HIGH IDLE. NO REMOTE CONTROL DEVICE REMOTE CONTROL PLUG J1 PIN 11 PLUG J1 PIN 10 IN 6 PIN 10 VDC CIRCUIT (LEAD 77A) (LEAD 75A) AMPHENOL AND ENGINE RUNNING AT HIGH IDLE. 0 – 5 VDC ARC CONTROL PLUG J7 PIN 12 PLUG J7 PIN 3 DEPENDENT ON ENGINE RUNNING CIRCUIT (LEAD 277) (LEAD 279) POSITION OF ARC AT HIGH IDLE. CONTROL (R2) PWM SIGNAL TO PLUG J3 PIN 9 PLUG J3 PIN 10 15 VDC AT 20 KHZ ENGINE RUNNING CHOPPER BOARD (LEAD 25) (LEAD 23) PWM SIGNAL AT HIGH IDLE. POWER TO PLUG J3 PIN 8 PLUG J3 PIN 16 ENGINE RUNNING 90 TO 100 VDC...
Page 74 LINCOLN ELECTRIC Cross Country™ 300 Service Manual ENGINE RUNNING AT HIGH IDLE AND MODE SWITCH PLUG J7 PIN 16 PLUG J7 PIN 11 0 VDC WELD MODE CIRCUIT (LEAD 222) (LEAD 217) SELECTOR SWITCH IN TIG POSITION. ENGINE RUNNING AT HIGH IDLE AND MODE SWITCH PLUG J7 PIN 16 PLUG J7 PIN 11 WELD MODE 0 VDC CIRCUIT (LEAD 222) (LEAD 217) SELECTOR SWITCH IN CV WIRE POSITION. ENGINE RUNNING AT HIGH IDLE AND MODE SWITCH PLUG J7 PIN 16 PLUG J7 PIN 15 0 VDC WELD MODE CIRCUIT (LEAD 222) (LEAD 220) SELECTOR SWITCH IN STICK POSITION. ENGINE RUNNING AT HIGH IDLE AND MODE SWITCH PLUG J7 PIN 16...
Page 75 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.31 – Weld control board location CONTROL PANEL (VIEWED FROM THE REAR) WELD CONTROL BOARD Figure F.32 – Weld control board plug locations...
Page 76 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.33 – Weld control board lead locations 217 277 218 220 222...
Page 77: Output Rectifier Bridge Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual OUTPUT RECTIFIER BRIDGE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Three-Phase Output Rectifier Bridge is grounded or if there are any failed diode groups. MATERIALS NEEDED 7/16” Nutdriver 7/16” Open-End Wrench 1/2” Nutdriver 1/2” Open-End Wrench Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the output rectifier bridge. See Figure F.34. See Wiring Diagram. 5. Using a 7/16” nutdriver and 7/16” open-end wrench, remove the bolt, nut, lock washer and two flat washers securing leads W1 and W6 to the top terminal of the rectifier bridge. See Figure F.35. See Wiring Diagram. Label leads for reassembly. 6. Using a 7/16” nutdriver and 7/16” open-end wrench, remove the bolt, nut, lock washer and two flat washers securing leads W2 and W3 to the middle terminal of the rectifier bridge. See Figure F.35. See Wiring Diagram. Label leads for reassembly. 7. Using a 7/16” nutdriver and 7/16” open-end wrench, remove the bolt, nut, lock washer and two flat washers securing leads W4 and W5 to the bottom terminal of the rectifier bridge. See Figure F.35. See Wiring Diagram. Label leads for reassembly. 8.
Page 78 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 10. Using a volt/ohmmeter, check for grounds by placing one of the ohmmeter probes on a clean, unpainted metal surface of the machine. Place the probe on each of the five terminals of the rectifier bridge. See Figure F.35. See Wiring Diagram. The resistance should be very high, 500,00 (500K) ohms minimum. If the resistance reading is less than specified, the rectifier is grounded and should be replaced. 11.
