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

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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 •

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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.

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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.

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

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

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

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

LOAD

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

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

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

FIGURE B.1

OUTPUT PANEL CONTROLS

3 4

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

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.

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.

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

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

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

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

CAUTION

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

). 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.

DC WIRE FEED WELDING (CV) WITH RANGER 300 D

1. Connect an LN-25 with internal contactor to the Ranger 300 D.

2. The only Innershield electrode recommended for use with the Ranger 300 D is NR211MP. The electrode sizes and welding ranges that can be used with the Ranger 300 D are shown in the following table:

The Ranger 300 D is recommended for limited "MIG" welding (GMAW - gas metal arc welding). The recommended electrodes are .030 and .035 L-50 and L-56. They must be used with a blended shielding gas such as C25 (75% Argon - 25% CO

). The .035 diameter

electrode gives improved starting compared to .030 diameter. The welding ranges that can be used with the Ranger 300 D are shown in the following table:

3. Set the IDLER control to AUTO.

4. Set the RANGE switch to WIRE FEED (CV-red setting).

5. Set the POLARITY SWITCH to either WIRE WELDING DC+ (red) or WIRE WELDING DC- (red), depending on the electrode.

6. Set the OUTPUT control to a setting between 1 and 10 that gives the most stable arc for the application.

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.

CARBON ARC GOUGING (CONSTANT CURRENT)

1. The recommended electrode is a 3/16” (4.8 mm) dia. carbon.

2 Set the RANGE switch to 300.

3 Set the POLARITY switch to DC+ (cc - blue setting).

4 Set the OUTPUT control to 10.

5. Strike an arc and begin gouging.

AFTER YOU FINISH GOUGING:

1. Stop the engine.

2. Allow the electrode and work to cool completely.

3. Remove the work clamp from the work.

OPERATION

B-14 B-14

RANGER 300 D AND 300 DLX

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Electrode

Diameter

Wire Speed

in. / min.

Approximate

Current Range

.035” .045” .068”

70 - 110 70 - 130

40 - 90

60 - 120 amps 120 - 170 amps 125 - 210 amps

Electrode

Diameter

Wire Speed

in. / min.

Approximate

Current Range

.030” .035”

150 - 450 100 - 350

80 - 170 amps 80 - 190 amps

OPERATION

B-15 B-15

RANGER 300 D AND 300 DLX

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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 CARBON ARC GOUGING - CC

TIG - CC K930-1 TIG MODULE / K936-1 CONTROL CABLE

WIRE FEED - CV, LN-25 WITH 42V REMOTE CONTROL KIT

WIRE FEED - CV, LN-25 WITH INTERNAL CONTACTOR

WIRE FEED - CV, LN-742

WIRE FEED - CV, LN-7 or LN-8

K487-15 WIRE FEEDCV SPOOL GUN / K488 CONTROL MODULE

Touch electrode to work. Welding starts immediately and engine goes to high idle.

Press Amptrol. Welding starts immediately.

Press gun trigger, Ranger 300 DLX contactor closes. Welding starts immediately and engine goes to high idle.

Press gun trigger, LN-25 contactor closes. Welding starts immediately and engine goes to high idle.

Press gun trigger, Ranger 300 DLX contactor closes. Welding starts immediately and engine goes to high idle.

Press gun trigger, Ranger 300 DLX contactor closes. Welding starts immediately.

YES

S23732-9

YES

S23732-3

NO S23732-1 S23732-2

YES

S23732-5

YES S23732-4 S23732-6

YES S23732-8

AUTO

HIGH

WELDER

REMOTE

WELDER

REMOTE

WELDER

ALWAYS

REMOTE

ALWAYS

REMOTE

HOT

COLD

INSTALLATION

B-16 B-16

RANGER 300 D AND 300 DLX

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CONTROL

CABLE &

DIAGRAM

IDLE

MODE

OUTPUT

CONTROL

SWITCH

ELECTRODE

WHEN NOT

WELDING

TO START WELDING

PROCESS

STICK - CC CARBON ARC GOUGING - CC

TIG - CC K930-1 TIG MODULE / K936-1 CONTROL CABLE

WIRE FEED - CV, LN-25 / INTERNAL CONTACTOR

WIRE FEED - CV, LN-7 / K240 CONTACTOR KIT

Touch electrode to work. Welding starts immediately and engine goes to high idle.

Press Amptrol. Welding starts immediately.

Press gun trigger, LN-25 contactor closes. Electrode touches work, welding starts immediately and engine goes to high idle.

Press gun trigger, K240 contactor closes. Welding starts immediately.

YES

S23732-10

NO S23732-1 S23732-2

YES

S23732-11

AUTO

HIGH

WELDER

REMOTE

WELDER

HOT

COLD

SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS, continued

TABLE B.4

SUMMARY OF WELDING PROCESSES FOR RANGER 300 D

AUXILIARY POWER

The Ranger 300 can provide up to 12,000 watts of 120/240 volts AC, single-phase 60 HZ power for continuous use. The front of the machine includes three receptacles for connecting AC power plugs, one 50 amp 120/240 V NEMA 14-50R receptacle and two 15 amp 120 V NEMA 5-15R receptacles. Do not connect any plugs that connect to the power receptacles in parallel.

Start the engine and set the “IDLER” control switch to the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptacles for auxiliary power.

Most single-phase motors through 2.0 HP can be started if there is no load on the motor or other load connected to the machine. Since the full load current of a 2.0 HP motor is typically 18 to 20 amps when

operated at 120 V or 9 to 11 amps when operated at 240 V, it should be connected to the 120/240 dual voltage receptacle. The full load current of a 1.5 HP motor is typically 15 to 17 amps when operated at 120 V or

7.5 to 8.5 amps when operated at 240 V. It also should be connected to the 120/240 dual voltage receptacle. A 1.0 HP motor that draws less than 15 amps at 120 V can be plugged into one of the 120 V duplex receptacles.

SIMULTANEOUS WELDING AND POWER LOADS

Auxiliary power ratings are with no welding load. Simultaneous welding and power loads are permitted by the following table. The permissible currents shown assume that current is being drawn from either the 120 V or 240 V supply (not both at the same time).

OPERATION

B-17 B-17

RANGER 300 D AND 300 DLX

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Output

Selector

Setting

Welding

Output

Amps

Permissible Power Watts (Unity Power

Permissible

Auxiliary Current in

Amperes @ 120V

Permissible

Auxiliary Current in

Amperes @ 240V

0 13 20 27 33 38 42

17 40

13 27

8 33

0 25

0 25 40 53 60 60 60

33 60

25 60

17 60

0 50

NONE

3000 4800 6400 8000 9000

10,000

4000 9600

3000 8800

2000 8000

6000

300 225 180 140 100

75 50

200

225

250 100

300 150

300 225 180 140 100

75 50

CV LOW (300 DLX)

CV (300 D)

CV MED. LOW

(300 DLX)

CV MED. HIGH

(300 DLX)

CV HIGH

(300 DLX)

TABLE B.5

RANGER 300 SIMULTANEOUS WELDING AND POWER LOADS

(OUTPUT CONTROL SET AT 10)

NOTE: Voltage and permissible watts decrease as “CONTROL” is adjusted to settings less than 10. It is recommended

that at settings less than 10, only incandescent lighting loads be connected to the auxiliary power receptacles.

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OPERATION

B-18 B-18

RANGER 300 D AND 300 DLX

120/240 V DUAL VOLTAGE RECEPTACLE

The 120/240 V receptacle can supply up to 50 amps of 240 V power to a two wire circuit, up to 50 amps of 120 V power from each side of the three wire circuit, (up to 100 amps total). Do not connect the 115 V circuits in parallel. Current sensing for the automatic idle feature is in both legs of the three wire circuit as shown below.

FIGURE B.5

120 V DUPLEX RECEPTACLES

The 120 V auxiliary power receptacles should only be used with three wire grounding type plugs or approved double insulated tools with two wire plugs.

MAXIMUM CURRENT DRAW FROM

120 V DUPLEX RECEPTACLES - NO WELDING

EACH HALF OF

EACH 120 V

DUPLEX

TOTAL FROM

ONE 120 V

DUPLEX

TOTAL FROM

BOTH 120 V

DUPLEXES

240 V LOAD FROM

FULL KVA

RECEPTACLE

0 20 AMPS 30 AMPS 40 AMPS 50 AMPS

15 AMPS 15 AMPS 15 AMPS 15 AMPS

30 AMPS 30 AMPS 30 AMPS 20 AMPS

60 AMPS 60 AMPS 40 AMPS 20 AMPS

MAXIMUM CURRENT DRAW FROM OPTIONAL

120 V GFCI DUPLEX RECEPTACLES - NO WELDING

EACH HALF OF

EACH 120 V

DUPLEX

TOTAL FROM

ONE 120 V

DUPLEX

TOTAL FROM

BOTH 120 V

DUPLEXES

240 V LOAD FROM

FULL KVA

RECEPTACLE

0 35 AMPS 50 AMPS

15 AMPS 15 AMPS

30 AMPS 30 AMPS

GND

120 V

240 V

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TABLE OF CONTENTS

- ACCESSORIES -

Accessories...........................................................................................................................Section C

General Options/Accessories.....................................................................................................C-2

TIG Welding Options/Accessories..............................................................................................C-2

Semiautomatic FCAW and MIG Welding (Ranger 300 DLX) Options/Accessories....................C-2

Semiautomatic FCAW and MIG Welding ( Ranger 300 D) Options/Accessories.......................C-2

Connection of Lincoln Electric Wire Feeders .............................................................................C-3

Connection of the LN-25 Using the K857 Remote Control.................................................C-3

Connection of the LN-25 Using the K444-1 Remote Control .............................................C-4

Connection of the LN-25 Using the K624-1 42 Volt Remote Control .................................C-5

Connection of the LN-7 .......................................................................................................C-6

Connection of the LN-8 Using the K867 Universal Adapter................................................C-7

Connection of the K488 SG Control Module and K487-25 Spool Gun ..............................C-8

Connection of the K930-1 TIG Module................................................................................C-9

Section C-1 Section C-1

RANGER 300 D AND 300 DLX

GENERAL OPTIONS / ACCESSORIES

The following options/accessories are available for your 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 towing with optional Fender and Light Kit. Load capacity is 2,100 lbs.

K802-R Power Plug Kit - Provides four 15 amp, 115 volt plugs and one 50 amp, dual voltage (115/230V), full kVA plug.

K703 Accessory Kit - Includes the following:

• Thirty-five feet (10.5 meters) of #1/0 AWG electrode cable.

• Thirty feet (9.1 meters) of # 1/0 AWG work cable.

• Headshield with No. 12 filter.

• GC500 work clamp.

• Cooltong® 300 insulated electrode holder.

The cables are rated at 300 amps, 100% duty cycle.

K903-1 Spark Arrester Kit - A field-installed kit for the RANGER 300 engine muffler exhaust pipe (either engine option). Includes a heavy-gauge steel, approved spark arrester, mounting clamp and adapter.

