Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - TABLE OF CONTENTS
vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1I...
Page 8 - vii
vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1Kubota Engine Maintenance Schedul...
Page 9 - INSTALLATION; INPUT - DIESEL ENGINE
A-1 INSTALLATION RANGER 300 D AND 300 DLX A-1 TECHNICAL SPECIFICATIONS - Ranger 300 D (K1522-1), Ranger 300 DLX (K1522-2) Make/Model Description Speed (RPM) Displacement Starting Capacities System Kubota 3 cylinder High Idle 3700 54.9 cu. in 12VDC battery Fuel: 10 gal. DH905 26.0 HP @ Low Idle 2150 ...
Page 10 - Store the machine in a cool, dry place when it is not; CANNOT; CAUTION
A-2 INSTALLATION RANGER 300 D AND 300 DLX A-2 SAFETY PRECAUTIONS Only qualified personnel should install,use, or service this equipment. LOCATION AND VENTILATION Whenever you use the RANGER 300, be sure thatclean cooling air can flow through the machine’sdiesel engine and the machine case. Avoid dus...
Page 11 - HIGH ALTITUDE OPERATION; Be sure machine is stable when lifting.; PRE-OPERATION ENGINE SERVICE; OIL
A-3 INSTALLATION RANGER 300 D AND 300 DLX A-3 HIGH ALTITUDE OPERATION It may be necessary to de-rate the welder output athigher altitudes. Derate the welder output 0.4% forevery 100 ft. (30 m) above 500 ft. (150 m). Someengine adjustment may be required above 5,000 ft.(1,500 m). Contact a Kubota Ser...
Page 13 - ELECTRICAL CONNECTIONS; MACHINE GROUNDING; CABLE SIZE AND LENGTH; CABLE INSTALLATION; TOTAL COMBINED LENGTH OF; Cable Length
A-5 INSTALLATION RANGER 300 D AND 300 DLX A-5 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of thismanual for location of the 115 and 230 volt recepta-c l e s , w e l d o u t p u t t e r m i n a l s , c i r c u i t b r e a k e r s a n dground stud. MACHINE GROUNDING Because the RANG...
Page 14 - CIRCUIT BREAKERS; PREMISES WIRING
A-6 INSTALLATION RANGER 300 D AND 300 DLX A-6 A U X I L I A R Y P O W E R R E C E P TA C L E S ,PLUGS, AND HAND-HELD EQUIPMENT The control panel of the RANGER 300 features threeauxiliary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) recepta- cles. • One 50 amp 120/...
Page 15 - CONNECTION OF RANGER 300 TO PREMISES WIRING
A-7 INSTALLATION RANGER 300 D AND 300 DLX A-7 C o n n e c t i o n o f R a n g e r 3 0 0 t o p r e m i s e s w i r i n gmust be done by a licensed electrician and mustcomply with the National Electrical Code and allother applicable electrical codes. 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER ...
Page 16 - OPERATION; GENERAL DESCRIPTION
B-1 OPERATION RANGER 300 D AND 300 DLX B-1 GENERAL DESCRIPTION The RANGER 300 is a diesel-engine driven, multi-process AC and DC arc welder and AC power genera-tor for commercial and residential applications. As agenerator it can supply up to 12,000 continuous wattsof 120/240 volt, 60 Hz, single-pha...
Page 17 - RECOMMENDED APPLICATIONS; WELDER; LIMITATIONS; n o t r e c o m m e n d e d; ADDITIONAL SAFETY PRECAUTIONS
B-2 OPERATION B-2 ADDITIONAL FEATURES RANGER 300 D (K1522-1): • One constant voltage wire-feed welding range - 80 to 200 amps. The wire feed setting permits the Ranger 300D to beused with the LN-25 Wire Feeder and .035, .045 or.068 NR®-211-MP Innershield electrodes. LimitedMIG (GMAW) welding can als...
Page 18 - OUTPUT PANEL CONTROLS
B-3 OPERATION B-3 FIGURE B.1 OUTPUT PANEL CONTROLS WELDER/GENERATOR CONTROLS See Figure B.1 for the location of the following features: 1. OUTPUT RANGE SELECTOR: Selects continuous current output for constant current stick or TIG appli-cations (blue settings) and constant voltage wire feedapplicatio...