Page 79 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Table F. 9 – Rectifier bridge diode tests OHMMETER OHMMETER READING (+) PROBE (–) PROBE EXPECTED READING FORWARD BIAS DC(+) (LOW RESISTANCE) FORWARD BIAS DC(+) (LOW RESISTANCE) FORWARD BIAS DC(+) (LOW RESISTANCE) FORWARD BIAS DC(–) (LOW RESISTANCE) FORWARD BIAS DC(–) (LOW RESISTANCE) FORWARD BIAS DC(–) (LOW RESISTANCE) REVERSE BIAS DC(–) (HIGH RESISTANCE) REVERSE BIAS DC(–) (HIGH RESISTANCE) REVERSE BIAS DC(–) (HIGH RESISTANCE) REVERSE BIAS DC(+) (HIGH RESISTANCE) REVERSE BIAS DC(+) (HIGH RESISTANCE) REVERSE BIAS DC(+)
Page 80 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.34 – Rectifier bridge location RECTIFIER BRIDGE POWER MODULE PANEL Figure F.35 – Rectifier bridge terminal locations NEGATIVE TERMINAL TOP TERMINAL (W1 & W6) MIDDLE TERMINAL (W2 & W3) BOTTOM TERMINAL (W4 & W5) POSITIVE TERMINAL...
Page 81: Flashing Voltage Test Procedure (Engine Not Running)
LINCOLN ELECTRIC Cross Country™ 300 Service Manual FLASHING VOLTAGE TEST PROCEDURE (ENGINE NOT RUNNING) 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test checks the Flashing Voltage with the engine stopped, by simulating a running condition. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Make sure the battery is fully charged and in good condition and the battery connections are clean and tight. 4. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch in to the ‘High Idle/Run’ position. See Figure F.36.
Page 82 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 14. Using a volt/ohmmeter, perform the tests outlined in Table F.10, at the following locations on the engine protection/idle control PC board. See Figures F.38 and F.39. See Wiring Diagram. 15. If battery voltage is present at leads 232, 232F but not present at lead 200, the PC board may be faulty. 16. If battery voltage is present at lead 232, but not at leads 232F or 200, check the engine protection wiring. See Wiring Diagram. 17. If battery voltage is not present at lead 232, check wiring per wiring diagram and check the Run/Stop switch. Also check the PC board chassis ground wire. 18. Turn off the engine and perform the Case Cover Replacement Procedure. Table F. 10 – Engine protection/idle pc board voltage tests TEST POINT TEST POINT EXPECTED READING POSITIVE METER PROBE NEGATIVE METER PROBE LEAD 232 (J31-1) LEAD 5 (B1) 12 VDC LEAD 232F (J31-2) LEAD 5 (B1)
Page 83 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.37 – Field capacitor terminal locations FIELD CAPACITOR Figure F.38 – Engine protection/idle PC board terminal locations IDLER/ENGINE SHUTDOWN...
Page 84 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.39 – Engine protection/idle PC board lead locations 232F...
Page 85: Rotor Resistance And Ground Test Procedure (Static)
LINCOLN ELECTRIC Cross Country™ 300 Service Manual ROTOR RESISTANCE AND GROUND TEST PROCEDURE (STATIC) 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Rotor Winding is open, shorted or grounded. MATERIALS NEEDED 7/16” Nutdriver Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Using a 7/16” nutdriver, label and disconnect leads 201 and 200B from the field capacitor. See Figure F.40. See Wiring Diagram. This will electrically isolate the rotor windings.
Page 86 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.40 – Field capacitor lead locations 200B FIELD CAPACITOR...
Page 87: Rotor Resistance And Ground Test Procedure (Dynamic)
LINCOLN ELECTRIC Cross Country™ 300 Service Manual ROTOR RESISTANCE AND GROUND TEST PROCEDURE (DYNAMIC) (Also referred to as flying resistance test) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test checks for faults in the Rotor Winding, while these windings are being stressed by the mechanical forces encountered during normal operation. MATERIALS NEEDED 7/16” Nutdriver Volt/Ohmmeter Wiring Diagram TEST PROCEDURE NOTE: This test requires that the brushes and slip rings are clean, in good condition and are properly seated. 1. Perform the Brush And Slip Ring Service Procedure. 2. Turn off the engine on the Cross Country 300 machine. 3. Perform the Case Cover Removal Procedure. 4. Using a 7/16” nutdriver, label and disconnect leads 201 and 200B from the field capacitor. See Figure F.41. See Wiring Diagram.
Page 88 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.41 – Field capacitor lead locations 200B FIELD CAPACITOR...