K857 Remote Control - Includes a control box with 25 feet (7.5 meters) of 4 conductor cable. Allows output voltage to be controlled remotely.

K896-1 GFCI Receptacle Kit - Includes two UL approved 120 volt ground fault circuit interrupter receptacles (duplex type) with covers and installation instructions. Each receptacle is rated 15 amps, but the maximum total current from each GFCI duplex is limited to 20 amps. The GFCI receptacles replace the two factory installed 120 volt duplex receptacles.

TIG WELDING OPTIONS / ACCESSORIES

K930-1 TIG Module - The TIG Module is an accesso-

ry that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications. It provides contactor control of constant current welding power sources having an internal contactor.

The TIG Module is supplied without accessories. Arc Start switches, Amptrols, cables, torches and mounting brackets must be purchased separately.

K939-1 Docking Kit - For mounting the K930-1 TIG Module on top of the Ranger 300.

K936-1 Control Cable - Control cable for connecting the K930-1 TIG Module to a RANGER 300 DLX.

K936-3 Control Cable - Control cable for connecting the K930-1 TIG module to a Ranger 300 D.

K814 Arc Start Switch - A remote start switch used in conjunction with the K930-1 TIG Module to energize the RANGER 300 DLX output terminals via the TIG module.

K963 Hand Amptrol - Remote output control on RANGER 300 D/DLX and contactor control on Ranger 300 DLX.

K870 Foot Amptrol - Remote output control on RANGER 300 D/DLX and contactor control on Ranger 300 DLX.

SEMIAUTOMATIC FCAW AND MIG WELDING (RANGER 300 DLX) OPTIONS / ACCESSORIES

LN-25 Wire Feeder - This portable unit provides

CC/CV for flux-cored arc welding (FCAW) and metal inert gas welding (MIG).

LN-7 or LN-8 Wire Feeder - Semiautomatic constant speed wire feeders.

NOTE: Gas-shielded welding requires a Magnum Gun. Gasless welding requires an Innershield Gun.

K487-25 Magnum Spool Gun - A lightweight, semiautomatic wire feeder for aluminum welding with argon gas. Has built-in remote wire speed control in the handle. Requires the K488 SG Control Module. Includes 50 feet (15.2 meters) of power cable.

K488 SG Control Module - Controls wire speed and gas flow. Provides the required control interface between the RANGER 300DLX and the K487-25 Magnum Spool Gun.

SEMIAUTOMATIC FCAW AND MIG WELDING (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 arc welding (FCAW) and metal inert gas welding (MIG). For remote control use either a K857 Remote Control Kit (25 ft.) or a K444-1 Remote Voltage Control Kit (25 ft.), which mount inside the LN-25.

ACCESSORIES

C-2 C-2

RANGER 300 D AND 300 DLX

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CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

ELECTRIC SHOCK can kill.

• Do not operate with panels open.

• Disconnect NEGATIVE (-) BATTERY LEAD before servicing.

• Do not touch electrically live parts.

MOVING PARTS can injure.

• Keep guards in place.

• Keep away from moving parts.

• Only qualified personnel should install, use or service this equipment.

CONNECTION OF THE LN-25 TO THE RANGER 300 D AND DLX “ACROSS THE ARC” USING THE K857 REMOTE CONTROL (SEE FIGURE C.1.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.1 shows the electrode connected for negative polarity. Use the Polarity switch on the Ranger 300 to select the desired electrode polarity. Change the LN-25 polarity switch.

3. Attach the single lead from the LN-25 to the work using the spring clip on the end of the lead. This is only a sense lead - it carries no welding current.

4. Place the IDLER switch in the “AUTO” or “HIGH” position, as desired.

If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the Ranger 300 is started.

5. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”

6. Set the WELDING TERMINALS switch to “WELDING TERMINALS ALWAYS ON.”

7. Adjust wire feed speed at the LN-25.

8. Set the LOCAL/REMOTE switch to “REMOTE” if a K857 remote control is used.

Electrode is always “HOT.”

ACCESSORIES

C-3 C-3

RANGER 300 D AND 300 DLX

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WARNING

CAUTION

(RANGER 300 DLX ONLY)

6 PIN AMPHENOL

TO WORK

14 PIN AMPHENOL

LN-25

ELECTRODE CABLE

WIRE FEEDER

TO WORK

WORK CLIP LEAD

OPTIONAL K857

REMOTE CONTROL

ELECTRODE

TO WORK

FIGURE C.1

RANGER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM –

K857 REMOTE CONTROL

CONNECTION OF THE LN-25 TO THE RANGER 300 D AND DLX “ACROSS THE ARC” USING THE K444-1 REMOTE CONTROL (SEE FIGURE C.2.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.2 shows the electrode connected for negative polarity. Use the Polarity switch on the Ranger 300 to select the desired electrode polarity. Change the LN-25 polarity switch.

3. Attach the single lead from the LN-25 to the work using the spring clip on the end of the lead. This is only a sense lead - it carries no welding current.

4. Place the IDLER switch in the “AUTO” or “HIGH” position as desired.

If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the Ranger 300 is started.

5. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”

6. Set the WELDING TERMINALS switch to “WELDING TERMINALS ALWAYS ON.”

7. Adjust wire feed speed at the LN-25.

8. Set the LOCAL/REMOTE switch to “REMOTE” if a K444-1 remote control is used.

Electrode is always “HOT.”

ACCESSORIES

C-4 C-4

RANGER 300 D AND 300 DLX

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FIGURE C.2

RANGER 300/LN-25 ACROSS THE ARC CONNECTION DIAGRAM –

K444-1 REMOTE CONTROL

CAUTION

(RANGER 300 DLX ONLY)

ELECTRODE CABLE

WIRE FEEDER

OPTIONAL K444-1 REMOTE CONTROL

TO WORK

WORK CLIP LEAD

6 PIN AMPHENOL

14 PIN AMPHENOL

TO WORK

LN-25

ELECTRODE

TO WORK

ACCESSORIES

C-5 C-5

RANGER 300 D AND 300 DLX

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CONNECTION OF THE LN-25 TO THE RANGER 300 (DLX ONLY) USING THE K624-1 42V REMOTE CONTROL (SEE FIGURE C.3.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

Use the Polarity switch on the Ranger 300 to select the desired electrode polarity. Change the LN-25 polarity switch.

3. Connect the K626-XX Control Cable to the 14-pin amphenol of the Ranger 300 DLX as indicated in Figure C.3. Make the proper connections for local or remote control according to Figure C.3.

4. Connect the K626-XX Control Cable to the LN-25.

Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage. If this voltage goes over 140 volts, wire feeder control circuits may be damaged. The engine governor setting is preset at the factory - do not adjust above RPM specifications listed in this manual.

5. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”

6. Set the WELDING TERMINALS switch to “REMOTELY CONTROLLED.”

7 Adjust wire feed speed at the LN-25.

8. Set the LOCAL/REMOTE switch to “REMOTE.”

FIGURE C.3

RANGER 300 DLX/LN-25 WITH K624-1 42 VOLT REMOTE CONTROL

ELECTRODE

TO WORK

14 PIN

TO WORK

AMPHENOL

CABLE PLUG

ELECTRODE CABLE

TO WIRE FEED UNIT

TO LN-25 INPUT

K626-XX INPUT CABLE ASSEMBLY

CAUTION

ACCESSORIES

C-6 C-6

RANGER 300 D AND 300 DLX

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CONNECTION OF THE LN-7 TO THE RANGER (300 DLX ONLY) USING K584 CONTROL CABLE (SEE FIGURE C.4.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-7 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.4 shows the electrode connected for positive polarity. Use the Polarity switch on the Ranger 300 DLX to select the desired electrode polarity.

3. Connect the K584-XX Control Cable to the LN-7.

4. Connect the K584-XX Control Cable to the 14-pin amphenol on the Ranger 300 DLX.

5. Place the IDLER switch in the “HIGH” position.

6. Set the LOCAL/REMOTE switch to “REMOTE” if a K857 remote control is used. Set the switch to “LOCAL” if no remote control is used.

7. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”

8. Set the WELDING TERMINALS switch to “WELDING TERMINALS REMOTELY CONTROLLED.”

9. Adjust wire feed speed at the LN-7.

NOTE: For remote control, a K857 remote control is required. Connect it to the 6-pin amphenol.

FIGURE C.4

RANGER 300 DLX/LN-7 WITH K584 CONTROL CABLE CONNECTION DIAGRAM

CAUTION

ELECTRODE

TO WORK

TO LN-7 INPUT CABLE PLUG

14 PIN AMPHENOL

OPTIONAL K857 REMOTE CONTROL

6 PIN AMPHENOL

ELECTRODE CABLE

TO WORK

TO WIRE FEED UNIT

K584 CONTROL CABLE

ACCESSORIES

C-7 C-7

RANGER 300 D AND 300 DLX

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CONNECTION OF THE LN-8 TO THE RANGER 300 (DLX ONLY) USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.5.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-8 to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.5 shows the electrode connected for positive polarity. Use the Polarity switch on the Ranger 300 to select the desired electrode polarity.

3. Connect the K867 Universal Adapter to the K196 input cable and the 14-pin amphenol of the Ranger 300 DLX as indicated in Figure C.5. Make the proper connections for local or remote control according to Figure C.5.

4. Connect the K196 input cable to the LN-8.

5. Place the IDLER switch in the “HIGH” position.

6. Set the LOCAL/REMOTE switch to “REMOTE.”

7. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”

8. Set the WELDING TERMINALS switch to “WELDING TERMINALS REMOTELY CONTROLLED.”

9. Adjust wire feed speed and voltage at the LN-8.

FIGURE C.5

RANGER 300 DLX/LN-8 WITH K867 ADAPTER CONNECTION DIAGRAM

14 PIN AMPHENOL

CV-

TO WORK

WIRE FEEDER

K196

K867 UNIVERSAL ADAPTER PLUG

INPUT CABLE

ELECTRODE CABLE TO WIRE FEED UNIT

2 4

76 77

SPARE

82 81

INSULATE UNUSED LEADS INDIVIDUALLY

}

GND

SPLICE LEADS AND INSULATE

}

LN-8

31 32

GND

CAUTION

ACCESSORIES

C-8 C-8

RANGER 300 D AND 300 DLX

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CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE RANGER 300 (DLX ONLY) (SEE FIGURE C.6.)

1. Shut the welder off.

2. Connect the electrode cable from the SG Control Module to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.6 shows the electrode connected for positive polarity. Use the Polarity switch on the Ranger 300 DLX to select the desired electrode polarity.

3. Connect the K691-10 Input Cable as shown in Figure C.6.

4. Set the slide switch on the SG Control Module to the “Lincoln” position.

Be sure the switch is set to the “Lincoln” (contact closure) position before attempting to operate the SG Control Module. Incorrect switch position could result in damage to the SG Control Module and/or the Ranger 300 DLX.