Page 19 - DIESEL ENGINE CONTROLS; ENGINE CONTROLS
B-4 OPERATION B-4 FIGURE B.2 DIESEL ENGINE CONTROLS ENGINE CONTROLS See Figure B.2 for the location of the following fea-tures: 1. GLOW PLUG PUSH-BUTTON: Activates glow plugs to preheat engine for starting. 2. IDLER CONTROL SWITCH: The idler switch has two positions. “HIGH” and “AUTO”. When in “HIGH...
Page 20 - ENGINE OPERATION
B-5 OPERATION B-5 7. WATER TEMPERATURE LIGHT: Remains off under normal operating temperatures. Ifthe red light turns on, the engine protection systemwill stop the engine. The light will remain on whenthe engine is over temperature and the “Engine”switch is in the “ON” position (engine not running)bu...
Page 21 - USE DIESEL FUEL ONLY; STARTING THE ENGINE; Ambient Temperature
B-6 OPERATION B-6 NOTE: DO NOT allow the RANGER 300 to run out offuel. If it does, you will have to bleed the injec-tion system. See the Maintenance section ofthis manual and the Engine Operators Manualfor instructions on bleeding the fuel injectionsystem. USE DIESEL FUEL ONLY Purchase diesel fuel i...
Page 22 - TYPICAL RANGER 300 FUEL CONSUMPTION; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n
B-7 OPERATION B-7 BREAK-IN PERIOD Any engine will use a small amount of oil during its“ b r e a k - i n ” p e r i o d . F o r t h e d i e s e l e n g i n e o n t h eRANGER 300, break-in is about 50 running hours. C h e c k t h e o i l e v e r y f o u r h o u r s d u r i n g b r e a k - i n .Change t...
Page 23 - WELDING CIRCUIT CONNECTIONS
B-8 OPERATION B-8 AC/DC STICK (CONSTANT CURRENT)WELDING 1. Remove the flange nuts from output terminals and place the work and electrode welding cables overthe terminals. See Figure B.4. Replace and tight-en the flange nuts securely. Be sure the connec-tions are tight. 2. Select the appropriate elec...
Page 24 - AFTER YOU FINISH WELDING:; AC TIG WELDING; DO NOT
B-9 OPERATION B-9 A C / D C T I G ( C O N S TA N T C U R R E N T )WELDING 1. Connect the K930-1 TIG Module to the RANGER 300. Follow the installation instructions provided with the kit. 2. Refer to the instruction manual with the TIG module (IM 528) for operation with a RANGER 300. And propermachine...
Page 26 - SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS; SUMMARY OF WELDING PROCESSES FOR RANGER 300 DLX
B-11 OPERATION B-11 RANGER 300 D AND 300 DLX SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS TABLE B.3 SUMMARY OF WELDING PROCESSES FOR RANGER 300 DLX CONTROL CABLE & DIAGRAM IDLE MODE OUTPUT CONTROL SWITCH WELDING TERMINALS SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC...
Page 27 - SUMMARY OF WELDING PROCESSES FOR RANGER 300 D
B-12 OPERATION B-12 RANGER 300 D AND 300 DLX SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS TABLE B.4 SUMMARY OF WELDING PROCESSES FOR RANGER 300 D CONTROL CABLE & DIAGRAM IDLE MODE OUTPUT CONTROL SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CCCARBON ARCGOUGING - CC TIG ...
Page 28 - AUXILIARY POWER; NONE; RANGER 300 SIMULTANEOUS WELDING AND POWER LOADS
B-13 OPERATION B-13 AUXILIARY POWER The Ranger 300 can provide up to 12,000 watts of120/240 volts AC, Single phase 60 HZ power for con-tinuous use. The front of the machine includes threereceptacles for connecting AC power Plugs, one 50amp 120/240 volt NEMA 14-50R receptacle and two15 amp 120 volt N...
Page 29 - V O LTA G E
B-14 OPERATION B-14 1 2 0 / 2 4 0 V O LT D U A L V O LTA G E RECEPTACLE The 120/240 volt receptacle can supply up to 50 ampsof 240 volt power to a two wire circuit, up to 50 ampsof 120 volt power from each side of the three wire cir-cuit, (up to 100 amps total). Do not connect the 115volt circuits i...
Page 30 - ACCESSORIES
C-1 ACCESSORIES C-1 GENERAL OPTIONS / ACCESSORIES The following options/accessories are available foryour RANGER 300 from your local Lincoln Distributor. K953-1 Two-Wheeled Trailer - For in-plant or yard towing of the RANGER 300. Suitable for road towingwith optional Fender and Light Kit. Load capac...
