Lincoln Electric SVM148-B User Manual
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SVM148-B
February, 2004
For use with machine code numbers 10399 thru 10850
RANGER 300 D and 300 DLX
TM
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SERVICE MANUAL
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2004 Lincoln Global Inc.
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SAFETY
i i
RANGER 300 D AND 300 DLX
FOR ENGINE
powered 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.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. AFree copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
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SAFETY
ii ii
RANGER 300 D AND 300 DLX
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
iii iii
RANGER 300 D AND 300 DLX
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
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SAFETY
iv iv
RANGER 300 D AND 300 DLX
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
NOTES
RANGER 300 D AND 300 DLX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi vi
RANGER 300 D AND 300 DLX
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications .............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation .............................................................................................................A-3
Pre-operation Engine Service .....................................................................................................A-4
High Frequency Generation for TIG Applications.......................................................................A-6
Remote Control...........................................................................................................................A-6
Welding Terminals .......................................................................................................................A-6
Electrical Output Connections....................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Design Features..........................................................................................................................B-3
Recommended Applications ......................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings.................................................................................................................B-5
Engine Operation ........................................................................................................................B-9
Welding Operation ....................................................................................................................B-11
Auxiliary Power .........................................................................................................................B-17
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual................................................................................................................................P-290
RETURN TO MAIN INDEX
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TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1 Section A-1
RANGER 300 D AND 300 DLX
Installation .............................................................................................................................Section A
Technical Specifications .............................................................................................................A-2
Input - Diesel Engine ............................................................................................................A-2
Rated Output - Welder .........................................................................................................A-2
Output - Welder and Generator ...........................................................................................A-2
Physical Dimensions ............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation .............................................................................................................A-3
Storing ..................................................................................................................................A-3
Stacking................................................................................................................................A-3
Tilting ....................................................................................................................................A-3
High Altitude Operation........................................................................................................A-4
Towing ..................................................................................................................................A-4
Lifting....................................................................................................................................A-4
Additional Safety Precautions ..............................................................................................A-4
Pre-operation Engine Service .....................................................................................................A-4
Oil .........................................................................................................................................A-4
Fuel.......................................................................................................................................A-5
Engine Coolant .....................................................................................................................A-5
Battery Connections.............................................................................................................A-5
Exhaust Deflector .................................................................................................................A-5
Spark Arrester ......................................................................................................................A-5
High Frequency Generation for TIG Applications.......................................................................A-6
Remote Control...........................................................................................................................A-6
Welding Terminals .......................................................................................................................A-6
Electrical Connections ................................................................................................................A-6
Machine Grounding..............................................................................................................A-6
Welding Cable Connections.................................................................................................A-7
Cable Size and Length...................................................................................................A-7
Cable Installation ...........................................................................................................A-7
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment ........................................A-7
Circuit Breakers....................................................................................................................A-7
Premises Wiring....................................................................................................................A-8
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INSTALLATION
A-2 A-2
RANGER 300 D AND 300 DLX
TECHNICAL SPECIFICATIONS - RANGER 300 D AND 300 DLX
INPUT - DIESEL ENGINE
Starting
Manufacturer Description Speed Displacement System Capacities
KUBOTA 3 cyl., 3600 RPM 54.9 cu. in. Electric Fuel: 10 gal. (38 L)
D905B-2 liquid-cooled Full load (898 cc) 12 VDC
diesel battery Oil: 5.4 qt. (5.1 L)
26 HP @ 3700 RPM
3600 RPM High idle
Cooling system:
2150 RPM 5.7 qts. (5.4 L)
Low idle
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 300 DC Constant Current 25
100% Duty Cycle 300 AC Constant Current 25
100% Duty Cycle 200 DC Constant Voltage (300 D) 20
60%
(1)
300 DC Constant Voltage (300 DLX) 30
100% 280 DC Constant Voltage (300 DLX) 30
OUTPUT - WELDER AND GENERATOR
Max. Open Auxiliary Power for
Welding Ranges Circuit Voltage Auxiliary Power
(2)
Wire Feeders
40 - 300 Amps 80 Volts RMS 12,000 Continuous Watts 42V, 60 Hz, 8 Amps
(3)
Constant Current @ 3700 RPM 60 Hz, 120/240 VAC
100% Duty Cycle 120V, 60 Hz, 8 Amps
(3)
PHYSICAL DIMENSIONS
Height Width Depth Weight
37.38 in. 24.75 in. 60.50 in. 1093 lbs. (300 D)
949.4 mm 628.7 mm 1528.6 mm 1133 lbs. (300 DLX)
480.8 kg (300 D)
499.0 kg (300 DLX)
(1)
Duty cycle is based on a 10-minute period. The machine can be loaded to 300 amps for 6 minutes out of every 10-minute period.
(2)
Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ±10% at all loads up to rated capacity.
When welding, available auxiliary power will be reduced.
(3)
Ranger 300 DLX only.
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual
supplied with your welder. It includes important safety
precautions, detailed engine starting, operating and
maintenance instructions, and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
See additional warning information at front of this
operator’s manual.
Only qualified personnel should install, use, or service this equipment.
LOCATION AND VENTILATION
Whenever you use the RANGER 300, be sure that
clean cooling air can flow through the machine’s diesel
engine and the machine case. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the engine end of the machine
anywhere near hot engine exhaust from another
machine or closer than two feet from a wall. And of
course, make sure that engine exhaust is ventilated to
an open, outside area.
The RANGER 300 may be used outdoors. Do not set
the machine in puddles or otherwise submerge it in
water. Such practices pose safety hazards and cause
improper operation and corrosion of parts.