Page 89: Rotor Voltage Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual ROTOR VOLTAGE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Rotor Winding is operating at normal voltage. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Connect the voltmeter probes to the field capacitor terminals (201 & 200B). See Figure F.42. See Wiring Diagram. 4. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch into the ‘High Idle/Run’ position. See Figure F.43. Start the engine and allow the RPM to stabilize for about 15 to 30 seconds. 5. The meter should read 145-175 VDC. 6. Set the ‘Stop / (Auto Idle/Run) / (High Idle/Run)’ switch to the ‘Stop’ position. See Figure F.43. 7. If the meter reading is normal, this test is complete. 8. If the voltage measures zero or very near zero, the rotor flashing circuit may be faulty, the leads may be open or the rotor may be shorted. 9. Perform the Rotor Resistance And Ground Test Procedure (Static), the Rotor Resistance And Ground Test Procedure (Dynamic) and the Flashing Voltage Test Procedure.
Page 90 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 13. Check the field bridge rectifier and capacitor, also check the wiring and terminals connecting them. See Wiring Diagram. 14. Perform the Rotor Resistance And Ground Test Procedure (Static), the Rotor Resistance And Ground Test Procedure (Dynamic). 15. Perform the Stator Short Circuit And Ground Test Procedure. 16. When the stator short circuit and ground test has been completed, reconnect leads to the field bridge rectifier. All other stator leads should remain disconnected and isolated at this time. 17.
Page 91 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.43 – Stop / (auto idle/run) / (high idle/run) switch locations STOP / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH...
Page 92: Stator Short Circuit & Ground Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual STATOR SHORT CIRCUIT & GROUND TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if there are poor electrical connections, defective or grounded windings within the Stator. This test should be performed if flashing voltage is present at the Rotor Slip Rings, Rotor resistance, Field Bridge Rectifier, Field Capacitor and all associated wiring are proven to be good, but the Stator output voltage fails to build-up to normal levels or is too high in one or more (but not all) of the Windings. MATERIALS NEEDED Offset Phillips Screwdriver 7/16” Nutdriver 7/16” Open-End Wrench Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Capacitor Discharge Procedure. 3. Unplug anything that may be connected to auxiliary receptacles. 4. Label, disconnect and isolate the GND (lead 5A) from the neutral stud on the auxiliary receptacle panel. See Figure F.44. See Wiring Diagram.
Page 93 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 10. If any of the readings are less than 500,000 (500k) ohms, check for damaged, contaminated or shorted wiring or components between the test points and the stator winding. If necessary, disconnect and isolate the stator leads as close to the stator winding as possible. See Wiring Diagram. If the low resistance is determined to be between the windings within the stator, the stator is defective and should be replaced*.
Page 94 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.45 – Field bridge rectifier location CONTROL PANEL (VIEWED FROM THE REAR) FIELD BRIDGE RECTIFIER Figure F.46 – Rectifier bridge lead locations RECTIFIER BRIDGE POWER MODULE PANEL...
Page 95: Stator Voltage Test Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual STATOR VOLTAGE TEST PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This test will determine if the Stator is able to produce correct voltage from its winding. It will only yield meaningful data if the Engine high idle speed is correct (1860 to 1890 RPM), and approximately 160 VDC is present across the Rotor Slip Rings. MATERIALS NEEDED Volt/Ohmmeter Wiring Diagram TEST PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. NOTE: Voltage tests of the 120 and 120/240 VAC receptacles can be performed by placing the meter probes directly into the appropriate connection slots in the front of the receptacles rather than testing at the lead connections. If the meter probes are not long enough to make contact with the conductors inside the receptacles, test pins may be used. To test the 120 VAC auxiliary winding: 3.
Page 96 LINCOLN ELECTRIC Cross Country™ 300 Service Manual To test the three-phase weld winding: 10. Locate weld winding leads W1, W2 and W3 where they connect to the three-phase rectifier bridge. See Figure F.48. See Wiring Diagram. 11. Start the engine and run at high idle (1860 – 1890 RPM). 12. Using a volt/ohmmeter, measure the voltage from leads W1 to W2, W2 to W3 and W1 to W3. See Figure F.48. See Wiring Diagram. Normal reading is about 60 to 65 VAC. 13. If these voltage readings are not within the specified limits, check for loose connections or broken wires between the test points and the stator windings. If there are no wiring problems, the stator may be faulty. 14. If faulty, perform the Stator, Rotor And Shaft Assembly Removal And Replacement Procedure. 15. Perform the Case Cover Replacement Procedure. Figure F.47 – 120 / 240 VAC receptacle locations 240 VAC THREE PHASE RECEPTACLE 120 VAC AUXILIARY RECEPTACLES 120 VAC / 240 VAC SINGLE PHASE RECEPTACLE...