Page 31 - - The recommended wire feeder
C-2 ACCESSORIES C-2 SEMIAUTOMATIC FCAW AND MIGWELDING (RANGER 300 D) OPTIONS / ACCESSORIES LN-25 Wire Feeder - The recommended wire feeder for use with the Ranger 300 D is the K449 LN-25.This portable unit provides CC/CV for flux-cored arcwelding (FCAW) and metal inert gas welding (MIG).for remote c...
Page 32 - MAINTENANCE
D-1 MAINTENANCE D-1 KUBOTA ENGINE MAINTENANCESCHEDULE TABLE D.1 (1) Replace air filter element after 600 hours of operation or sooner under dusty operating conditions. (2) If the engine is operated under heavy load, in high ambient temperatures, or under dusty conditions, change the oil and oil filt...
Page 33 - BE SURE TO MAINTAIN THE OIL LEVEL; OIL COMPONENT LOCATIONS
D-2 MAINTENANCE D-2 ROUTINE AND PERIODIC ENGINEMAINTENANCE To prevent the engine from accidentally starting, dis-connect the negative battery cable before servicingthe engine. ------------------------------------------------------------------------ See Table D.1 for a summary of maintenance inter-va...
Page 34 - FUEL; AIR VENT PLUG; FUEL BLEEDING COMPONENT LOCATIONS
D-3 MAINTENANCE D-3 FUEL At the end of each day ’ s use, refill the fuel tank to minimize moisture condensation and dirt contami-nation in the fuel line. Do not overfill; leave room forthe fuel to expand. Use only fresh, No. 2 grade DIESEL fuel. Do not usekerosene. See the Kubota Engine Operator's M...
Page 35 - BATTERY MAINTENANCE
D-4 MAINTENANCE D-4 Always premix the antifreeze and clean tap waterbefore adding to the radiator or the overflow tank. It isvery important that a precise 50/50 solution be usedwith this engine year round. This gives proper coolingduring hot weather and freezing protection to -34 ° F (- 37 ° C). Coo...
Page 36 - CHARGING THE BATTERY; STORAGE; Store the RANGER 300 in clean, dry protected areas.; CLEANING
D-5 MAINTENANCE D-5 CHARGING THE BATTERY When you charge, jump, replace, or otherwise con-nect battery cables to the battery, be sure the polarityis correct. Improper polarity can damage the chargingcircuit. The RANGER 300 positive (+) battery termi-nal has a red terminal cover. If you need to charg...
Page 37 - TROUBLESHOOTING; Look under the column labeled; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 RANGER 300 D AND 300 DLX If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION WARNING ELE...
Page 38 - PROBLEMS
E-2 TROUBLESHOOTING E-2 RANGER 300 D AND 300 DLX Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical trou...
Page 41 - CONNECTION DIAGRAMS
F-1 CONNECTION DIAGRAMS F-1 RANGER 300 D AND 300 DLX (RANGER 300 DLX ONLY) 6 PIN AMPHENOL TO WORK 14 PINAMPHENOL LN-25 N.E. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED. N.C. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION. ...
Page 47 - WIRING DIAGRAM; ram for a particular code is pasted inside
F-7 WIRING DIAGRAM F-7 RANGER 300 D AND 300 DLX 5A 221 INDICATES JACK NUMBER 5 1 CAPACITORS 236A OUTPUT 4 RECTIFIER 5A _ C2 (-) A2 + 245 DC+ 232 R4 R3 W7 224 224C C1 3B WHITE 3F 11 3A 15A BLACK BLACK 12 BLACK BLACK WHITE 120/240V J8 BLACK BLACK BLACK BLACK BLACK BLACK CB7 3D (15AMP) SWITCH A1 210 W1...
Page 50 - DIMENSION PRINT; DIMENSION PRINT - RANGER 300
F-10 DIMENSION PRINT F-10 RANGER 300 D AND 300 DLX 30.50 6-20-97 13.00 33.81 60.18 13.85 18.48 6.75 34.86 20.25 12.36 60.50 17.37 18.00 11.98 6.26 M18399 L 18.00 31.00 46.08 C RADIATOR CAP CENTER OF GRAVITY .24 2.70 9.96 24.04 24.75 DIMENSION PRINT - RANGER 300
Page 51 - NOTES
Page 53 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P...
Page 54 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...