Always operate the RANGER 300 with the case roof on
and all machine components completely assembled.
This will protect you from the dangers of moving parts,
hot metal surfaces, and live electrical devices.
STORING
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the Maintenance section of
this manual for details on changing oil.
3. If you are storing the machine for more than 30
days, drain the coolant from the radiator. Open the
cock at the bottom of the radiator and remove the
pressure cap so that the coolant drains completely.
Attach a note that says “NO WATER” on the radiator.
4. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
5. If the engine is not used for a long period of time,
every two to three months fill the radiator and run
the engine for about five minutes to keep it free from
rust.
STACKING
RANGER 300 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The diesel engine is designed to run in a level position
for best performance. It can operate at an angle, but
this should never be more than 20 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level at the
FULL mark as it would be in its normal level condition.
Also, fuel capacity will be a little less at an angle.
INSTALLATION
A-3 A-3
RANGER 300 D AND 300 DLX
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WARNING
HIGH ALTITUDE OPERATION
It may be necessary to de-rate the welder output at
higher altitudes. Derate the welder output 0.4% for
every 100 ft. (30 m) above 500 ft. (150 m). Some
engine adjustment may be required above 5,000 ft.
(1,500 m). Contact a Kubota Service Representative.
TOWING
The recommended trailer for use with this equipment
for road, in-plant, and yard towing by a vehicle1is
Lincoln’s K-953-1. If the user adapts a non-Lincoln
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:
1. Design capacity of the trailer vs. weight of the
Lincoln equipment and likely additional attachments.
2. Proper support of and attachment to the base of
the welding equipment so that there will be no
undo stress to the trailer’s framework.
3. Proper alignment of the equipment on the trailer to
insure stability side-to-side and front-to-back when
it is being moved and when standing by itself.
4. Typical conditions of use, such as travel speed,
roughness of the surface on which the trailer will be
operated, and environmental conditions.
5. Proper preventative maintenance of the trailer.
6. Conformance with federal, state, and local laws.
1
1
Consult applicable federal, state, and local laws regarding specific
requirements for use on public highways.
LIFTING
The RANGER 300 weighs approximately 1150 lbs/522
kg. A lift bail is mounted to the machine frame and
should always be used when lifting the machine.
ADDITIONAL SAFETY PRECAUTIONS
FALLING EQUIPMENT can cause
injury.
• Do not lift this machine using lift bail
if it is equipped with a heavy accessory such as trailer or gas cylinder.
• Lift only with equipment of adequate lifting
capacity.
• Be sure machine is stable when lifting.
PRE-OPERATION ENGINE SERVICE
READ and UNDERSTAND the engine operating and
maintenance instructions supplied with this machine.
• Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
The RANGER 300 is shipped with the engine filled with
SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE
YOU START THE ENGINE. If it is not full, add enough
oil to fill it to the full mark.
Always use oil that is rated for diesel engine service
(API classification of CD/CE).
For more information on oil viscosity and service conditions, see the Maintenance section of this manual
and the engine Operator’s Manual.
INSTALLATION
A-4 A-4
RANGER 300 D AND 300 DLX
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WARNING
CAUTION
WARNING
FUEL
Fill the fuel tank with clean No. 2, diesel fuel only. Do
not fill to the top of the filler neck to allow room for
expansion.
The RANGER 300 has a 10 gallon (38 liter) fuel tank
with a top fill and fuel gauge mounted on the control
panel. See the Operation and Maintenance sections
of this manual for more details about fuel.
ENGINE COOLANT
HOT COOLANT can burn skin.
• Do not remove cap if radiator is hot.
The welder is shipped with the engine and radiator
filled with a 50% mixture of ethylene glycol and water.
The recovery bottle should be partially filled. See the
Maintenance section and the engine Operator’s
Manual for more information on coolant.
BATTERY CONNECTIONS
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and connect to
new battery last.
• CONNECTING A BATTERY CHARGER — remove
battery from welder by disconnecting negative
cable first, then positive cable and battery clamp.
When reinstalling, connect negative cable last.
Keep well ventilated.
• USING A BOOSTER — connect positive lead to
battery first then connect negative lead to negative
battery lead at engine foot.
BATTERY ACID can burn eyes and skin.
•Wear gloves and eye protection and
be careful when working near battery.
• Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
The RANGER 300 is shipped with the negative battery
cable disconnected. Before you operate the machine,
make sure the Engine Switch is in the OFF position
and attach the disconnected cable securely to the
negative (-) battery terminal.
Remove the insulating cap from the negative battery
terminal. Replace and tighten the negative battery
cable terminal.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be sure to use the correct
polarity when charging the battery.
EXHAUST DEFLECTOR
Shut off the machine and allow the muffler to cool
before touching the muffler.
The RANGER 300 is shipped with the exhaust deflector detached. Install it on the muffler outlet using the
clamp supplied. Rotate the deflector to the desired
direction before tightening the clamp.
SPARK ARRESTER
Diesel engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
Standard muffler and deflectors (like the ones included with the RANGER 300) do not act as spark
arresters. When local laws require it, a spark arrester
must be installed on the machine and properly maintained. An optional spark arrester kit (K903-1) is available for your RANGER 300. See the Accessories section of this manual for more information.
An incorrect spark arrester may lead to damage to the
engine or reduce performance.