5. Place the IDLER switch in the “HIGH” position.

6. Set the LOCAL/REMOTE switch to “REMOTE” if a K857 remote control is used. Set the switch to “LOCAL” if no remote control is used.

7. Set the OUTPUT RANGE switch to “WIRE WELDING CV.”

8. Set the WELDING TERMINALS switch to “WELDING TERMINALS REMOTELY CONTROLLED.”

9. Adjust wire feed speed at the SG Control Module.

NOTE: For remote control, a K857 remote control is required. Connect it to the 6-pin amphenol.

FIGURE C.6

RANGER 300 DLX/K691/K488/K487 SPOOL GUN CONNECTION DIAGRAM

K488 SG

TO WORK

CONTROL MODULE

RECEPTACLE

14 PIN WIRE FEEDER

RANGER

115V RECEPTACLE

K487-25 SPOOL GUN

ELECTRODE

INPUT CABLE

K691-10

6 PIN REMOTE

TO CONTROL MODULE

ELECTRODE CABLE

RECEPTACLE

TO WORK

CAUTION

CONNECTION OF THE K930-1 TIG MODULE TO THE RANGER 300 (DLX ONLY) USING K936 CONTROL CABLE (SEE FIGURE C.7.)

1. Shut the welder off.

2. Connect the electrode cable from the K930-1 TIG Module to the ELECTRODE terminal of the welder. Connect the work cable to the WORK terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

NOTE: Figure C.7 shows the electrode connected for positive polarity. Use the Polarity switch on the Ranger 300 DLX to select the desired electrode polarity.

3. Connect the K936-1 Control Cable to the K930-1 TIG Module and to the 14-pin amphenol on the Ranger 300 DLX.

4. Connect the K870 Foot Amptrol or K963-1 Hand Amptrol or K814 Arc Start Switch to the K930-1 TIG Module.

5. Place the IDLER switch in the “AUTO” or “HIGH” position as desired.

6. Set the LOCAL/REMOTE switch to “REMOTE.”

7. Set the OUTPUT RANGE switch to “STICK WELDING.”

8. Set the WELDING TERMINALS switch to “WELDING TERMINALS REMOTELY CONTROLLED.”

ACCESSORIES

C-9 C-9

RANGER 300 D and 300 DLX

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FIGURE C.7

RANGER 300 DLX/K930-1 TIG MODULE CONNECTION DIAGRAM

14 PIN AMPHENOL

ELECTRODE

K963-1 HAND AMPTROL

-OR-

K814 ARC START SWITCH

K870 FOOT AMPTROL

FLOWMETER

K936-1 CONTROL CABLE

INPUT

REGULATOR

TO GAS

FITTING

CYLINDER

ARGON GAS

TO WORK

CAUTION

NOTES

RANGER 300 D AND 300 DLX

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Section D-1 Section D-1

RANGER 300 D AND 300 DLX

TABLE OF CONTENTS

-MAINTENANCE-

Maintenance .........................................................................................................................Section D

Safety Precautions......................................................................................................................D-2

Kubota Engine Maintenance Schedule .....................................................................................D-2

Kubota Engine Maintenance Components ...............................................................................D-2

Routine and Periodic Maintenance ...........................................................................................D-3

Engine Maintenance.............................................................................................................D-3

Oil ..................................................................................................................................D-3

Changing the Oil ............................................................................................................D-3

Oil Filter ..........................................................................................................................D-3

Fuel.................................................................................................................................D-4

Bleeding the Fuel System ..............................................................................................D-4

Air Cleaner......................................................................................................................D-4

Tightening the Fan Belt .................................................................................................D-4

Cooling System..............................................................................................................D-4

Spark Arrester Screen....................................................................................................D-5

Battery Maintenance ............................................................................................................D-5

Cleaning the Battery ......................................................................................................D-5

Checking Specific Gravity..............................................................................................D-5

Checking Electrolyte Level.............................................................................................D-5

Charging the Battery......................................................................................................D-6

Welder/Generator Maintenance ...........................................................................................D-6

Storage...........................................................................................................................D-6

Cleaning .........................................................................................................................D-6

Brush Removal and Replacement ................................................................................D-6

Nameplates ....................................................................................................................D-6

Receptacles ...................................................................................................................D-6

Cable Connections.........................................................................................................D-6

Major Component Locations ...............................................................................................D-7

SAFETY PRECAUTIONS

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

Do not put your hands near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

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 throughout this operator’s manual and the Kubota Engine Operator’s Manual as well.

KUBOTA ENGINE MAINTENANCE SCHEDULE

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 filter every 100 hours.

Refer to your Kubota Engine Operator's Manual for periodic maintenance at 500 hours and beyond.

KUBOTA ENGINE MAINTENANCE COMPONENTS

TABLE D.2

MAINTENANCE

D-2 D-2

RANGER 300 D AND 300 DLX

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WARNING

FREQUENCY

Daily or Before Starting Engine

Every 50 Hours Every 100 Hours

Every 200 Hours

Every 400 Hours

MAINTENANCE REQUIRED

• Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose, or damaged parts.

• Check air intake and cooling areas, clean as necessary.

• Check fuel lines and clamps.

• Clean air filter element.

(1)

• Check battery electrolyte level.

• Check fan belt tightness.

• Change engine oil.

(2)

• Replace oil filter cartridge.

(2)

• Check radiator hoses.

• Replace fuel filter element.

ITEM

Oil Filter Element

Air Cleaner Element Fuel Filter Element

MAKE AND PART NUMBER

Kubota 16271-32092 Fram PH 3593A

Donaldson P148970 Kubota 15231-43560

Fram C6921

ROUTINE AND PERIODIC MAINTENANCE

ENGINE MAINTENANCE

(Refer to Figure D.3 for the location of maintenance components.)

To prevent the engine from accidentally starting, disconnect the negative battery cable before servicing the engine.

See Table D.1 for a summary of maintenance intervals for the items listed below. More frequent service may be required, depending on your specific application and operating conditions. See the Kubota Engine Operator's Manual for further information.

OIL

Check the oil level before starting engine or daily. BE SURE TO MAINTAIN THE OIL LEVEL. Change the oil for the first time after 50 hours of operation. Then, under normal operating conditions, change the oil as specified in the maintenance schedule.

CHANGING THE OIL

Change the oil, while the engine is still warm, as follows:

1. Drain the oil from the drain plug located on the engine bottom, as shown in Figure D.1.

2. Replace the plug and tighten it securely.

3. Remove the oil fill cap and add oil until the level reaches the full mark on the dipstick. The quantity of oil required for an oil and oil filter change is 5.4 quarts (5.1 L). Use oil that is rated for diesel engine service (API classification CD/CE). Use SAE viscosity grades per Table D.3.

TABLE D.3

4. Reinstall the oil fill cap and the dipstick and start the engine. Run for several minutes and stop engine. Wait 5 minutes to allow the oil to come down to the oil pan and check oil level again.

FIGURE D.1

OIL COMPONENT LOCATIONS

OIL FILTER

Change the oil filter the first time after 50 hours of operation. Then, under normal operating conditions, change the oil filter at every oil change. See Table D.2 for recommended oil filters.

Change the oil filter as follows:

1. Drain the oil from the engine and allow the oil filter to drain.

2. Remove the old filter (spin it off) and discard it. Wipe off the filter mounting surface and adapter.

3. Apply a thin coat of new oil to the rubber gasket on the new oil filter.

4. Spin the new filter on to the mounting adapter until the gasket just touches the mounting surface, then turn it down another 1/2 to 3/4 turn. Do not overtighten the new filter.

5. Refill the engine with the proper amount and type of oil as described in the Changing the Oil section. Start the engine and check for leaks around the filter element. Correct any leaks (usually by retightening the filter, but only enough to stop leaks) before placing the RANGER 300 back in service.

6. If there are no leaks, stop the engine and recheck the oil level. If necessary, add oil to bring the level up to the FULL mark, but do not overfill.

MAINTENANCE

D-3 D-3

RANGER 300 D AND 300 DLX

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CAUTION

Ambient Temperature

Above 25°C (77°F) 0°C (32°F) to 25°C (77°F) Below 0°C (32°F)

Viscosity Grades

SAE 10W-30, SAE10W-40 or SAE30

SAE 10W-30, SAE10W-40 or SAE20

SAE 10W-30, SAE10W-40 or SAE10

OIL DRAIN PLUG

OIL FILTER

OIL FILL CAP

OIL LEVEL DIP STICK

FUEL

At the end of each day’s use, refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the fuel to expand.

Use only fresh, No. 2 grade DIESEL fuel. Do not use kerosene.

See the Kubota Engine Operator's Manual for instructions on replacing the fuel filter. See Table D.2 for recommended fuel filters.

BLEEDING THE FUEL SYSTEM

You will need to bleed air from the fuel system any time the fuel filter or fuel lines have been detached and refitted; after the fuel tank has been run out of fuel; or before using the engine after long storage. Bleed the fuel system as follows:

To avoid personal injury, do not bleed a hot engine. This could cause fuel to spill onto a hot exhaust manifold, creating a danger of fire.

Refer to Figure D.2

1. Fill the fuel tank. Open the fuel cock.

2. Open the air vent plug on the fuel injection pump two turns using a 10mm wrench.

3. Move the fuel feed pump lever by hand until fuel flows out of the air vent plug.

4. Tighten the air vent plug.

FIGURE D.2

FUEL BLEEDING COMPONENT LOCATIONS

AIR CLEANER

The Kubota diesel engine is equipped with a dry type air filter. Never apply oil to it. See Table D.2 for recom- mended air cleaner. Service the air cleaner as follows:

1. Remove the dust cup from the bottom of the air cleaner housing. Clean out any accumulated dust.

2. If dust is sticking to the element, blow compressed air through the element from the inside out. Turn the element as you apply air. Air pressure should be under 99 psi (68 newton/cm

). Replace the fil-

ter if there is carbon or oil on the element.

3. Replace the element at least every 600 hours of operation and sooner under dusty conditions.

TIGHTENING THE FAN BELT

If the fan belt is loose, the engine can overheat and the battery lose its charge. Check tightness by pressing on the belt midway between the pulleys. It should deflect about .25 in. (6 mm) under a load of 20 lbs. (9 Kg).

COOLING SYSTEM

HOT COOLANT can burn skin.

• Do not remove cap if radiator is hot.

Check the coolant level by observing the level in the plastic reserve overflow tank. Add 50/50 antifreeze/ water solution if the level is close to or below the “LOW” mark. Do not fill above the “FULL” mark. Remove radiator cap and add coolant to radiator if overflow tank is empty.

To drain the coolant, open the petcock at the bottom of the radiator. Open the radiator cap to allow complete drainage. (Tighten the petcock and refill with a 50/50 antifreeze/water solution.) Use an automotive grade (low silicate) ethylene glycol antifreeze. The cooling system capacity is 5.4 quarts (5.1l.). Replace and tighten the radiator cap.