Page 97 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.48 – Rectifier bridge lead locations RECTIFIER BRIDGE POWER MODULE PANEL...
Page 98: Removal And Replacement Procedures
LINCOLN ELECTRIC Cross Country™ 300 Service Manual Removal And Replacement Procedures STOP / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Stop / (Auto Idle/Run) / (High Idle/Run) Switch. MATERIALS NEEDED Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Disconnect the lead from the negative battery terminal. See Wiring Diagram. 5. Carefully depress the tabs at the top and bottom of the of the rear side of the switch. See Figure F.49. 6. Carefully maneuver the switch thru the front of the control panel. 7. Label and disconnect leads 232A, 5R, 236A, 256 and 257 from terminals 8, 7, 2, 5, 3 and 6 of the switch. See Figure F.50. See Wiring Diagram. 8. Route wires back thru the control panel and remove the switch backing plate. 9. The switch can now be removed and replaced. REPLACEMENT PROCEDURE 1. Carefully position switch backing plate over the wiring for the switch and route the leads thru the front panel of the machine.
Page 99 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 4. Connect the lead to the negative battery terminal. 5. Perform the Case Cover Replacement Procedure. 6. Perform the Retest After Repair Procedure. Figure F.49 – Start / (auto idle/run) / (high idle/run) switch tab locations MOUNTING TABS START / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH (VIEWED FROM THE REAR)
Page 100 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.50 – Start / (auto idle/run) / (high idle/run) switch lead and terminal locations 232A 236A 232A 232B START / (AUTO IDLE/RUN) / (HIGH IDLE/RUN) SWITCH (VIEWED FROM THE REAR)
Page 101: Weld Mode Selector Switch Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual WELD MODE SELECTOR SWITCH REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Weld Mode Selector Switch. MATERIALS NEEDED Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Disconnect the lead from the negative battery terminal. See Wiring Diagram. 5. Carefully depress the tabs at the top and bottom of the of the rear side of the switch. See Figure F.51. 6. Carefully maneuver the switch thru the front of the control panel. 7. Label and disconnect leads 214, 217, 222A, 220 and 218 from terminals 1, 4, 2, 3, 6 and 5 of the switch. See Figure F.52. See Wiring Diagram.
Page 102 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.51 – Weld mode selector switch tab locations MOUNTING TABS WELD MODE SELECTOR SWITCH (VIEWED FROM THE REAR) Figure F.52 – Weld mode selector switch lead and terminal locations 222A 222A WELD MODE SELECTOR SWITCH (VIEWED FROM THE REAR)
Page 103: Field Bridge Rectifier Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual FIELD BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Field Bridge Rectifier. MATERIALS NEEDED 3/8” Nutdriver Dow Corning 340 Heat Sink Compound (Lincoln Part #T12837) Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect leads 200A, 200, 5H, 201A and 6A from the field bridge rectifier. See Figure F.53. See Wiring Diagram. 5. Using a 3/8” nutdriver, remove the nut, lock washer, flat washer and insulating washer securing the field bridge rectifier to the mounting post. See Figure F.54. 6. The field bridge rectifier can now be removed and replaced. REPLACEMENT PROCEDURE 1. Clean the mating surfaces of the control panel and the field bridge rectifier. 2. Apply a coating of Dow Corning 340 heat sink compound to the mating surface of the field bridge rectifier. 3. Carefully position the field bridge rectifier onto the mounting post. 4. Using a 3/8” nutdriver, attach the nut, lock washer, flat washer and insulating washer securing the field bridge rectifier to the mounting post.
Page 104 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.53 – Field bridge rectifier lead locations 201A 200A Figure F.54 – Field bridge rectifier mounting hardware locations FIELD BRIDGE RECTIFIER PLAIN WASHER LOCK WASHER MOUNTING POST HEX NUT INSULATING CONTROL PANEL WASHER...
Page 105: Chopper Module Pc Board Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual CHOPPER MODULE PC BOARD REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Chopper Module PC Board. MATERIALS NEEDED 7/16” Nutdriver 3/8” Nutdriver Wiring Diagram Penetrox Heat Sink Compound (Lincoln Part #T12837-1) REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect the quick-connects attaching leads 23 and 25 to terminals B7 and B8 of the chopper module board. See Figure F.55. See Wiring Diagram.