INSTALLATION
A-5 A-5
RANGER 300 D AND 300 DLX
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WARNING
WARNING
CAUTION
CAUTION
HIGH FREQUENCY GENERATORS
FOR TIG APPLICATIONS
The K799 Hi-Freq Unit and the K930-1 or -2 TIG
Module can be used with the Ranger 300. The
machine is equipped with the required RF bypass circuitry for the connection of high frequency generating
equipment. The high frequency bypass network supplied with the K799 Hi-Freq Unit does NOT need to be
installed into the Ranger 300.
The Ranger 300 and any high frequency generating
equipment must be properly grounded. See the K799
Hi-Freq Unit and the K930-1 TIG Module operating
manuals for complete instructions on installation,
operation, and maintenance. Also see the Acces-
sories section of this manual.
REMOTE CONTROL
The Ranger 300 DLX is equipped with a 6-pin and a
14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control (optional) or
the K870 hand Amptrol or K812 foot Amptrol (TIG
applications).
The 14-pin connector is used to connect a wire feeder
or K930-1 TIG Module control cable. When a remote
output control is used, the output control toggle switch
must be set at REMOTE.
NOTE: When using the 14-pin connector, do NOT
connect anything to the 6-pin connector if the wire
feeder has a built-in power source output control.
Also see the Accessories section of this manual for
more information on wire feeder connections.
WELDING TERMINALS
The Ranger 300 DLX has a toggle switch for selecting
“hot” welding terminals (WELDING TERMINALS
ALWAYS ON position) or “cold” welding terminals
(WELDING TERMINALS REMOTELY CONTROLLED
position).
ELECTRICAL CONNECTIONS
See Figure A.1 for location of the 120 and 240 volt
receptacles, weld output terminals, circuit breakers
and ground stud.
MACHINE GROUNDING
Because the RANGER 300 creates its own power from
its diesel-engine driven generator, and if the machine
is not connected to premises wiring (home, shop, etc.),
you do not need to connect the machine frame to an
earth ground. However, for best protection against
electrical shock, connect a heavy gauge wire (#8 AWG
or larger) from the ground stud located on the bottom
of the output panel (Figure A.1) to a suitable earth
ground such as a metal pipe driven into the ground.
The ground stud is marked with the ground symbol.
Do not ground the machine to a pipe that carries
explosive or combustible material.
When the Ranger 300 is mounted on a truck or a trailer, the machine generator ground stud MUST be
securely connected to the metal frame of the vehicle.
See Figure A.1.
If the RANGER 300 is connected to premises wiring
such as a home or shop, it must be properly connected to the system earth ground.
INSTALLATION
A-6 A-6
RANGER 300 D AND 300 DLX
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WARNING
F
E
2
1
4
3
1. 120/240 VOLT, 50 AMP RECEPTACLE
2. 120 VOLT, 15 AMP RECEPTACLES (2)
3. WELD OUTPUT TERMINALS
4. GROUND STUD
FIGURE A.1
RANGER 300 OUTPUT CONNECTIONS
WELDING CABLE CONNECTIONS
CABLE SIZE AND LENGTH
Be sure to use welding cables that are large enough.
The correct size and length becomes especially important when you are welding at a distance from the
welder.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the Accessories
section of this manual for more information.
TABLE A.1
CABLE INSTALLATION
Install the welding cables to your RANGER 300 as follows. See Figure A.1 for location of parts.
1. The diesel engine must be OFF to install welding
cables.
2. Remove the flanged nuts from the weld output terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identified on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp
and cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
The control panel of the RANGER 300 features three
auxiliary power receptacles. See Figure A.1.
• Two 15 amp, 120 volt duplex (double outlet) recep-
tacles.
• One 50 amp 120/240 volt simplex (single outlet)
receptacle.
Through these receptacles the machine can supply up
to 12,000 rated continuous watts of single-phase, 60
Hz AC power.
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an
Underwriter’s Laboratories (UL) approved double insulation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the Accessories section of this manual for more information.
If you need ground fault protection for hand-held
equipment, refer to the K896-1 GFCI Receptacle kit in
the Accessories section of this manual for more information.
CIRCUIT BREAKERS
The RANGER 300 machines are equipped with 50
amp circuit breakers on the 120/240 V receptacle and
15 amp circuit breakers on the 120 V receptacles for
overload protection. Under high heat a breaker may
tend to trip at lower loads than it would normally.
INSTALLATION
A-7 A-7
RANGER 300 D AND 300 DLX
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TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-50 Ft. (0-15 meters)
50-100 Ft. (15-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
200-250 Ft. (61-76 meters)
Cable Size for
300 Amps
100% Duty Cycle
1/0 AWG
1/0 AWG
2/0 AWG
2/0 AWG
3/0 AWG
CAUTION
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Never bypass the circuit breakers. Without overload
protection, the RANGER 300 D/DLX could overheat
and/or cause damage to the equipment being used.
PREMISES WIRING
The RANGER 300 is suitable for temporary, standby,
or emergency power using the engine manufacturer’s
recommended maintenance schedule. With its threewire grounded neutral generator, it can be permanently installed as a standby power unit for 240 volt, threewire, single phase 50 ampere service.
Only a licensed, certified, trained electrician should
install the machine to a premises or residential electrical system. Be certain that:
• The installation complies with the National Electrical
Code and all other applicable electrical codes.
• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and local
laws require the premises to be isolated before the
generator is linked to the premises. Check your
state and local requirements.
• A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit
breaker is connected between the generator power
and the utility meter.
The following information and the connection diagram,
Figure A.2, can be used as a guide by the electrician
for most applications to premises wiring.
1. Install a double pole, double throw switch between
the power company meter and the premises disconnect. The switch rating must be the same as
or greater than the premises disconnect and
service overcurrent protection.