MAINTENANCE

D-4 D-4

RANGER 300 D AND 300 DLX

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WARNING

AIR VENT PLUG

FUEL FEED PUMP LEVER

WARNING

AIR VENT PLUG

FUEL FEED PUMP LEVER

Always premix the antifreeze and clean tap water before adding to the radiator or the overflow tank. It is very important that a precise 50/50 solution be used with this engine year round. This gives proper cooling during hot weather and freezing protection to -34°F (-37°C).

Cooling solution exceeding 50% ethylene glycol can result in engine overheating and damage to the engine. Coolant solution must be premixed before adding to radiator.

Periodically remove the dirt from the radiator fins.

Periodically check the fan belt and radiator hoses. Replace if signs of deterioration are found.

SP ARK ARRESTER SCREEN

If the muffler has the optional spark arrester, remove it every 50 hours or once a year, whichever comes first, and inspect it. Clean the arrester. Replace it if you find any damage.

BATTERY MAINTENANCE

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY – disconnect neg- ative 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.

To prevent ELECTRICAL DAMAGE when:

a) Installing a battery.

b) Using a booster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an ignition switch, turn it off when engine is not running.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 kg) of baking soda and 1 quart (0.946 l) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells.

After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clean water. Coat the battery terminals lightly with petroleum jelly or a non-conductive grease to retard corrosion.

Keep the battery clean and dry. Moisture accumulation on the battery can lead to more rapid discharge and early battery failure.

CHECKING SPECIFIC GRAVITY

Check each battery cell with a hydrometer. A fully charged battery will have a specific gravity of 1.260. Charge the battery if the reading is below 1.215.

NOTE: Correct the specific gravity reading by adding four gravity points (0.004) for every five degrees the electrolyte temperature is above 80°F (27°C). Subtract four gravity points (9.004) for every five degrees the electrolyte temperature is below 80°F (27°C).

CHECKING ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks.

The battery is a group 45, with a rating of 495 cold cranking amps.

MAINTENANCE

D-5 D-5

RANGER 300 D AND 300 DLX

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CAUTION

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MAINTENANCE

D-6 D-6

RANGER 300 D AND 300 DLX

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The RANGER 300 positive (+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. after the battery is charged, reconnect the positive battery cable first and the negative cable last. Failure to do so can result in damage to the internal charger components.

Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.

WELDER / GENERATOR MAINTENANCE

STORAGE

Store the RANGER 300 in clean, dry protected areas.

CLEANING

Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT

It is normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary.

Do not attempt to polish slip rings while the engine is running.

NAMEPLATES

Whenever routine maintenance is performed on this machine - or at least yearly - inspect all nameplates and labels for legibility. Replace nameplates that are no longer clear. Refer to the parts list for the replacement item number.

RECEPTACLES

Keep the electrical receptacles in good condition. Remove any dirt, oil, or other debris from their surfaces and holes.

CABLE CONNECTIONS

Check the welding cable connections at the weld output terminals often. Be sure that the connections are always firm.

WARNING

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MAINTENANCE

D-7 D-7

RANGER 300 D AND 300 DLX

FIGURE D.3

MAJOR COMPONENT LOCATIONS

11. CAPACITOR BANK (RANGER 300 DLX ONLY)

12. RADIATOR ASSEMBLY

13. CHOKE ASSEMBLY

14. LIFT BAIL WELDED ASSEMBLY

15. CASE BACK ASSEMBLY

16. FIELD CAPACITOR AND RECTIFIER BRIDGE

17. CONTACTOR (RANGER 300 DLX ONLY)

18. FUEL SHUTOFF & IDLER ASSEMBLY

19. CASE TOP

20. DOOR ASSEMBLY

1. OUTPUT TERMINALS

2. ENGINE CONTROLS

3. AUXILIARY POWER RECEPTACLES

4. OUTPUT CONTROL PANEL

5. REACTOR ASSEMBLY

6. FUEL TANK

7. DIESEL ENGINE

8. ROTOR/STATOR ASSEMBLY

9. BASE WELDED ASSEMBLY

10. P.C. BOARD COVER

NOTES

RANGER 300 D AND 300 DLX

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Section E-1 Section E-1

RANGER 300 D AND 300 DLX

Theory of Operation .............................................................................................................Section E

Battery, Starter, Engine, Glow Plugs, Engine Protection, Rotor, Stator, and

Idler Solenoid ..............................................................................................................................E-2

Rotor Field Feedback, Auxiliary and Wire Feeder Power...........................................................E-3

Weld Winding, Reactor, and Range Switch ................................................................................E-4

Output Bridge, Choke, Polarity Switch, CV Contactor, and Output Terminals ..........................E-5

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

RANGE

SWITCH

REACTOR

STATOR

ROTOR

MECHANICAL

ROTATION

ENGINE

GLOW PLUGS

BATTERY

6 PIN

AMPHENOL

14 PIN

AMPHENOL

OUTPUT

CONTROL

REMOTE SWITCH

BY-PASS

BOARD

SHUTDOWN

SOLENOID

STARTER

MOTOR

ALTERNATOR

IDLER

SOLENOID

PRINTED CIRCUIT BOARD

FIELD

CAPACITOR

FIELD

BRIDGE

115 & 230VAC RECEPTACLES

OUTPUT

RECTIFIER

BRIDGE

CAPACITORS

PART OF

RANGE

SWITCH

CHOKE

POLARITY

SWITCH

WORK

TERMINAL

ELECTRODE

TERMINAL

CONTACTOR CLOSURE

ROTOR

SLIP

RINGS

42VAC

115VAC

output

contactor

CONTACTOR CLOSURE

OIL &

WATER

SENSORS

RANGER 300 DLX

FIGURE E.1

RANGER 300 BLOCK LOGIC DIAGRAM

BATTERY, STARTER, ENGINE, GLOW PLUGS, ENGINE PROTECTION, ROTOR, STATOR AND IDLER SOLENOID

The 12VDC battery powers the starter motor and glow plugs. The glow plugs are used to preheat the diesel engine to enhance starting. When the engine is started and running, the battery circuit voltage is fed through the printed circuit board to the rotating field coil in the rotor via a brush and slip ring configuration. This excitation (“flashing”) voltage magnetizes the rotor lamination. The rotor is mechanically coupled to the engine. This rotating magnet induces a voltage in the stationary windings of the main alternator (stator). There are four separate and isolated windings incorporated in the stator lamination assembly. Each set has a different number of turns producing different magnitudes of AC output voltages. These four windings are the weld winding, the auxiliary power winding, the field

feedback winding and the auxiliary power winding for wire feeders. The field feedback winding provides rotor current during machine operation. The output of the Ranger 300 is dependent on two criteria, the engine RPM and the amount of current in the rotor winding.

The engine alternator supplies “charging” current for the battery circuit. The battery circuit provides power for the printed circuit board and also for the idler solenoid. The idler solenoid is mechanically connected to the engine's throttle linkage. If welding or auxiliary current is being drawn from the Ranger 300, the printed circuit board activates the idler solenoid, which then brings the engine to the high RPM state. When no output current is sensed, either weld or auxiliary, the printed circuit board deactivates the idler solenoid and the engine returns to low RPM.

The engine protection circuit shuts the engine off in the event of low oil pressure or engine coolant over-temperature.

THEORY OF OPERATION

E-2 E-2

RANGER 300 D AND 300 DLX

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FIGURE E.2

BATTERY, STARTER, ENGINE, GLOW PLUGS,ENGINE PROTECTION,

ROTOR, STATOR AND IDLER SOLENOID

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGE

SWITCH

REACTOR

STATOR

ROTOR

MECHANICAL

ROTATION

ENGINE

GLOW PLUGS

BATTERY

6 PIN

AMPHENOL

14 PIN

AMPHENOL

OUTPUT

CONTROL

REMOTE

SWITCH

BY-PASS

BOARD

SHUTDOWN SOLENOID

STARTER

MOTOR

ALTERNATOR

IDLER

SOLENOID

PRINTED CIRCUIT BOARD

FIELD

CAPACITOR

FIELD

BRIDGE

115 & 230VAC

RECEPTACLES

OUTPUT

RECTIFIER

BRIDGE

CAPACITORS

PART OF

RANGE

SWITCH

CHOKE

POLARITY

SWITCH

WORK

TERMINAL

ELECTRODE

TERMINAL

CONTACTOR CLOSURE

ROTOR

SLIP

RINGS

42VAC

115VAC

cv output contactor

CONTACTOR CLOSURE

OIL &

WATER

SENSORS

RANGER 300 DLX

ROTOR FIELD FEEDBACK, AUXILIARY AND WIRE FEEDER POWER

The AC voltage developed in the field winding is fed to the full wave field bridge. The DC output of the field bridge is filtered by the field capacitor and controlled by the printed circuit board according to the setting of the machine’s output control or remote control. This filtered and controlled voltage is fed to the rotor winding via the brush and slip ring configuration. As the feedback voltage is increased or decreased, the outputs of the weld and auxiliary windings are increased or decreased.

When full field voltage is applied to the rotor and the engine is running at high speed (3600 RPM), a 230VAC voltage is developed in the stator auxiliary winding. This winding is tapped to provide 115VAC. The two voltages (115VAC and 230VAC), are connected to the appropriate receptacles and offer 12,000 watts (total) of AC power.

The auxiliary wire feeder winding offers 115VAC and is tapped to also provide 42VAC. The current draw from this winding should be limited to 8 amps. These voltages and remote control signals are fed through the by-pass (filter) board to the amphenol receptacles.

THEORY OF OPERATION

E-3 E-3

RANGER 300 D AND 300 DLX

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

FIGURE E.3

ROTOR FIELD FEEDBACK, AUXILIARY AND WIRE FEEDER POWER

RANGE

SWITCH

REACTOR

STATOR

ROTOR

MECHANICAL

ROTATION

ENGINE

GLOW PLUGS

BATTERY

6 PIN

AMPHENOL

14 PIN

AMPHENOL

OUTPUT

CONTROL

REMOTE SWITCH

BY-PASS BOARD

SHUTDOWN

SOLENOID

STARTER

MOTOR

ALTERNATOR

IDLER

SOLENOID

PRINTED CIRCUIT BOARD

FIELD

CAPACITOR

FIELD

BRIDGE

115 & 230VAC

RECEPTACLES

OUTPUT

RECTIFIER

BRIDGE

CAPACITORS

PART OF

RANGE

SWITCH

CHOKE

POLARITY

SWITCH

WORK

TERMINAL

ELECTRODE

TERMINAL

CONTACTOR CLOSURE

ROTOR

SLIP

RINGS

42VAC

115VAC

output

contactor

CONTACTOR CLOSURE

OIL &

WATER

SENSORS

RANGER 300 DLX

WELD WINDING, REACTOR AND RANGE SWITCH

The stator weld winding is connected to the reactor and range switch. The inductance in the reactor offers an impedance to current flow. The reactor coil is tapped at various points. As the range switch is rotated, different amounts of reactor coil are brought into

the current path. As more turns of reactor are brought into the circuit, the more impedance there is to current flow. Simply stated, the more reactor in the circuit, the lower the welding current.