Page 106 LINCOLN ELECTRIC Cross Country™ 300 Service Manual REPLACEMENT PROCEDURE 1. Carefully position new chopper module PC board onto the power module panel. 2. Using a 3/8” Nutdriver, attach the four screws securing the chopper module PC board to the power module panel. 3. Apply a thin coating of Penetrox heat sink compound to terminals B1, B2, B3, B4, B5 and B6 of the chopper module PC board. 4. Using a 7/16” nutdriver, attach the bolt, lock washer and flat washer securing the W10 lead to terminal B6 of the chopper module PC board. See Wiring Diagram. 5. Using a 7/16” nutdriver, attach the bolt, lock washer and flat washer securing the POS lead to terminal B5 of the chopper module PC board. See Wiring Diagram. 6. Using a 7/16” nutdriver, attach the bolt, lock washer and flat washer securing the NEG lead to terminal B4 of the chopper module PC board. See Wiring Diagram. 7. Using a 7/16” nutdriver, attach the bolt, lock washer and flat washer securing leads W9 and 15 to terminal B3 of the chopper module PC board. See Wiring Diagram. 8. Using a 7/16” nutdriver, attach the bolt, lock washer and flat washer securing the POS lead and leads 13 and 13A to terminal B2 of the chopper module PC board. See Wiring Diagram. 9. Using a 7/16” nutdriver, attach the bolt, lock washer and flat washer securing the NEG lead and lead 14 to terminal B1 of the chopper module PC board. See Wiring Diagram. 10. Connect the quick-connects attaching leads 23 and 25 to terminals B7 and B8 of the chopper module board. See Wiring Diagram. 11. Perform the Case Cover Replacement Procedure. 12. Perform the Retest After Repair Procedure. 101...
Page 107 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.55 – Chopper module board terminal locations (LEAD 23) (LEAD 25) Figure F.56 – Chopper module board mounting screw locations MOUNTING SCREWS POWER MODULE PANEL 102...
Page 108: Choke Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual CHOKE REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Choke Assembly. MATERIALS NEEDED 3/4” Nutdriver 1/2” Nutdriver 1/2” Open-End Wrench Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Perform the Field Capacitor Removal Procedure. 5. Carefully slide the front panel away from the machine to gain access to the choke lead mounting screws.
Page 109 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 3. Using a 1/2” nutdriver and a 1/2” open-end wrench, attach the bolt, nut, lock washer and two flat washers securing the choke assembly to the choke bracket. 4. Using a 3/4” nutdriver, attach the bolt, lock washer and flat washer securing the choke lead to the rear side of the negative CV output terminal. See Wiring Diagram. 5. Using a 3/4” nutdriver, attach the bolt, lock washer and flat washer securing the choke lead to the rear side of the negative CC output terminal. See Wiring Diagram. 6. Replace any previously removed cable ties. 7. Perform the Field Capacitor Replacement Procedure. 8. Perform the Case Cover Replacement Procedure. 9. Perform the Retest After Repair Procedure. Figure F.57 – Choke lead connection points NEGATIVE (-) CC OUTPUT TERMINAL NEGATIVE (-) CV OUTPUT TERMINAL 104...
Page 110 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.58 – Choke assembly mounting hardware location MOUNTING HARDWARE CHOKE ASSEMBLY 105...
Page 111: Weld Control Board Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual WELD CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Weld Control Board. MATERIALS NEEDED 3/8” Nutdriver Phillips Screwdriver Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect plugs J1, J2, J3, J4, J5, J6 and J7 from the weld control board. See Figure F.59. See Wiring Diagram. 5. Using a 3/8” nutdriver, remove the four nuts securing the PC board mounting bracket to the control panel. See Figure F.60. 6. Carefully remove the weld control board and bracket assembly out of the machine. 7. Using a Phillips screwdriver, remove the four screws securing the weld control board to the PC board mounting bracket. See Figure F.61.
Page 112 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.59 – Weld control board plug locations Figure F.60 – PC board bracket mounting screw location MOUNTING NUTS CONTROL PANEL (VIEWED FROM THE REAR) 107...
Page 113 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.61 – Weld control board mounting screw location MOUNTING SCREWS PC BOARD MOUNTING BRACKET 108...
Page 114: Output Rectifier Bridge Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Output Rectifier Bridge. MATERIALS NEEDED 1/2” Nutdriver 1/2” Open-End Wrench 7/16” Nutdriver 7/16” Open-End Wrench Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Using a 1/2” nutdriver and a 1/2” open-end wrench, remove the bolt, nut, lock washer and two flat washers securing leads B1-NEG and B4-NEG to the negative terminal of the rectifier bridge. See Figure F.62. See Wiring Diagram.