2. Take the necessary steps to assure that the load is
limited to the capacity of the RANGER 300 by
installing a 50 amp 240 volt double pole circuit
breaker. Maximum rated load for the 240 volt auxiliary is 50 amperes. Loading above 50 amperes
will reduce output voltage below the allowable
– 10% of rated voltage. This may damage appliances or other motor-driven equipment.
3. Install a 50 amp 120/240 volt plug (NEMA type 14-
50) to a double pole circuit breaker using No. 8 or
larger, 4 conductor cable of the desired length.
(The 50 amp 120/240 volt plug is available in the
optional power plug kit.)
4. Plug this cable into the 50 amp 120/240 volt
receptacle on the RANGER 300 case front.
INSTALLATION
A-8 A-8
RANGER 300 D AND 300 DLX
WARNING
CAUTION
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INSTALLATION
A-9 A-9
RANGER 300 D AND 300 DLX
FIGURE A.2
CONNECTION OF RANGER 300 TO PREMISES WIRING
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
50AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
Connection of Ranger 300 to premises wiring must
be done by a licensed electrician and must comply
with the National Electrical Code and all other
applicable electrical codes.
WARNING
NOTES
RANGER 300 D AND 300 DLX
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Section B-1 Section B-1
RANGER 300 D AND 300 DLX
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
Additional Safety Precautions..............................................................................................B-2
General Description ....................................................................................................................B-3
Design Features .........................................................................................................................B-3
Recommended Applications ......................................................................................................B-4
Welder .................................................................................................................................B-4
Generator .............................................................................................................................B-4
Limitations...................................................................................................................................B-4
Controls and Settings.................................................................................................................B-5
Welder/Generator Controls .................................................................................................B-5
Engine Controls....................................................................................................................B-7
Engine Operation ........................................................................................................................B-9
Before Starting the Engine ...................................................................................................B-9
Starting the Engine...............................................................................................................B-9
Cold Weather Starting........................................................................................................B-10
Stopping the Engine...........................................................................................................B-10
Break-in Period ..................................................................................................................B-10
Welding Operation ....................................................................................................................B-11
General Information............................................................................................................B-11
AC/DC Stick (Constant Current) Welding ..........................................................................B-11
AC/DC TIG (Constant Current) Welding.............................................................................B-12
DC Wire Feed Welding (CV) with Ranger 300 DLX............................................................B-13
DC Wire Feed Welding (CV) with Ranger 300 D ................................................................B-14
Carbon Arc Gouging (Constant Current)............................................................................B-14
Summary of Welding Processes and Machine Settings....................................................B-15
Auxiliary Power ........................................................................................................................B-17
Simultaneous Welding and Power Loads ..........................................................................B-17
120/240 V Dual Voltage Receptacle ..................................................................................B-18
120 V Duplex Receptacles.................................................................................................B-18
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your RANGER 300.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with
any of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door
closed and the side panels in place. These provide
maximum protection from moving parts and insure
proper cooling air flow.
OPERATION
B-2 B-2
RANGER 300 D AND 300 DLX
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WARNING
WARNING
GENERAL DESCRIPTION
The RANGER 300 is a diesel-engine driven, multiprocess AC and DC arc welder and AC power generator for commercial and residential applications. As a
generator it can supply up to 12,000 continuous watts
of 120/240 volt, 60 Hz, single-phase AC power to
operate AC power tools, battery chargers, and lighting. It can also be used to provide standby power. As
a welder it provides 300 amps of AC current for welding with AC stick electrodes or 300 amps of DC current for DC stick welding. The RANGER 300 can also
perform AC/DC TIG welding and DC semiautomatic
wire feed welding.
The engine used on the Ranger 300 machines is the
Kubota "Super Five" water-cooled, 3 cylinder DH905
engine. The DH905 has an offset piston design with
built-in steel strut and a more rigid crankcase. The
Kubota "Three Vortex Combustion System" gives
higher power output, lower fuel consumption, lower
noise, and cleaner exhaust. The "Super Glow System"
gives rapid pre-heating for easy starting in cold weather. The large oil sump adds to the long life of this
engine. The high capacity 30 amp alternator gives fast
charging of the 495 CCA battery. The engine is
extremely smooth and has very low vibration, even at
low idle speed.
The Ranger 300 machines are housed in a heavy
gauge steel case that is protected by a durable powder paint finish. The case is completely insonorized for
remarkably quiet operation. An easy to open hinged
door allows access to the engine for single side service. The welder alternator has all copper windings
and a high temperature insulation system that includes
three coats of electrical grade varnish.
DESIGN FEATURES - ALL MODELS
FOR WELDING
• Excellent AC and DC constant current output for
stick welding applications.
• 40 to 300 amps constant current output with seven
range settings.
• Excellent semi-automatic wire feed welding on constant voltage output range(s).
• TIG welding - full range on DC and up to 250 amps
on AC.
• 100% duty cycle rating on all output ranges.
• Remote control capability standard on all models.
Amphenol receptacle for easy connection of Lincoln
remote control accessories.
FOR AUXILIARY POWER
• 12,000 watts of 120/240 volt 60Hz AC auxiliary
power.
• Power for tools, lights, electric pumps and for
standby emergency power.
• Ability to drive a 2 HP motor (provided it is started
under no load).
• Two 15 amp industrial grade 120 volt duplex receptacles for up to 60 amps of 120 volt power.
• One 50 amp 120/240 volt dual voltage receptacle
for up to 50 amps of 240 volt auxiliary power.
Allows easy connection to premises wiring.