If a constant voltage is desired for wire feeding, then the reactor is bypassed, and the range switch is connected to one of four taps on the stator weld winding to provide a lower but “stiffer” output voltage.

THEORY OF OPERATION

E-4 E-4

RANGER 300 D AND 300 DLX

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FIGURE E-4

WELD WINDING, REACTOR AND RANGE SWITCH

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGE

SWITCH

REACTOR

STATOR

ROTOR

MECHANICAL

ROTATION

ENGINE

GLOW PLUGS

BATTERY

6 PIN

AMPHENOL

14 PIN

AMPHENOL

OUTPUT

CONTROL

REMOTE

SWITCH

BY-PASS

BOARD

SHUTDOWN SOLENOID

STARTER

MOTOR

ALTERNATOR

IDLER

SOLENOID

PRINTED CIRCUIT BOARD

FIELD

CAPACITOR

FIELD

BRIDGE

115 & 230VAC

RECEPTACLES

OUTPUT

RECTIFIER

BRIDGE

CAPACITORS

PART OF

RANGE

SWITCH

CHOKE

POLARITY

SWITCH

WORK

TERMINAL

ELECTRODE

TERMINAL

CONTACTOR CLOSURE

ROTOR

SLIP

RINGS

42VAC

115VAC

cv output contactor

CONTACTOR CLOSURE

OIL &

WATER

SENSORS

RANGER 300 DLX

OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, OUTPUT CONTACTOR AND OUTPUT TERMINALS

The AC voltage developed in the stator weld winding is delivered, through the reactor and range switch, to the output bridge and polarity switch. Depending upon the setting of the polarity switch, either AC voltage or DC voltage is delivered to the output terminals. If AC output is selected, the current path is from the stator weld winding through the reactor, range switch, and polarity switch; through the output contactor to the output terminals. If a DC output is called for, the current path is through the output rectifier bridge,

where the AC voltage is rectified to a DC voltage; and then to the choke, where the DC output is filtered. The filtered DC current path is through the polarity switch and output contactor to the output terminals.

When a CV (constant voltage) is desired, the reactor is passed by. The range switch applies a lower AC voltage to the rectifier bridge. The DC output of the bridge is filtered and “stiffened” by the capacitors. This lower but “stiffer” DC output is passed through the tapped portion of the choke, the polarity switch, and output contactor to the output terminals.

In the Ranger 300DLX machines, the output contactor is in series with the electrode terminal and must be energized (closed) to provide welding voltage at the output terminals.

THEORY OF OPERATION

E-5 E-5

RANGER 300 D AND 300 DLX

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RANGE

SWITCH

REACTOR

STATOR

ROTOR

MECHANICAL

ROTATION

ENGINE

GLOW PLUGS

BATTERY

6 PIN

AMPHENOL

14 PIN

AMPHENOL

OUTPUT

CONTROL

REMOTE SWITCH

BY-PASS BOARD

SHUTDOWN

SOLENOID

STARTER

MOTOR

ALTERNATOR

IDLER

SOLENOID

PRINTED CIRCUIT BOARD

FIELD

CAPACITOR

FIELD

BRIDGE

115 & 230VAC RECEPTACLES

OUTPUT

RECTIFIER

BRIDGE

CAPACITORS

PART OF

RANGE

SWITCH

CHOKE

POLARITY

SWITCH

WORK

TERMINAL

ELECTRODE

TERMINAL

CONTACTOR CLOSURE

ROTOR

SLIP

RINGS

42VAC

115VAC

output

contactor

CONTACTOR CLOSURE

OIL &

WATER

SENSORS

RANGER 300 DLX

FIGURE E.5 – OUTPUT BRIDGE, CHOKE, POLARITY SWITCH, OUTPUT CONTACTOR

AND OUTPUT TERMINALS

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

NOTES

RANGER 300 D AND 300 DLX

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Section F-1 Section F-1

RANGER 300 D AND 300 DLX

Troubleshooting & Repair Section.................................................................................Section F

How to Use Troubleshooting Guide ......................................................................................F-2

PC Board Troubleshooting Procedures .................................................................................F-3

Troubleshooting Guide.................................................................................................F4 - F-20

Test Procedures ...................................................................................................................F-21

Rotor Resistance Test ..................................................................................................F-21

Output Rectifier Bridge Test .........................................................................................F-23

Fuel Shutdown Solenoid Resistance Test ...................................................................F-25

High Speed Solenoid Test ............................................................................................F-27

Engine Throttle Adjustment Test ..................................................................................F-29

Auxiliary and Field Winding Test ...................................................................................F-33

Rotor Voltage Test ........................................................................................................F-37

Charging Circuit Test.....................................................................................................F-39

Oscilloscope Waveforms .....................................................................................................F-41

Normal Open Circuit Voltage Waveform (115 VAC Supply) .........................................F-41

Typical DC Weld Output Voltage Waveform (CV Mode High Tap) ................................F-42

Typical DC Weld Output Voltage Waveform..................................................................F-43

Typical AC Weld Output Voltage Waveform..................................................................F-44

Abnormal Open Circuit DC Weld Voltage Waveform ....................................................F-45

Abnormal Open Circuit Weld Voltage Waveform (High CV Mode) ...............................F-46

Normal Open Circuit Weld Voltage Waveform (High CV Mode) ...................................F-47

Normal Open Circuit DC Weld Voltage Waveform .......................................................F-48

Normal Open Circuit AC Weld Voltage Waveform .......................................................F-49

Replacement Procedures ....................................................................................................F-50

Brush Removal and Replacement ...............................................................................F-50

Field Capacitor and/or Rectifier Bridge Removal and Replacement ...........................F-53

Control Board Removal and Replacement ..................................................................F-56

Output Rectifier Bridge Removal and Replacement.....................................................F-59

Output Capacitor Bank Removal and Replacement.....................................................F-62

Output Contactor Removal and Replacement..............................................................F-64

Stator and/or Rotor Removal and Replacement .........................................................F-67

Retest After Repair ..............................................................................................................F-72

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

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TROUBLESHOOTING & REPAIR

F-2 F-2

RANGER 300 D AND 300 DLX

HOW TO USE TROUBLESHOOTING GUIDE

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.

CAUTION

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM” (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into four main categories: Output Problems, Engine Problems Function Problems, and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case cover.

Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

WARNING

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.

TROUBLESHOOTING & REPAIR

F-3 F-3

RANGER 300 D AND 300 DLX

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Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC board can be damaged by static electricity.

- Remove your body’s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

- If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

ELECTRIC SHOCK can kill.

•

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shielding bag.

- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure

symptom has been corrected by the replacement PC board.

NOTE

: It is desirable to have a spare (known good)

PC board available for PC board troubleshooting. NOTE: Allow the machine to heat up so that all

electrical components can reach their operating temperature.

5. Remove the replacement PC board and

substitute it with the original PC board to recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was

followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

WARNING

CAUTION

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TROUBLESHOOTING & REPAIR

F-4 F-4

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical damage is evident.

1. Contact your local Lincoln Authorized Field Service Facility.

1. Contact The Lincoln Electric Service Dept. 1-800-833-9353 (WELD).

No weld output and no auxiliary power. Engine operates normally.

1. Make sure the REMOTE switch (S8) is in the proper position – “MACHINE CONTROL” – if a remote control unit is NOT connected to the machine.

2. Check the brushes for wear and proper contact to the rotor slip rings.

1. Perform the Rotor Voltage Test.

2. If the Rotor Voltage Test is normal, perform the Rotor Resistance Test.

3. If the Rotor Voltage Test is NOT normal, perform the Auxiliary

and Field Winding Voltage Test. Then check the field

diode bridge (D2), the field capacitor (C1), and the Output Control (R3). Replace if necessary.

4. The control board may be faulty. Replace.

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TROUBLESHOOTING & REPAIR

F-5 F-5

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

No weld output, the auxiliary power (230-115VAC) is operating normally. Engine operates normally.

1. On DLX machines, the output contactor must be activated (closed).

2. Normal AC open circuit voltage is approximately 70 to 80 volts. Normal DC is 64 to 74VDC. If the open circuit voltage is NOT present at the welder output terminals, contact your local Lincoln Authorized Field Service Facility.

3. If normal open circuit voltage is present at the output terminals, check the welding cables, clamps, and electrode holder for loose or broken connections.

1. On DLX machines, the output contactor or associated leads may be faulty. See the Wiring Diagram. The output contactor coil is energized by 12VDC. If the coil is not receiving 12VDC when the Welding Terminals Switch is in the “Always ON” position, the control board may be faulty. Also check associated leads #224 and #232.

2. If OCV is absent in both modes (CV & CC), disconnect lead W1 from the output bridge (D1). With the engine at high idle and the output control at maximum, check for 70 to 76VAC from lead W1 to lead W2 on the main stator winding. See the Wiring Diagram. If the AC voltage is NOT present, the winding may be faulty. Check the winding for continuity and test to be sure it is NOT grounded to the stator iron. Replace if necessary. If the voltage is present, proceed to step #3.

(continued on page F-6)

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TROUBLESHOOTING & REPAIR

F-6 F-6

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES

TROUBLESHOOTING GUIDE

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

(continued from page F-5) 3. Check the reactor, range switch

(S2) and associated wires for loose or faulty connections. Check the reactor winding for continuity and test to be sure it is NOT grounded to the reactor iron.

4. Check the choke (L1), polarity mode switch (S1), and associated wires for loose or faulty connections. Check the choke winding for continuity and test to be sure it is NOT grounded to the choke iron.

5. Check the weld output terminals and associated wires for loose or faulty connections.

6. Perform the Output Rectifier

Bridge Test.

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TROUBLESHOOTING & REPAIR

F-7 F-7

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

No auxiliary power at receptacles

- welding output is normal - engine runs normally.

1. If the machine is equipped with circuit breakers, check circuit breakers. Reset if tripped.

2. Make sure the output control (R1) is set at the maximum position.

3. Check for a loose or faulty plug(s) at the power receptacles.

1. Check the auxiliary power receptacles and associated wires for loose or faulty connections.

2. Perform the Auxiliary and

Field Winding Voltage Test.

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TROUBLESHOOTING & REPAIR

F-8 F-8

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES

TROUBLESHOOTING GUIDE

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

Machine has low welding output and low auxiliary output.

1. If a remote control unit is NOT connected to the machine, make sure the REMOTE switch is in the proper position “MACHINE CONTROL.”

2. The brushes may be worn. Contact your local Lincoln Authorized Field Service Facility.

3. The Engine RPM may be low.

1. If the engine high idle RPM is low, perform the Engine

Throttle Adjustment Test.

2. Perform the Rotor Voltage Test.

3. If the rotor voltage is low, the field capacitor (C1) or the field bridge (D2) may be faulty. Test and replace if necessary.