Page 115 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 10. Using a 1/2” nutdriver, loosen the nut securing the bottom of the rectifier bridge to the power module panel. See Figure F.63. 11. The output rectifier bridge can now be removed and replaced. REPLACEMENT PROCEDURE 1. Carefully position new output rectifier bridge into the machine. 2. Using a 1/2” nutdriver, tighten the nut securing the bottom of the rectifier bridge to the power module panel. 3. Using a 1/2” nutdriver, tighten the nut securing the top of the rectifier bridge to the power module panel. 4. Using a 7/16” nutdriver and a 7/16” open-end wrench, attach the bolt, nut, lock washer and two flat washers securing leads W4 and W5 to the bottom terminal of the rectifier bridge. See Wiring Diagram. 5. Using a 7/16” nutdriver and a 7/16” open-end wrench, attach the bolt, nut, lock washer and two flat washers securing leads W2 and W3 to the middle terminal of the rectifier bridge. See Wiring Diagram. 6.
Page 116 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.62 – Rectifier bridge terminal and lead locations NEGATIVE TERMINAL (B1-NEG & B4-NEG) TOP TERMINAL (W1 & W6) MIDDLE TERMINAL (W2 & W3) BOTTOM TERMINAL (W4 & W5) POSITIVE TERMINAL (B2-POS & B5-POS) Figure F.63 – Rectifier bridge mounting nut locations RECTIFIER BRIDGE MOUNTING NUT MOUNTING NUT POWER MODULE PANEL 111...
Page 117: Field Capacitor Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual FIELD CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Field Capacitor. MATERIALS NEEDED 3/8” Nutdriver 7/16” Nutdriver 1/2” Nutdriver 3/8” Socket With An Extension Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Perform the Fuel Tank Removal Procedure. 5. Using a 3/8” nutdriver, remove the two screws securing the output stud cover above the field capacitor. See Figure F.64.
Page 118 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 12. The field capacitor can now be removed and replaced. REPLACEMENT PROCEDURE 1. Carefully position the new field capacitor into the capacitor bracket. 2. Using a 3/8” socket with an extension, tighten the screw securing the capacitor bracket to the fan guard. 3. Carefully position the front panel onto the machine. 4. Using a 1/2” nutdriver, attach the six screws securing the front panel assembly to the machine. 5. Using a 7/16” nutdriver, attach the nut, lock washer and flat washer securing leads 200B and 200A to the positive terminal of the field capacitor. See Wiring Diagram. 6. Using a 7/16” nutdriver, remove the nut, lock washer and flat washer securing leads 201 and 201A to the negative terminal of the field capacitor. See Wiring Diagram. 7. Using a 3/8” nutdriver, attach the two screws securing the output stud cover above the field capacitor. 8. Perform the Fuel Tank Replacement Procedure. 9. Perform the Case Cover Replacement Procedure. 10. Perform the Retest After Repair Procedure. Figure F.64 – Output stud cover location OUTPUT COVER MOUNTING SCREW (2) 113...
Page 119 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.65 – Field capacitor lead locations 200B FIELD CAPACITOR Figure F.66 – Front panel mounting screw locations MOUNTING SCREWS (6 TOTAL) 114...
Page 120: Brush And Brush Holder Assembly Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual BRUSH AND BRUSH HOLDER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Brush And Brush Holder Assembly. MATERIALS NEEDED 3/8” Nutdriver 5/8” Nutdriver Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Using a 3/8” nutdriver, remove the two screws securing the brush holder bracket to the machine base. See Figure F.67.
Page 121 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 5. Using a 3/8” nutdriver, attach the two screws securing the brush holder bracket to the machine base. 6. Perform the Case Cover Replacement Procedure. 7. Perform the Retest After Repair Procedure. Figure F.67 – Brush holder bracket mounting screw locations BRUSH & BRUSH HOLDER ASSEMBLY MOUNTING SCREWS (2) 116...
Page 122 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.68 – Brush holder lead locations LEAD 201 LEAD 200B Figure F.69 – Brush holder mounting screw locations MOUNTING SCREWS BRUSH HOLDER BRACKET 117...