• Four 15 amp circuit breakers for 120V duplex
receptacles and two 50 amp circuit breakers for
240V receptacle.
• Ability to weld and have AC power at the same time
(within machine total capacity).
• Compatible with GFCIs (ground fault circuit interrupters).
OTHER FEATURES
• Insonorized for extremely quiet operation [(99LW(A)
and 74 db(A) @ 23 ft (7m)].
• Kubota 3-cylinder, liquid cooled, diesel engine.
Designed for long life, easy maintenance, excellent
fuel economy and low noise.
• Engine always starts in low idle for minimum engine
wear in cold weather.
• Manual operated lift pump for easy priming of
engine if it runs out of fuel.
• Engine protection system shuts engine down on low
oil pressure or over temperature of coolant.
• Indicator lights for low oil pressure, over temperature and battery charger low output.
• Engine Hour Meter standard on all models.
• Engine coolant recovery bottle eliminates air in radiator and makes it easy to check coolant level.
• Battery with 495 cold cranking amps.
• Straight through ventilation - cooling air for welder
alternator enters front of machine and is exhausted
out rear.
• Large capacity 10 gallon (38 l) fuel tank.
• Automatic idler reduces engine speed when not
welding or drawing auxiliary power. Machine
always starts in low idle. Reduces fuel consumption
and extends engine life.
• Compact size fits many smaller trucks.
• Single side engine service with easy to open access
door.
• Copper alternator windings and high temperature
insulation for dependability and long life.
• Powder painted case and base for outstanding corrosion protection.
OPERATION
B-3 B-3
RANGER 300 D AND 300 DLX
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OPERATION
B-4 B-4
RANGER 300 D AND 300 DLX
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 be
used with the LN-25 Wire Feeder and .035, .045 or
.068 NR®-211-MP Innershield electrodes. Limited
MIG (GMAW) welding can also be done with .030 or
.035 L-50 and L-56 using blended Argon shielding
gas. “Auto-Idle” functions when using an LN-25
with an internal contactor.
ADDITIONAL FEATURES
RANGER 300 DLX (K1522-2)
• Four constant voltage (CV) wire-feed welding
ranges with fine control on each range for welding
at 40 to 300 amps.
• Excellent arc characteristics with MIG (GMAW) and
recommended Innershield electrodes (FCAW).
• Wire feeder amphenol receptacle (14-pin) for quick
connection of control cable.
• Voltmeter for reading CV wire-feed welding arc voltage.
• Built in contactor with front panel selection of
“cold” or “hot” welding terminals.
• Aluminum TIG welding when used with K930-1 TIG
Module. Output contactor control with Amptrol.
• Recommended wire feeders are the LN-25 with 42
Volt Remote Output Control Module or with internal
contactor and all models of the LN-7.
RECOMMENDED APPLICATIONS
WELDER
The RANGER 300 provides excellent constant current
AC/DC welding output for stick (SMAW) welding and
for TIG welding, and it offers constant voltage output
for DC semiautomatic wire feed welding.
GENERATOR
The RANGER 300 gives AC generator output for medium use demands.
LIMITATIONS
• The Ranger 300 is not recommended for any
processes besides those that are normally performed using stick welding (SMAW), TIG welding
(GTAW), MIG (GMAW) welding and Innershield®
(FCAW) welding.
• The RANGER 300 D/DLX is not recommended for
pipe thawing.
• During welding, generator power is limited and output voltages can drop. Therefore, DO NOT OPER-
ATE ANY SENSITIVE ELECTRICAL EQUIPMENT
WHILE YOU ARE WELDING. See Table B.5 for
permissible simultaneous welding and auxiliary
power loads.
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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
applications (blue settings) and constant voltage
wire feed applications (red settings). The amperages on the dial correspond to the maximum
amperages for each corresponding range setting.
Never change the range switch setting while welding, since this could damage the switch.
2. FINE OUTPUT CONTROL: Allows fine adjustment
of current or voltage within the selected output
range.
3. POLARITY SWITCH: Selects DC+, DC- or AC
welding output. Color codings aid in the proper
selection of stick (blue) or wire feed (red) polarity
setting. On the RANGER 300 DLX the color setting
of the polarity switch must match the color setting
of the OUTPUT RANGE SELECTOR. Never
change the polarity switch setting while welding
since this could damage the switch.
4. CONTROL AT WELDER/REMOTE CONTROL
SWITCH: Allows the operator to control welding
output at the welding control panel or at a remote
station. Remote connections are made at the 6 pin
or 14 pin amphenol connector.
OPERATION
B-5 B-5
RANGER 300 D AND 300 DLX
F
E
FIGURE B.1
OUTPUT PANEL CONTROLS
8
2
1
7
3 4
5
6
14
12
13
10
9
11
CONTROLS AND SETTINGS
All generator/welder controls are located on the
Output Control Panel of the machine case front.
Diesel engine glow plug, idler control, and start/stop
controls are also on the case front. See Figure B.1 and
the explanations that follow.
5. WELDING TERMINALS SWITCH (DLX Model Only)
The toggle switch labeled “WELDING TERMINALS
ALWAYS ON” and “WELDING TERMINALS
REMOTELY CONTROLLED” is used to control the
operation of the RANGER 300 DLX output contactor. With the switch in the “WELDING TERMINALS
ALWAYS ON” position, the contactor is closed at
low and high idle.
When a wire feeder or TIG Module control cable is
attached to either the 6-pin or 14-pin amphenol
connector and the Welding Terminals switch is in
the “WELDING TERMINALS REMOTELY CONTROLLED” position, the contactor is open in low
idle and high idle until and the wire feeder trigger or
Amptrol is closed. This closes the 2-4 circuit.