4. Check the output control potentiometer (R3). Normal resistance is 10,000 ohms. Also check associated wiring for loose or faulty connections.

5. The rotor may be faulty. Perform the Rotor Resistance

Test.

6. The control board may be faulty. Replace.

7. If the engine high idle RPM is OK, the engine may have lost horsepower and be in need of major repair.

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TROUBLESHOOTING & REPAIR

F-9 F-9

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

No DC welding output. AC welding output and auxiliary power are normal.

1. Make sure the polarity mode switch (S1) is in the proper position and is “seated” correctly.

2. Make sure the electrode and polarity are correct for the process being used.

1. Perform the Output Rectifier

Bridge Test.

2. Check the choke (L1), the polarity mode switch (S1) and associated wires for loose or faulty connections. Check the choke winding for continuity and test to be sure it is NOT grounded to the choke iron.

No AC welding output. DC welding output and auxiliary power are normal.

1. Make sure the polarity mode switch (S1) is in the proper position and is “seated” correctly.

2. Make sure the electrode is correct for the process being used.

3. Make sure the welding cables are not coiled or too long.

1. Check the operation of the polarity switch (S1). Also check the associated wires for loose or faulty connections. See the Wiring Diagram.

2. Check for continuity from lead “A1” to lead “A2.” See the Wiring Diagram.

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TROUBLESHOOTING & REPAIR

F-10 F-10

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES

TROUBLESHOOTING GUIDE

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

OUTPUT PROBLEMS

No constant voltage (CV) welding output. Constant current (CC) and auxiliary power are operating normally.

1. Make sure the range switch (S2) is in the proper position and “seated” correctly.

2. Make sure the wire feeder and welding cables are connected correctly.

1. Check the operation of the range switch (S2) and check the associated wires for loose or faulty connections. See the Wiring Diagram.

2. Check the continuity from leads C1 to lead W1 located in the main stator. See the Wiring Diagram. On DLX machines, also check leads C2, C3, and C4 to lead W1.

3. On DLX machines, check the capacitors and associated leads. See the Wiring Diagram.

The constant voltage (CV) welding output is low or unstable. Constant current (CC) and auxiliary power are operating normally.

1. Make sure the range switch and polarity switch are in the correct position (CV) and “seated” correctly.

2. Make sure the wire feeder and welding cables are connected correctly.

1. Check the operation of the range switch (S2) and check the associated wires for loose or faulty connections. See the Wiring Diagram.

2. On DLX machines the capacitor bank (C2, C3, C4, and C5) may be faulty. Check or replace.

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TROUBLESHOOTING & REPAIR

F-11 F-11

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

Engine will not idle down to low speed. Machine has normal weld output and auxiliary power.

1. Make sure the idler switch (S5) is in the “Auto” position.

2. Make sure there is NOT an external load on the weld terminals nor the auxiliary power receptacles.

1. With the idler switch (S5) in the “Auto” position, no external load connected to the machine and the engine running, check the DC voltage at leads #222J to #214 located at the idler solenoid. Also check from leads #222H to #213. No (zero) volts is normal. If 12VDC IS present, the control board may be faulty. If no voltage is indicated and the solenoid is keeping the engine in a high speed condition, the idler solenoid may be faulty. Also check for a mechanical restriction in the throttle linkage.

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F-12 F-12

RANGER 300 D AND 300 DLX

TROUBLESHOOTING & REPAIR

OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DETAILED IN THE BEGINNING OF THIS MANUAL.

CAUTION

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

Engine will not go to high idle when attempting to weld. Welding output is normal when idler switch is in “HIGH” position. Automatic idle function works properly when the auxiliary power is loaded.

1. Make sure the welding cables and connections are tight.

2. If welding without a control cable connected to the DLX machine, the welding terminals switch (S7) must be in the “Always On” position.

1. Check for broken or faulty connections in the sensing leads #254 and #254 A & B). Make sure their connections are tight at the work output terminal and polarity mode switch. See the Wiring Diagram.

2. Make sure leads #254 and #254C are looped three times through the current sensor on the control board. See the Wiring Diagram.

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TROUBLESHOOTING & REPAIR

F-13 F-13

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

The engine will not go to high idle when attempting to weld or when the auxiliary power is loaded.

1. Check circuit breaker CB8. Reset if tripped.

2. Make sure the welding cables and auxiliary power lead connections are tight.

3. Automatic idler may not function if the auxiliary power is loaded to less than 150 watts.

1. Check for broken or faulty connections in the sensing leads (#254, #254A, and lead #3 and #6). Make sure leads #3 and #6 are looped through the AC current sensor.

2. The control board may be faulty. Replace.

3. Perform the High Speed

Solenoid Resistance Test.

4. Check the leads and associated connections between the high speed solenoid and the control board.

The engine will not crank or cranks very slowly.

1. Check for loose or faulty battery cable connections.

2. The battery may be faulty.

1. If the battery is replaced or tests good, the charging circuit may be faulty. Perform the

Charging Circuit Test.

2. The starter motor or starter solenoid may be faulty.

3. The engine may be hard to crank due to a mechanical failure in the engine.

CAUTION

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TROUBLESHOOTING & REPAIR

F-14 F-14

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES

TROUBLESHOOTING GUIDE

DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

The engine cranks but will not start.

1. The engine may be low on or out of fuel.

2. Make sure the on/off switch (S6) is in the “ON” position.

3. The oil level or pressure may be low, causing the engine protection system to shut off fuel flow to the engine. Check the oil pressure light.

4. The engine coolant may be overheated, causing the engine protection system to shut off fuel flow to the engine. Check the water temperature light.

5. The engine “glow” plugs may not be operating correctly.

1. The fuel solenoid may be faulty. Perform the Fuel Shutdown

Solenoid Resistance Test.

2. The engine may be faulty.

3. The control board may be faulty.

CAUTION

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TROUBLESHOOTING & REPAIR

F-15 F-15

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

ENGINE PROBLEMS

The engine shuts off shortly after starting.

1. The oil level or pressure may be low, causing the engine protection system to shut off fuel flow to the engine. Check the oil pressure light.

2. Check for adequate fuel supply.

3. Circuit breaker CB9, located in the engine compartment, may be open. If CB9 is tripped, the oil pressure and charging indicator lights will not be on when the engine switch is in the “ON” position and the engine is not running.

1. The fuel shutdown solenoid may be faulty. Perform the Fuel

Shutdown Solenoid Resistance Test.

2. The control board may be faulty.

CAUTION

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TROUBLESHOOTING & REPAIR

F-16 F-16

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

Output control on welder not functioning.

1. Make sure the REMOTE switch (S8) is in the MACHINE CONTROL position.

2. The output control (R3) may be defective.

1. Check the output control (R3). Normal resistance is 10,000 ohms. Replace if defective.

2. Check the REMOTE switch (S8) and associated wiring. See the Wiring Diagram (leads #75, #76 and #77).

3. The control board may be faulty. Replace.

Remote output control not functioning.

1. Make sure the remote switch (S8) is in the REMOTE position.

2. The remote control unit may be faulty. Repair or replace.

1. Check the remote switch (S8) and associated wiring. See the Wiring Diagram (leads #75, #76 and #77).

2. The RF bypass board may be defective. Check or replace.

CAUTION

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TROUBLESHOOTING & REPAIR

F-17 F-17

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

The wire feeder does not work when connected to the welder 14pin amphenol (DLX machines only).

1. Check circuit breaker CB1. Reset if tripped.

2. The wire feeder control cable may be faulty. Check or replace.

3. The wire feeder may be faulty. Check or replace.

1. Check for the presence of 115VAC at leads #31A and 32. See the Wiring Diagram.

2. Check for the presence of 42VAC at leads #31B to #42. See the Wiring Diagram.

3. If any of the above voltages are missing or low, check the circuit breaker CB1 for proper operation.

4. The RF bypass board may be faulty. Check or replace.

5. Perform the Auxiliary and

Field Winding Voltage Test.

CAUTION

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TROUBLESHOOTING & REPAIR

F-18 F-18

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES TROUBLESHOOTING GUIDE DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

With the engine running, the output contactor does not pull in when using a wire feeder with a control cable connected to the RANGER 300 DLX amphenol.

1. Make sure the Welding Terminals switch (S8) is in the “Welding Terminals Remotely Controlled” position.

2. If the output contactor activates (closes) when switch S8 is in the “Welding Terminals Always On” position, the contactor and control PC board are functioning.

3. Install a jumper wire from pins “D” to “C” on the 14-pin amphenol. If the output contactor activates, the problem is external to the RANGER 300 DLX. The wire feeder or control cable may be faulty.

1. With Welding Terminals switch (S8) in the “Welding Terminals Always On” position, check for 12VDC from leads #224(+) to #232(-) at the output contactor. If 12VDC is present and the contactor does NOT activate, the contactor may be defective. See the Wiring Diagram.

2. If the correct voltage is NOT present in Step #1, check from lead #224 to ground (lead #5) for the presence of 12VDC. If 12VDC IS present, check the continuity of lead #232 to 9J2 on the control board. See the Wiring Diagram.

3. If 12VDC is NOT present from lead #224 to ground (lead #5), check the continuity of lead #224 to 1J1 on the control board. See the Wiring Diagram.

4. The control board may be faulty.

CAUTION

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TROUBLESHOOTING & REPAIR

F-19 F-19

RANGER 300 D AND 300 DLX

TROUBLESHOOTING GUIDE OBSERVE SAFETY GUIDELINES

DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

FUNCTION PROBLEMS

The battery does not stay charged. 1. Check for loose or faulty con-

nections at the battery and engine charging system.

1. Perform the Charging Circuit

Test.

CAUTION

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F-20 F-20

TROUBLESHOOTING & REPAIR

RANGER 300 D AND 300 DLX

OBSERVE SAFETY GUIDELINES

TROUBLESHOOTING GUIDE

DETAILED IN THE BEGINNING OF THIS MANUAL.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

RECOMMENDED COURSE OF ACTION

WELDING PROBLEMS

The welding arc is “cold.” The engine runs normally (3700 RPM no load). The auxiliary power is functioning normally.

1. Check for loose or faulty connections at the weld output terminals and welding cable connections.

2. The welding cables may be too long or coiled, causing an excessive voltage drop.

1. Check for the correct open circuit voltage (OCV) at the welding output terminals. If the correct voltage is present at the output terminals, check for loose connections on the heavy current carrying leads inside the Ranger 300 D. See the Wiring Diagram.

2. If the OCV is low at the welder output terminals, perform the

Engine Throttle Adjustment Test.

3. Perform the Output Rectifier Bridge Test.

4. Check for shorted or grounded windings in the reactor and also in the main stator. See the Wiring Diagram.

CAUTION

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ROTOR 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.

TEST DESCRIPTION

This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.

MATERIALS NEEDED

Volt/Ohmmeter 5/16” Nut driver 3/8” Nut driver Need nose pliers Wiring Diagram

This procedure requires approximately 20 minutes to perform.