Page 123: Engine Protection / Idle Control Pc Board Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual ENGINE PROTECTION / IDLE CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Engine Protection / Idle Control PC Board. MATERIALS NEEDED 3/8” Nutdriver Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect leads 55, 271 and 227 from terminals B1, B2 and B3 of the engine protection / idle control PC board. See Figure F.70. See Wiring Diagram. 5. Label and disconnect plugs J31, J32 and J33 from the engine protection / idle control PC board. See Figure F.70. See Wiring Diagram. 6. Using a 3/8” nutdriver, remove the four nuts securing the engine protection / idle control PC board to the mounting posts. See Figure F.71. 7. The engine protection / idle control PC board can now be removed and replaced. REPLACEMENT PROCEDURE 1. Carefully position new engine protection / idle control PC board onto the mounting posts. 2. Using a 3/8” nutdriver, attach the four nuts securing the engine protection / idle control PC board to the mounting posts. 3.
Page 124 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 6. Perform the Retest After Repair Procedure. Figure F.70 – Engine protection / idle control PC board lead and plug locations IDLER/ENGINE SHUTDOWN J33 J32 Figure F.71 – Engine protection / idle control PC board mounting nut locations MOUNTING NUTS IDLER/ENGINE SHUTDOWN MOUNTING NUTS 119...
Page 125: Fuel Tank Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual FUEL TANK REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Fuel Tank Assembly. MATERIALS NEEDED Fuel Siphon Container For Fuel Storage Slotted Screwdriver 3/8” Nutdriver Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Perform the Chopper Module PC Board Removal Procedure. 5. Perform the Output Rectifier Bridge Removal Procedure. 6. Perform the Engine Protection / Idle Control PC Board Removal Procedure. 7. Label and disconnect the quick-connect terminals from leads 229 and 5J to the fuel level sensor. See Figure F.72. See Wiring Diagram.
Page 126 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 14. Using a 3/8” nutdriver, remove the two screws securing the power panel to the breaker and relay panel. See Figure F.74. 15. Label and disconnect leads 13A and 15 from the resistor (R4). See Figure F.75. See Wiring Diagram. 16. Carefully remove the breaker and relay panel from the machine. 17. Carefully remove the power panel from the machine. 18. The fuel tank can now be removed and replaced. REPLACEMENT PROCEDURE 1. Carefully position new fuel tank into the machine. 2. Carefully position the power panel into the machine. 3. Carefully position the breaker and relay panel onto the support rail. 4. Connect leads 13A and 15 to resistor (R4). See Wiring Diagram. 5. Using a 3/8” nutdriver, attach the two screws securing the power panel to the breaker and relay panel. 6. Using a 3/8” nutdriver, attach the two screws securing the power panel to the support rail. 7. Using a 3/8” nutdriver, attach the two screws securing the breaker and relay panel to the support rail. 8. Using a 3/8” nutdriver, attach the two screws securing the breaker and relay panel to the lift bale frame. 9. Using a slotted screwdriver, tighten the hose clamp securing the fuel line to the top of the fuel tank. 10. Using a slotted screwdriver, tighten the hose clamp securing the fuel line to the bottom of the fuel tank. 11. Connect the quick-connect terminals to leads 229 and 5J to the fuel level sensor. See Wiring Diagram.
Page 127 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.72 – Fuel level sensor lead locations LEADS 229 & 5J FUEL LEVEL SENSOR (POWER PANEL NOT SHOWN) Figure F.73 – Fuel tank fuel line connection locations TOP FUEL LINE CONNECTION BOTTOM FUEL LINE CONNECTION FUEL TANK (VIEWED FROM THE SIDE) 122...
Page 128 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.74 – Power panel and breaker and relay panel mounting hardware location BREAKER & RELAY PANEL POWER PANEL Figure F.75 – Resistor (R4) location RESISTOR (R4) POWER MODULE PANEL 123...
Page 129: Stator, Rotor And Shaft Assembly Removal And Replacement Procedure
LINCOLN ELECTRIC Cross Country™ 300 Service Manual STATOR, ROTOR AND SHAFT ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 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 electrical 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Stator, Rotor and Shaft Assembly. MATERIALS NEEDED 3/8” Nutdriver 1/2” Nutdriver 3/4” Nutdriver Slotted Screwdriver 7/16” Nutdriver Wood Or Steel Blocking Large Adjustable Wrench Two 3/4” Deep Well Sockets Hoist And Appropriate Rigging 9/16” Nutdriver Gear Puller Wiring Diagram REMOVAL PROCEDURE 1. Turn off the engine on the Cross Country 300 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Perform the Fuel Tank Removal Procedure. 5. Using a 3/8” nutdriver, remove the two screws securing the fuel tank tray to the lift bail frame. See Figure F.76. 6. Carefully route wiring thru the fuel tank tray, cutting cable ties as necessary. Remove the fuel tank tray.