When the gun trigger or Amptrol is released, the
contactor opens and there is no voltage present at
the electrode (300 DLX only).
6. WIRE FEEDER POWER CIRCUIT BREAKER:
Opens the wire feeder circuit and disables the
feeder if a fault is detected in the circuit (300 DLX
only).
7. 15 AMP, 120 VOLT DUPLEX RECEPTACLES:
Connection point for supplying 120 volt power to
operate one or two electrical devices.
8. 50 AMP, 120/240 VOLT RECEPTACLE: Connection
point for supplying 240 volt power to operate one
electrical device.
9. WELD OUTPUT TERMINAL (TO WORK) WITH
FLANGE NUT: Provides the connection point for
the work cable.
10. WELD OUTPUT TERMINAL (TO ELECTRODE
HOLDER) WITH FLANGE NUT: Provides the connection point for the electrode holder.
11. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
12. 6-PIN AMPHENOL: For attaching optional remote
control equipment to the RANGER 300 D/DLX
(Includes contactor closure circuit on the Ranger
300 DLX and remote control circuit).
13. 14-PIN AMPHENOL (DLX Model Only): For
attaching wire feeder control cables to the
RANGER 300 DLX (Includes contractor closure
circuit, remote control circuit, wire feeder 115/42
volt power source).
14. VOLTMETER (DLX MODEL ONLY): Displays actual voltage at the output terminals when welding in
CV-mode.
OPERATION
B-6 B-6
RANGER 300 D AND 300 DLX
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OPERATION
B-7 B-7
RANGER 300 D AND 300 DLX
FIGURE B.2
ENGINE CONTROLS
ENGINE CONTROLS
See Figure B.2 for the location of the following features:
1. GLOW PLUG PUSH-BUTTON: Activates
glow plugs to preheat engine for starting.
2. IDLER CONTROL SWITCH: The idler switch has
two positions, “HIGH” and “AUTO”.
When in “HIGH” ( ) position, the engine will
run continuously at high speed.
When in “AUTO” ( / ) idle position, the
idler operates as follows:
a) Welding
Low idle with Ranger 300 DLX in the “WELDING
TERMINALS ALWAYS ON” mode or with a Ranger
300D - When the electrode touches work, the
welding arc is initiated and the engine accelerates
to full speed.
Low idle and in the “WELDING TERMINALS
REMOTELY CONTROLLED” mode - Pressing the
gun trigger or Amptrol closes the Ranger 300 DLX
output contactor and causes the engine to accelerate to full speed.
After the gun trigger or Amptrol is released and/or
welding ceases (and no auxiliary power is being
drawn), the engine will return to low idle after
approximately 10 to 14 seconds.
b) Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or tools drawing approximately
100-150 watts or greater from the receptacles, the
engine will accelerate to high speed. If no power is
being drawn from the receptacles (and not welding)
for 10-14 seconds, the engine returns to low idle.
F
E
5
4
6
9
1
8
2
3
7
3. START PUSHBUTTON: When the pushbutton is held, the starter motor cranks over
the engine - release the button once the
engine starts.
NOTE: If you press the START pushbutton when the
engine is running, you may damage the ring gear or
starter motor.
4. ENGINE HOUR METER: Records engine running
time. Use to determine when to perform required
maintenance.
5. BATTERY LIGHT: Is off when battery charging system is functioning normally. If the red light turns on
while the engine is running, the fan belt may be
broken or the alternator or the voltage regulator
may be defective.
It is normal for the light to go on when the “Engine”
switch is switched to the “ON” position with the
engine not running. It will go off after one minute
to prevent discharging the battery if the engine is
not started. If this happens, the engine protection
circuit must be reset by turning the “Engine” switch
to the “OFF” position and back to the “ON” position.
6. OIL PRESSURE LIGHT: Remains off
with proper oil pressure. If the red light
turns on while the engine is running, the engine
protection system will stop the engine.
It is normal for the light to go on when the “Engine”
switch is switched to the “ON” position with the
engine not running. It will go off after one minute
to prevent discharging the battery if the engine is
not started. If this happens, the engine protection
circuit must be reset by turning the “Engine” switch
to the “OFF” position and back to the “ON” position.
7. WATER TEMPERATURE LIGHT: Remains
off under normal operating temperatures.
If the red light turns on, the engine protection system will stop the engine. The light will
remain on when the engine is over temperature and
the “Engine” switch is in the “ON” position (engine
not running) but will go off as the engine cools.
8. FUEL LEVEL GAUGE: Displays the level of diesel
fuel in the 10-gallon fuel tank.
9. ENGINE ON-OFF SWITCH: Energizes the fuel solenoid in the “ON” position. In the STOP position,
stops fuel flow to the injection pump and stops the
engine.
OPERATION
B-8 B-8
RANGER 300 D AND 300 DLX
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ENGINE OPERATION
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.
The maximum allowable high idle speed for the
RANGER 300 is 3700 RPM, no load. Do NOT adjust
the governor screw on the engine. Severe personal
injury and damage to the machine can result if it is
operated at speeds above the maximum rated speed.
Read and understand all safety instructions included in
the Kubota instruction manual that is shipped with your
RANGER 300.
BEFORE STARTING THE ENGINE
Check the engine oil level:
See Figure D.1 for location of dipstick.
1. Be sure the machine is on a level surface.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.
4. Replace the dipstick.
Check and fill the engine fuel tank:
DIESEL fuel can cause fire or
explosion.
• Stop engine when fueling.
• Do not smoke when fueling.