TROUBLESHOOTING & REPAIR

F-21 F-21

RANGER 300 D AND 300 DLX

WARNING

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TROUBLESHOOTING & REPAIR

F-22 F-22

RANGER 300 D AND 300 DLX

ROTOR RESISTANCE TEST (continued)

FIGURE F.1 – ROTOR BRUSH LEADS REMOVED

TEST PROCEDURE

1. Conduct the test with the engine OFF.

2. Using the 5/16” and 3/8” nut drivers, remove the right front case side.

3. Locate, label and remove the two leads from the rotor brush holder assembly (lead #219 from the negative brush and lead #220A from the positive brush). See Figure F.1. This will electrically isolate the rotor windings.

4. Using the volt/ohmmeter, check the rotor winding resistance across the slip rings. Set the meter on the low scale (X1). Normal resistance is approximately 5 or 6 ohms.

5. Measure the resistance to ground. Set the meter on the high scale (X100,000). Place one meter probe on either of the slip rings. Place the other probe on any good unpainted ground. The resistance should be very high, at least 500,000 ohms.

6. If the test does not meet the resistance specifications, then the rotor may be faulty.

7. Connect the leads previously removed from the brush assembly. Make sure the leads are connected to the proper brushes

- lead #219 to the negative brush, lead #200A to the positive brush.

8. Replace the right front case side previously removed.

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TROUBLESHOOTING & REPAIR

F-23 F-23

RANGER 300 D AND 300 DLX

WARNING

OUTPUT RECTIFIER BRIDGE TEST

TEST DESCRIPTION

This test will determine if there are faulty diodes in the output rectifier bridge.

MATERIALS NEEDED

Volt/Ohmmeter (Diode Tester) 5/16” Nut driver 3/8” Nut driver 1/2” Wrench Wiring Diagram

This procedure requires approximately 35 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-24 F-24

RANGER 300 D AND 300 DLX

OUTPUT RECTIFIER BRIDGE TEST (continued)

FIGURE F.2 – LOCATION OF OUTPUT RECTIFIER DIODE LEADS

TEST PROCEDURE

1. Conduct this test with the engine off.

2. Using the 3/8” wrench, remove the sheet metal screws from the right and left front case sides.

3. Carefully remove the right and left front case sides.

4. Locate the two halves of the output rectifier. The negative plate is located on the lower left side of the machine behind the case front. The positive plate is located on the lower right side of the machine behind the case front. See Figure F.2.

5. Using the 1/2” wrench, remove the nuts and washers holding the diode pigtails and the heavy current-carrying leads to the studs on the rectifier plates. Note leads and pigtail placement for reassembly.

6. Electrically isolate the diode pigtail leads by carefully bending them out into “free air.”

7. With an ohmmeter or diode tester, check each of the four diodes from their pigtails to their respective heat sinks.

8. Reverse the tester leads and check the diodes again. Diodes should have a low resistance in one polarity and a very high resistance in the opposite polarity.

9. Replace any “shorted” or “open” diode as the tests indicate. See the Diode

Removal and Replacement Procedure.

10. Replace the pigtails and heavy leads onto the correct studs. Assemble the washers and nuts.

11. Replace the left and right front case sides.

Left side (–)

Right side (+)

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TROUBLESHOOTING & REPAIR

F-25 F-25

RANGER 300 D AND 300 DLX

WARNING

FUEL SHUTDOWN SOLENOID RESISTANCE TEST

TEST DESCRIPTION

This test will determine if the shutdown solenoid coil resistances are normal.

MATERIALS NEEDED

Ohmmeter Wiring Diagram

This procedure requires approximately 25 minutes to perform.

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TEST PROCEDURE

1. Conduct this test with the engine off.

2. Unlatch and open the right side engine access door.

3. Locate and disconnect plug J12. See Figure F.3. Also see the Wiring Diagram.

TROUBLESHOOTING & REPAIR

F-26 F-26

RANGER 300 D AND 300 DLX

FUEL SHUTDOWN SOLENOID RESISTANCE TEST (continued)

FIGURE F.3 – PLUG J12 LOCATION

FIGURE F.4 – PLUG J12 PIN/LEAD ASSIGNMENTS

LEAD #237

LEAD #224B

LEAD #5K

4. Using the ohmmeter, check the resistance from lead #237 to lead #5K. See Figure F.4. Normal resistance of the “pull-in” coil is approximately 0.5 ohms.

5. Using the ohmmeter, check the resistance from lead #224B to lead #5K. See Figure F.4. Normal resistance of the “hold-in” coil is approximately 11.5 ohms.

NOTE: This solenoid is activated with 12VDC. The “hold-in” voltage is derived from the control board. The “pull-in” voltage is derived from the starter contactor. See the Wiring Diagram. If the 12VDC is not present, check the leads and associated connections.

6. Reassemble plug J12 and close and latch the engine access door.

PLUG J12 LOCATION

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TROUBLESHOOTING & REPAIR

F-27 F-27

RANGER 300 D AND 300 DLX

WARNING

HIGH SPEED SOLENOID TEST

TEST DESCRIPTION

This test will determine if the solenoid coil resistance is normal and also if the solenoid is capable of functioning when it is energized with 12VDC.

MATERIALS NEEDED

External 12VDC supply (30 amps) Wiring Diagram Volt/Ohmmeter

This procedure requires approximately 35 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-28 F-28

RANGER 300 D AND 300 DLX

HIGH SPEED SOLENOID TEST (continued)

FIGURE F.5 – SOLENOID LEADS

PULL-IN COIL (LARGER TERMINALS TOP AND BOTTOM #222H AND #213A)

HOLD-IN COIL (SMALLER TERMINALS TOP AND BOTTOM #222J AND #214A)

TEST PROCEDURE

1. Turn the engine off.

2. Unlatch, lift and secure the right side engine service access door.

3. Locate and remove the four spade connectors that attach the solenoid terminals to the wiring harness leads (#222J, #222H, #213A and #214A). See Figure F.5 and the Wiring Diagram. Remove any necessary wire wraps.

4. Check the pull-in coil resistance (larger terminals #222H and #213A). The normal resistance is approximately 0.4 ohms.

Check the hold-in coil resistance (smaller terminals #222J and #214A). The normal resistance is approximately 20 ohms).

If either coil resistance is not correct, the solenoid may be faulty. Replace.

5. Using the external 12VDC supply, apply 12VDC to the larger solenoid terminals (#222H+ to #213A-). The solenoid should activate. The solenoid should deactivate when the 12VDC is removed.

When the solenoid activates, remove the voltage immediately. Do not leave the external supply connected to terminals #222H and #213A for longer than three seconds. Component damage could result.

8. If the solenoid does not operate properly, check for a mechanical restriction in the linkage.

9. Using the external 12VDC supply, apply 12VDC to the smaller solenoid terminals for the hold-in coil (#222J+ to #214A-). Push in the solenoid plunger. With the 12VDC applied to the hold-in coil, the plunger should stay in until the 12VDC is removed.

10. If the linkage is intact and the solenoid does not operate correctly when the 12VDC is applied, the solenoid may be faulty. Replace.

11. Replace the harness leads to the correct terminals. See Figure F.5 and the Wiring Diagram. Replace any previously removed wire wraps.

12. Close and secure the right side engine service access door.

CAUTION

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TROUBLESHOOTING & REPAIR

F-29 F-29

RANGER 300 D AND 300 DLX

WARNING

ENGINE THROTTLE ADJUSTMENT TEST

TEST DESCRIPTION

If the machine output is low or high, this test will determine whether the engine is operating at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjusting the throttle to the correct RPM are given.

MATERIALS NEEDED

5/16” Nut driver 3/8” Nut driver 10mm Wrench 7/16” Wrench White or red marking pencil Strobe-tach, frequency counter, or oscilloscope

This procedure requires approximately 30 minutes to perform.

TROUBLESHOOTING & REPAIR

F-30 F-30

RANGER 300 D AND 300 DLX

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ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.6 – STROBE MARK LOCATION

TEST PROCEDURE

1. Conduct this procedure with the engine OFF.

2. Unlatch, lift, and secure the right side service access door. With the 3/8” nut driver, remove the right front side cover.

3. With a white or red marking pencil, place a mark on one of the flywheel bolts. See Figure F.6 for location.

4. Connect the strobe-tach according to the manufacturer’s instructions.

5. Start the engine and direct the strobe-tach light on the flywheel bolt. Synchronize it to the rotating mark.

With the machine at HIGH IDLE the tach should read between 3650 and 3700 RPM.

With the machine at LOW IDLE the tach should read between 2150 and 2220 RPM.

FLYWHEEL

CHALK MARK

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TROUBLESHOOTING & REPAIR

F-31 F-31

RANGER 300 D AND 300 DLX

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.7 – HIGH IDLE ADJUSTMENT

FIGURE F.8 – LOW IDLE ADJUSTMENT

SOLENOID LINKAGE

LOW SPEED SET SCREW AND LOCKING NUT

LOCKING NUT

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TROUBLESHOOTING & REPAIR

F-32 F-32

RANGER 300 D AND 300 DLX

ENGINE THROTTLE ADJUSTMENT TEST (continued)

6. If either of the readings is incorrect, adjust the throttle as follows:

Adjust HIGH IDLE: First make sure there is NOT a load on the machine. Set the IDLER switch to the HIGH position. The solenoid should activate. Using the 7/16” wrench, adjust the high speed solenoid linkage to lengthen the linkage until the engine speed starts to decrease. See Figure F.7. Adjust the linkage in the opposite direction until the engine speed is within limits (3650 3700 RPM). Tighten the locking nut. The high speed set screw is preset and sealed by the engine manufacturer and normally should not be adjusted.

Adjust LOW IDLE: First make sure there is NOT a load on the machine. Set the IDLER switch to AUTO and wait for the engine to change to low idle speed. Use the 10mm wrench to loosen the lock nut on the low speed set screw. See Figure F.8. Adjust the set screw until the engine speed is between 2150 and 2220 RPM. Tighten the lock nut.

equency Counter Method

1. Plug the frequency counter into one of the 115 VAC receptacles.

2. Start the engine and check the frequency counter. At HIGH IDLE (3700 RPM), the counter should read 63 Hz. At LOW IDLE (2220 RPM), the counter should read 37 Hz. Note that these are median measurements; Hertz readings may vary slightly above or below.

3. If either of the readings is incorrect, adjust the throttle as follows:

Adjust HIGH IDLE: First make sure there is NOT a load on the machine. Set the IDLER switch to the HIGH position. The solenoid should activate. Using the 7/16” wrench, adjust the high speed solenoid linkage to lengthen the linkage until the engine speed starts to decrease. See Figure F.7. Adjust the linkage in the opposite direction until the frequency is 63 Hz. Tighten the locking nut. The high speed set screw is preset and sealed by the engine manufacturer and normally should not be adjusted.