Page 130 LINCOLN ELECTRIC Cross Country™ 300 Service Manual 8. Using a 1/2” nutdriver, remove the screws securing the support rails to the lift bail frame. See Figure F.76. 9. Using a 3/4” nutdriver, remove the bolt, lock washer and flat washer securing leads to the positive output stud. See Wiring Diagram. 10. Using a slotted screwdriver, loosen the screw securing leads 3, 4 and 6 to circuit breaker (CB1). See Figure F.77. See Wiring Diagram. Take note of the direction and number of turns around the toroid by leads 3 and 6 for reassembly. 11. Label and disconnect lead 6A from the field bridge rectifier. See Figure F.78. See Wiring Diagram. 12. Using a 3/8” nutdriver, remove the nut, lock washer and flat washer securing lead 5A to the neutral stud on the auxiliary power receptacle panel. See Figure F.78. See Wiring Diagram. Label and disconnect lead 5A.
Page 131 LINCOLN ELECTRIC Cross Country™ 300 Service Manual REPLACEMENT PROCEDURE 1. Using a hoist and appropriate rigging, mate the rotor and shaft assembly with the engine. Using a 1/2” nutdriver, attach the six bolts, lock washers and flat washers securing the six disc clamping bars to the engine assembly. 3. Using a hoist and appropriate rigging, position the stator frame assembly into the machine and mate it with the engine. 4. Using a 9/16” nutdriver, attach the eight screws and lock washers securing the stator frame to the engine. 5. Using a hoist and appropriate rigging, position the stator frame onto its mounting point. 6. Using two 3/4” deep well sockets, attach the two bolts, nuts, flat washers and spacers securing the stator frame to the base. 7. Carefully slide the fan onto the rotor shaft. 8. Place a piece of wood blocking between the fan blades to prevent the fan blades from rotating. 9. Using a large adjustable wrench, attach the bolt and lock washer securing the fan to the rotor shaft. 10. Carefully slide the fan guard into the machine. 11. Using a 3/8” nutdriver, attach the four screws securing the fan guard to the base. 12. Using a 7/16” nutdriver, attach the four nuts, lock washers and flat washers securing the choke bracket to the base of the machine. 13. Perform the Choke Replacement Procedure. 14. Carefully position the front panel in front of the machine. 15. Using a 3/8” nutdriver, attach the nut, lock washer and flat washer securing lead 5 to the right ground stud on the upper control panel. See Wiring Diagram. 16. Using a 3/8” nutdriver, attach the nut, lock washer and flat washer securing lead 5A to the neutral stud on the auxiliary power receptacle panel. See Wiring Diagram.
Page 132 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.76 – Support rail and lit bail frame locations LIFT BAIL FRAME SUPPORT RAILS Figure F.77 – Circuit breaker (CB1) and neutral stud lead locations GND-L GND-C CIRCUIT BREAKER (CB1) GND-E GND-D 206B GND-J 208B NEUTRAL STUD AUXILIARY POWER RECEPTACLE PANEL (VIEWED FROM THE REAR) 127...
Page 133 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.78 – Field bridge rectifier and ground stud lead locations FIELD BRIDGE RECTIFIER CONTROL PANEL GROUND STUD (VIEWED FROM THE REAR) (LEAD 5) Figure F.79 – Fan guard and choke bracket locations FAN GUARD CHOKE BRACKET 128...
Page 134 LINCOLN ELECTRIC Cross Country™ 300 Service Manual Figure F.80 – Stator frame and rotor mounting hardware locations ROTOR AND SHAFT ASSEMBLY STATOR FRAME DISC CLAMPING BARS (6) LOCK WASHER MOUNTING NUT STATOR FRAME MOUNTING HARDWARE 129...
Page 135: Retest After Repair
LINCOLN ELECTRIC Cross Country™ 300 Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. ENGINE OUTPUT MODE NO LOAD RPM LOAD RPM LOW IDLE 1300 - 1400 HIGH IDLE 1850 - 1890 1800 WELDER DC OUTPUT FINE CURRENT COARSE CURRENT OPEN CIRCUIT LOAD VOLTS LOAD AMPS CONTROL CONTROL VOLTAGE MAXIMUM MAXIMUM 55 – 60 300 130...

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