• Do not overfill tank.
• Keep sparks and flame away from tank.
1. Remove the fuel tank cap.
2. Fill the tank approximately 4 inches (100 mm) from
the top of the filler neck to allow for fuel expansion
(observe the fuel gauge.) DO NOT FILL THE TANK
TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: DO NOT allow the RANGER 300 to run out of
fuel. If it does, you will have to bleed the injection system. See the Maintenance section of this manual and
the Engine Operator’s Manual for instructions on
bleeding the fuel injection system.
USE DIESEL FUEL ONLY
Purchase diesel fuel in quantities that will be used
within 30 days, to assure freshness.
STARTING THE ENGINE
Remove all loads connected to the AC power receptacles and the welder before starting the diesel engine.
1. Open the engine compartment door and check that
the fuel shutoff valve located above the clear plastic fuel filter housing is in the open position (lever in
the vertical position). See Figure B.3.
FIGURE B.3
2. Check for proper level of coolant in the plastic
reserve overflow tank. The level should be
between the full and the low marks.
3. Check for proper oil level on the oil dipstick. Close
engine compartment door.
4. Set “IDLER” switch to “AUTO”. /
5. Set the “ENGINE” switch to “ON”. Observe that
both the oil pressure light and battery charger light
are on. Check the fuel gauge to make sure that
there is an adequate fuel level. (NEVER ALLOW
THE RANGER 300 D/DLX TO RUN OUT OF FUEL.)
OPERATION
B-9 B-9
RANGER 300 D AND 300 DLX
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WARNING
CAUTION
CAUTION
WARNING
6. Press the “GLOW PLUG” button to preheat the cylinders per the following table:
Never press the Glow Plug button continuously for
more than 20 seconds.
7. Release the “GLOW PLUG” button and
press the “START” button to crank the
engine. Release when the engine starts.
8. Check that the indicator lights are off. If not, immediately stop the engine and investigate the indicated problem.
9. Allow the engine to warm up at low idle speed for
several minutes before applying a load and/or
switching to high idle. Allow a longer warm up time
in cold weather.
NOTE: If the engine fails to start in 60 seconds or
stops running, the “ENGINE” switch must be
switched to “OFF” and then switched back to “ON”
before attempting to restart the engine. This resets
the engine protection circuit.
COLD WEATHER STARTING AND
OPERATION
The Kubota engine used in the Ranger 300 can be
started in temperatures as low as 5°F (-15°C). At temperatures below 23°F (-5°C), it is recommended that
No. 1D diesel fuel be used in place of No. 2D. Allow
engine to warm up before applying a load or switching
to HIGH idle.
STOPPING THE ENGINE
1. Remove all welding and generator power loads and
let the engine cool by running it for several minutes
at low idle.
2. Stop the engine by placing the Engine Switch in the
“OFF” position. This turns off the fuel solenoid.
You can also stop the engine by turning off the fuel
valve located on the fuel filter housing.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
“break-in” period. For the diesel engine on the
RANGER 300, break-in is about 50 running hours.
Check the oil every four hours during break-in.
Change the oil after the first 50 hours of operation,
every 100 hours thereafter. Change the oil filter at the
second oil change.
During break-in, subject the RANGER 300 to moderate
loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow the
engine to cool several minutes.
TABLE B.1
TYPICAL RANGER 300 FUEL CONSUMPTION
* DLX model only
OPERATION
B-10 B-10
RANGER 300 D AND 300 DLX
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Ambient Temperature
Above 50°F (10°C)
50°F (10°C) to 23°F(-5°C)
Below 23°F (-5°C)
Pre-Heat Time
NOT REQUIRED
Approximately 5 seconds
Approximately 10 seconds
CAUTION
Low Idle - No Load
2000 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
300 Amps @ 25 Volts
DC CC Weld Output
300 Amps @ 25 Volts
DC CV Weld Output
300 Amps @ 28 Volts*
Auxiliary Power
12,000 kVA
.30 gallons/hour
(1.0 liters/hour)
.60 gallons/hour
(2.2 liters/hour)
1.1 gallons/hour
(4.2 liters/hour)
1.2 gallons/hour
(4.6 liters/hour)
.90 gallons/hour
(3.6 liters/hour)
1.3 gallons/hour
(4.9 liters/hour)
WELDING OPERATION
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual
supplied with your welder. It includes important safety precautions, detailed engine starting, operating and
maintenance instructions, and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear and body protection.
See additional warning information throughout this
operator’s manual.
GENERAL INFORMATION
The RANGER 300 machines can deliver from 45 to 300
amps of constant current for AC/DC stick welding.
The Ranger 300 DLX can deliver 45 to 300 amps of
constant voltage current for DC semiautomatic wire
feed welding. The Ranger 300 D can deliver 45 to 200
amps of constant voltage current for DC semiautomatic wire feed welding. AC/DC constant current TIG
welding is possible across the entire range from 45 to
300 amps, although 250 amps is the maximum recommended for AC TIG welding of aluminum.
Output can be adjusted by setting the POLARITY
SWITCH, the OUTPUT RANGE dial, and the FINE
CONTROL dial on the output control panel to the settings that are best for your selected welding process.
AC/DC STICK (CONSTANT CURRENT)
WELDING
1. Remove the flange nuts from output terminals and
place the work and electrode welding cables over
the terminals. See Figure B.4. Replace and tighten the flange nuts securely. Be sure the connections are tight.
2. Select the appropriate electrode. See “Welding
Tips 1” included with your RANGER 300.
3. Attach the work clamp securely to the work you are
welding.