Oscilloscope Method

1. Connect the oscilloscope to the 115 VAC receptacle, according to the manufacturer’s instructions. At HIGH IDLE (3700 RPM), the waveform should exhibit a period of 15.8 milliseconds. At LOW IDLE (2220 RPM), the waveform should exhibit a period of 27.02 milliseconds. Refer to the NORMAL OPEN

CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE - NO LOAD in this

section of the manual.

2. If either of these waveform periods is incorrect, adjust the throttle as follows:

Adjust HIGH IDLE: First make sure there is NOT a load on the machine. Set the IDLER switch to the HIGH position. The solenoid should activate. Using the 7/16” wrench, adjust the high speed solenoid linkage to lengthen the linkage until the engine speed starts to decrease. See Figure F.7. Adjust the linkage in the opposite direction until the period is 15.8 milliseconds. Tighten the locking nut. The high speed set screw is preset and sealed by the engine manufacturer and normally should not be adjusted.

Adjust LOW IDLE: First make sure there is NOT a load on the machine. Set the IDLER switch to AUTO and wait for the engine to change to low idle speed. Use the 10mm wrench to loosen the lock nut on the low speed set screw. See Figure F.8. Adjust the set screw until the period is 27.02 milliseconds. Tighten the lock nut.

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TROUBLESHOOTING & REPAIR

F-33 F-33

RANGER 300 D AND 300 DLX

WARNING

AUXILIARY AND FIELD WINDING TEST

TEST DESCRIPTION

This test will determine if the correct AC voltages are being generated from the stator windings.

MATERIALS NEEDED

Volt/Ohmmeter 5/16” Nut driver 3/8” Nut driver Wiring Diagram

This procedure requires approximately 45 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-34 F-34

RANGER 300 D AND 300 DLX

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.9 – LOCATION OF LEADS #3A AND #3B

TEST PROCEDURE

To test the 115 VAC winding:

1. With the 5/16” and 3/8” nut drivers, remove the case left side.

2. Make sure that the LOCAL/REMOTE switch (S8) is in the CONTROL AT WELDER position.

3. Set the voltmeter to the AC volts position.

4. Connect the volt/ohmmeter probes to leads #3A and #3B where they connect to the 15 amp circuit breakers. See Figure F.9.

5. Start the engine and run it at high idle (3700 RPM).

6. Set the output control to the maximum position (position 10).

7. Check the AC voltage reading. It should be approximately 125 VAC.

To test the 230 VAC winding:

1. With the 5/16” and 3/8” nut drivers, remove the case left side.

2. Set the voltmeter to the AC volts position.

3. Connect the volt/ohmmeter probes to leads #6 and #3 where they connect to the 50 amp circuit breakers. See the Wiring Diagram.

NOTE: It is easier to insert the probes directly into the receptacle to perform this test. However, the probes may not reach in far enough to make or keep a good connection.

4. Start the engine and run it at high idle (3700 RPM).

5. Set the output control to the maximum position (position 10).

6. Check the AC voltage reading. It should be approximately 240 VAC.

15 AMP CB LEADS #3A AND #3B LOCATED ON REAR OF PANEL

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TROUBLESHOOTING & REPAIR

F-35 F-35

RANGER 300 D AND 300 DLX

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.10 – LOCATION OF LEADS #7 AND #9 AT FIELD BRIDGE RECTIFIER

200 200A 200B

201

201A

200 200A 200B

201 201A

Field Bridge Rectifier

Retaining Tab

Cable Tie

Capacitor

To test the field winding:

1. With the 5/16” and 3/8” nut drivers, remove the case right side.

2. Connect the volt/ohmmeter probes to leads #7 and #9 where they connect to the Field Bridge Rectifier. See Figure F.10.

3. Start the engine and run it at high idle (3700 RPM).

4. Set the output control to the maximum position (position 10).

5. Check the AC voltage reading. It should be between 40 and 47 VAC.

If the reading is missing or not within specifications, check for loose or broken wires between the test points and the stator windings. See the Wiring Diagram. Make sure that the windings are NOT grounded internally to the stator iron. If the leads are intact, then the stator may be faulty. Replace the stator. If the voltage reading is within specifications, the windings are good and functioning properly.

6. Reinstall the right case side.

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TROUBLESHOOTING & REPAIR

F-36 F-36

RANGER 300 D AND 300 DLX

AUXILIARY AND FIELD WINDING TEST (continued)

FIGURE F.11 – 14-PIN AMPHENOL PIN ASSIGNMENTS

To test the feeder winding: Ranger 300 DLX Models

1. With the 5/16” and 3/8” nut drivers, remove the case left side.

2. Set the voltmeter to the AC volts position.

3. Connect the volt/ohmmeter probes to leads #31 and #32 where they connect to 15 amp circuit breaker CB1 and the 14-pin amphenol. See the Wiring Diagram. See Figure F.11.

NOTE: It is possible to check this voltage reading at the amphenol by inserting the test probes at pin A (for lead #32) and pin J (for lead #31A). See Figure F.11. However, if you use this method and get no voltage reading, it could mean there is a break or loose connection in the leads between the circuit breaker and the amphenol. Check the reading again with one probe at the circuit breaker connection for lead #31 and the other probe at amphenol pin A.

4. Start the engine and run it at high idle (3700 RPM).

5. Set the output control to the maximum position (position 10).

6. Check the AC voltage reading. It should be between 115 and 126 VAC.

7. Connect the volt/ohmmeter probes to leads #31 and #42 where they connect to 15 amp circuit breaker CB1 and the 14-pin amphenol. See the Wiring Diagram.

NOTE: It is possible to check this voltage reading at the amphenol by inserting the test probes at pin K (for lead #42) and pin I (for lead #31B). See Figure F.11. However, if you use this method and get no voltage reading, it could mean there is a break or loose connection in the leads between the circuit breaker and the amphenol. Check the reading again with one probe at the circuit breaker connection for lead #31 and the other probe at amphenol pin K.

8. Set the output control to the maximum position (position 10).

9. Check the AC voltage reading. It should be between 43 and 50 VAC.

If the voltage readings are within specifications, then the windings are good and functioning properly.

If any one or more of the readings are missing or not within specifications, check for loose or broken wires between the test points and the stator windings. See the Wiring Diagram. Make sure that the windings are NOT grounded internally to the stator iron. If the leads are intact, then the stator may be faulty. Replace the stator.

10. Reinstall the right case side.

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TROUBLESHOOTING & REPAIR

F-37 F-37

RANGER 300 D AND 300 DLX

WARNING

ROTOR VOLTAGE TEST

TEST DESCRIPTION

This test will determine if the correct DC voltage is being applied to the rotor at maximum engine speed (3700 RPM - high idle). This information will aid the technician in determining if the generator field is operating properly.

MATERIALS NEEDED

Volt/Ohmmeter (Multimeter) 5/16” Nut driver 3/8” Nut driver Wiring Diagram

This procedure requires approximately 20 minutes to perform.

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TROUBLESHOOTING & REPAIR

F-38 F-38

RANGER 300 D AND 300 DLX

ROTOR VOLTAGE TEST (continued)

FIGURE F.12 – LOCATION OF LEADS 200A AND 219 FOR ROTOR VOLTAGE TEST

TEST PROCEDURE

1. With the 5/16” and 3/8” nut drivers, remove the right case side.

2. Set the volt/ohmmeter to the DC volts position.

3. Connect the positive meter probe to the brush nearest the rotor lamination (lead #200A). See Figure F.12 for location.

4. Connect the negative meter probe to the other brush (lead #219).

5. Set the LOCAL/REMOTE switch (S8) to the CONTROL AT WELDER position. Start the engine and run it at high idle (3700 RPM). Set the output control to the MAXIMUM position (position 10).

6. Check the voltage reading on the voltmeter. It should read approximately 37-40 VDC.

7. If the voltage reading is low or not present, the generator field is not functioning properly. Perform the Rotor Resistance Test. The Field Diode Bridge (D2), the Field Capacitor (C1), and/or the control board may be faulty.

8. If the voltage reading is normal, the field circuit is functioning properly. Install the right case side.

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INSTALLATION

F-39 F-39

RANGER 300 D AND 300 DLX

WARNING

CHARGING CIRCUIT TEST

TEST DESCRIPTION

This test will determine if the engine alternator and associated circuitry are functioning properly.

MATERIALS NEEDED

Volt/Ohmmeter 5/16” Nut driver 3/8” Nut driver Wiring Diagram

This procedure requires approximately 20 minutes to perform.

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INSTALLATION

F-40 F-40

RANGER 300 D AND 300 DLX

CHARGING CIRCUIT TEST (continued)

FIGURE F.13 – VOLTAGE REGULATOR LEADS

TEST PROCEDURE

1. With the 5/16” and 3/8” nut drivers, remove the right case side.

2. Locate the engine alternator and leads. See Figure F.13.

3. Set the voltmeter for DC volts and check for the typical DC voltages according to the Charging Circuit Test Chart below.

4. If the DC voltages are correct, the engine alternator is operating normally.

If any of the voltage readings are missing or not normal, the engine alternator or associated wiring may be faulty. See the Wiring Diagram.

CHARGING CIRCUIT TEST CHART

TEST CONDITIONS TEST POINTS TYPICAL VOLTAGE

Ignition Switch Off Lead 222D to Frame Ground 12 VDC

Ignition Switch Off Lead 224A to Frame Ground 0 VDC

Ignition Switch Off Lead 227 to Frame Ground 0 VDC

Ignition Switch On Lead 222D to Frame Ground 12 VDC

Ignition Switch On Lead 224A to Frame Ground 12 VDC

Ignition Switch On Lead 227 to Frame Ground 0.7 VDC

Engine running at 3700 RPM Lead 222D to Frame Ground 14.5 VDC

Engine running at 3700 RPM Lead 224A to Frame Ground 14.3 VDC

Engine running at 3700 RPM Lead 227 to Frame Ground 14.3 VDC

222D

224A

ALTERNATOR

227

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TROUBLESHOOTING & REPAIR

F-41 F-41

RANGER 300 D AND 300 DLX

This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

Note: Scope probes connected at machine 115VAC receptacle.

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

0 volts

5 ms

50 volts

15.8 ms

Lincoln Electric SVM148-B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

No weld output and no auxiliary power. Engine operates normally.

Machine has low welding output and low auxiliary output.

The constant voltage (CV) welding output is low or unstable. Constant current (CC) and auxiliary power are operating normally.

Engine will not idle down to low speed. Machine has normal weld output and auxiliary power.

The engine will not go to high idle when attempting to weld or when the auxiliary power is loaded.

The engine will not crank or cranks very slowly.

The engine cranks but will not start.

The engine shuts off shortly after starting.

With the engine running, the output contactor does not pull in when using a wire feeder with a control cable connected to the RANGER 300 DLX amphenol.

The battery does not stay charged. 1. Check for loose or faulty con-

The welding arc is “cold.” The engine runs normally (3700 RPM no load). The auxiliary power is functioning normally.