4. Insert the electrode into the electrode holder.
5. Set the IDLER CONTROL to AUTO and start the
diesel engine.
6. Set the RANGE switch to a setting equal to or
slightly lower than the welding current recommended for the electrode being used. For the best
welding performance, always set the RANGE
switch to the lowest CC-blue setting that will give
the desired weld current. This will assure that the
OUTPUT dial is set towards the high end of the
dial. If the OUTPUT dial is set at 10 and the welding current is set to low, move the RANGE switch
to the next highest setting.
7. Set the POLARITY switch to the desired polarity
(CC-blue setting).
8. Set the OUTPUT control. For stick welding, always
use a setting between 5 and 10 on the dial (blue
range).
9. Strike an arc and begin welding. The OUTPUT
control can be adjusted while welding.
OPERATION
B-11 B-11
RANGER 300 D AND 300 DLX
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CAUTION
DO NOT change the RANGE switch setting while
welding. This can result in damage to the switch.
FIGURE B.4
WELDING CIRCUIT CONNECTIONS
AFTER YOU FINISH WELDING:
1. Stop the engine.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from the
electrode holder.
5. If you are finished using the RANGER 300 for welding, disconnect the welding cables from the weld
output terminals. Reattach the flange nuts and
leave them on the terminals.
AC/DC TIG (CONSTANT CURRENT)
WELDING
1. Connect the K930-1 TIG Module to the RANGER
300. Follow the installation instructions provided
with the kit.
2. Refer to the instruction manual with the TIG module (IM-528) for operation with a RANGER 300 and
proper machine settings.
3. Set the RANGE switch to the appropriate setting
for the electrode you are using. Refer to IM-528
with the TIG module or refer to Table B.2 for AC
TIG welding.
4. Set the POLARITY SWITCH to the desired polarity.
5. Do not AC TIG weld on the 300 AC range setting.
The output current may exceed the rating of the
RANGER 300.
6. Start the arc and begin welding.
NOTE: When using the RANGER 300 for AC TIG welding of aluminum, the TIG Module is to be set for CONTINUOUS HF.
AFTER YOU FINISH WELDING:
1. Stop the engine.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
OPERATION
B-12 B-12
RANGER 300 D AND 300 DLX
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RANGE SETTING
ON MACHINE
ACTUAL
CURRENT RANGE
50
75
100
140
180
225
300
30 to 50 AMPS
50 to 75 AMPS
70 to 100 AMPS
95 to 140 AMPS
110 to 180 AMPS
130 to 225 AMPS
160 to 300 AMPS
F
E
CAUTION
1
5
8
7
6
4
3
2
1. OUTPUT CONTROL PANEL
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. OUTPUT TERMINALS
6. WORK
7. WORK CLAMP
8. WORK CABLE
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OPERATION
B-13 B-13
RANGER 300 D AND 300 DLX
TABLE B.2
AC TIG WELDING – TIG ELECTRODE/RANGE SETTINGS
Pure (EWP) “Range” Appropriate
Tungsten Diameter Switch Settings Welding Current
1/8” 75, 100 or 140
(1)
100 - 200 amps
3/32” 50, 75 or 100 50 - 100 amps
1/16” 50, 75 or 100 45 - 150 amps
1% Thoriated “Range” Appropriate
Tungsten Diameter Switch Settings Welding Current
1/8” 100, 140 or 180 160 - 250 amps
3/32” 50, 100 or 140 100 - 180 amps
1/16” 50 or 100 60 - 120 amps
(1)
The welding current will be approximately 200 amps with the range switch set at 120 and the OUTPUT CONTROL set at 10. Do not use a range setting higher than 120 for AC TIG welding.
DC WIRE FEED WELDING (CV) WITH
RANGER 300 DLX
1. Connect one of the following: the LN-25, LN-7 or
LN-8 Wire Feeder.
2. Some recommended Innershield electrodes are:
.068 NR-211MP, .068 NR-232, NR-203 series, 5/64
NR-311, and 5/64 NS-3M. Lincore® 33 and 55
hardfacing electrodes can also be used. Cable
length and other conditions can affect the ultimate
results of this application. Request Lincoln publication N-675 for additional information.
Recommended Outershield electrodes are .045
(1.1 mm), .052 (1.3 mm), and 1/16 (1.6 mm)
Outershield 71 and 1/16 (1.6 mm) Outershield 70.
Request Lincoln publication GS-200 for additional
information.
For MIG welding, the recommended electrodes are
.030 (0.8 mm), .035 (0.9 mm) and .045 (1.1 mm) L50 and L-56. You must use a blended shielding
gas such as C25 (75% Argon, 25% CO
2
). Request
Lincoln publication GS-100 for additional information.
3. Set the IDLER CONTROL to “AUTO” for the LN-25
or “HIGH” for the LN-7 or LN-8 and start the diesel
engine.
4. Set the RANGE switch to either HIGH, MEDIUM
HIGH, MEDIUM LOW, or LOW (CV-red) depending
on your wire size and speed.
5. Set the POLARITY SWITCH to either WIRE WELDING DC+ or WIRE WELDING DC- depending on
the electrode.
6. Set the OUTPUT control to a setting between 1 and
10 that gives the most stable arc for the application. Try a higher RANGE switch setting if the arc
is unstable.
7. Strike an arc and begin welding. The OUTPUT
control can be adjusted while welding. DO NOT
change the RANGE switch setting while welding.
This can result in damage to the switch.
AFTER YOU FINISH WELDING:
1. Stop the engine.
2. Allow the work to cool completely.
3. Remove the work clamp from the work.
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