Home

Lincoln Electric 250 Welder User Manual

Contents

1. 0 16 029 5 2 1 J 008 9p 8l 0 o o 3X 0p es a 9 71 5202 6 oge 81709 18 22 C 9 T 2 ALIAYHO JOU3IN33 7 0606 98 v 809 0509 00 NOISNAWIG RANGER 300 D AND 300 DLX LINCOLN E NOTES RANGER 300 D AND 300 DLX LINCOLN 8 NOTES RANGER 300 D AND 300 DLX LINCOLN 8 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information a
2. Lae 006 RANGER 300 D AND 300 DLX LINCOLN E Jequunu epoo y 104 s eui sjeued y euo UO pejsed si epoo sejnomed Aq 10 eq you JO S SIUL 310 COLIT 810022 F 9 WAG ALIAM S AVINI er Az AYAU NONA MSASINSNOdNWOO INONI SSVO TIV SE WON 5 d m DEF r LESTA SIOSWAS TVIINIOSTS F SALON 99 99 acc ott awa SSSNNEH 2099 T i SSANUWH ONE avaT ss INWE SIOHTONSHdNWV SAOGV NOLIO3NNOO aio NEOs GIONFIOS red MINOS f EN 105 cocca gone ore N SS ANU VH TANYA OL MUN 4 er NOIOZNNOO 55 x T SIVNL WSL im inva ON a ipn 159 5 D usns 415 ZT lt E OLON 106 vs Bh E G4 W 008 3
3. ec e o 2 e o 1 FIGURE B 1 OUTPUT PANEL CONTROLS WELDER GENERATOR CONTROLS See Figure B 1 for the location of the following features 1 OUTPUT RANGE SELECTOR Selects continuous current output for constant current stick or TIG cations 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 weld ing 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 out put at the welding control panel or at a remote station Remote connections are made at the 6 pin or 14 pin amphenol connector 5 WELDING TERMINALS SWITCH DLX Model Only The toggle switch labeled WELDING TERMINA
4. act 1100 a T 3 t as 2 891 WOLDVIN 4 05 gt T A 9702 Y lt 4 1 WIS 7T BLOWAY N sez 1 z t 4 vano zv ate qNnoss 54050607 HOLIMS 210888 TIO SLONEH as s ma MoT ve poil 1 NOILISd Mi NI NMOHS OTCE zc 10 559 HOLIMS avez DIIS WIE 9 M d ee 9002 HOLIMS 3440 NO 55 HOLIMS SLOWEY 95 aTa MOTD G9L MS REO REE ERA 302455 NOILISOd HOI NT NOES Eg A HOLIMS aL J pe ss o CE i
5. 4 2 jenem EI A 2 cred A 2 ME A 2 High Altitude A 3 Miu sont A 3 Additional Safety Precautions i creo iioi A 3 Pre Operation Engine A 3 3 E 4 Engine e M A 4 Battery Connections gt ps Gages des esr e needs cee dang geese dann deste ek exo A 4 2 10 4 Aester asci 4 Electrical Connections A 5 Machine Grounding 5 Welding Cable A 5 Auxiliary Power Receptacles Plugs and Hand Held Equipment A 6 CirGUit Breaker iss css scott A 6 wire A 6 ie cu T Section B General Lm B 1 Design Features c
6. SAIN e 104 ejqiDejr si 2y sjeued einsoj oue 10 euo uo eui peised si epoo sejnoiped siy Aq 10 eq jou juo SI 4141 31ON 792011 9222 710 SLN3NOdWOO LNO 3SVO TV 45913 Had STOSWAS UC er Vir H YOY 4 OX wee 0 p uoi sa 1 1 aur n 045105 NOILOSNNOO por we OLY J H 3002 ava ssanuvH 048 0431 SS3NYYH i H GIONTIOS 1083105 99791 Modem ee n NOLIVNIAY AS ru 183HV3N ONIH S meN a 2 Ad3Llvg8 418 3AlLISOd 0340109 EENG fol Ton vs frm is 19 008 v92 YOLOWINOO z 92 0 t 80 0 STWNINGSI 100 I gr 66 0109105 avez ae pic mox y og oC ros
7. Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page ISHAM ATION Section A Technical Specification Susini NEE E E NANEN ENEGA A 1 2 Location and
8. 5 15 AMPS 30AMPS 40 AMPS 40 AMPS 15 AMPS 20AMPS 20 AMPS RANGER 300 D AND 300 DLX LINCOLN C1 ACCESSORIES 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 Ibs K802 R Power Plug Kit Provides four 15 amp 115 volt plugs and one 50 amp dual voltage 115 230V full plug K703 Accessory Kit Includes the following Thirty five feet 10 5 meters of 1 0 AWG elec trode 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 out put 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
9. B 13 Simultaneous Welding and Power Loads sse B 13 120 240 Volt Dual Voltage B 14 120 V Duplex Receptacles rr er rn tn Forti erts et rne ier sina as eine B 14 INCCOSSOMIOS Section C General Options C 1 TIG Welding Options C 1 Semiautomatic FCAW and MIG Welding Ranger 300 DLX Options Accessories C 1 Semiautomatic FCAW and MIG Welding Ranger 300 D Options Accessories C 2 vii TABLE OF CONTENTS Page E Section 0 Safety Precautioris Geeks born Ve et D 1 Kubota Engine Maintenance D 1 Kubota Engine Maintenance D 1 Routine and Periodic Engine Maintenance D 2 D 2 0 2 D 3 Bleeding The Fuel D 3 gll D 3 Tightening the Fan D 3 Cooling gout re d Un po RR DR NER ERE Run D 3 Battery Maintenance ciet ue mn peii D 4 Welder Generator Maintena
10. 0048108 03395 1 HO1IMS 10 300410373 880 7 00 H39NV8 RANGER 300 D AND 300 DLX LINCOLN E WIRING DIAGRAM F 8 F 8 Jequunu epoo SAIN e 104 eorues si eui sjeued eunsoj oue euo uo eui pejsed si epoo Aq 10 eq jou 101 S SIUL 310 995011 IEEE Ebr Eb EE wem V16 01L 6 ALIAVO S31V2IONI Tar 9222 riz WOH SLN3NOdWOO 1NOH3 3SVO TIV 1 HOW S31VOIONI 16813 Had S1O8WAS 1 S3LON 0999 1 1 ANNOYS ANIONS HS WOIVNB3IETV os Bad 01083105 43101 3AO8V NMOOLNHSAN4 3000 OOOO 1 oin WH T3NVd 01 3 3 STWNINGAL 0990109 Vv en dS 3ALLISOd 0 QN9 0 X 4 iow n oe an 008 as o 9 WOLOVINOO 0088108 gorrota uiis 9
11. 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 Operator s Manual for periodic maintenance at 500 hours and beyond KUBOTA ENGINE MAINTENANCE COMPONENTS TABLE D 2 ITEM MAKE AND PART NUMBER Oil Filter Element Kubota 16271 32092 Fram PH 3593A Donaldson P148970 Air Cleaner Element Kubota 15231 43560 Fram C6921 Fuel Filter Element RANGER 300 D AND 300 DLX LINCOLN 8 D 2 MAINTENANCE D 2 ROUTINE AND PERIODIC ENGINE MAINTENANCE A WARNING To prevent the engine from accidentally starting dis connect the negative battery cable before servicing the engine See Table D 1 for a summary of maintenance inter vals for the items listed below More frequent service may be required depending on your specific applica tion 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 oper ation Then under normal operating conditions change the oil as specified in the maintenance sched ule CHANGING THE OIL Change the oil while the engine is still warm as fol lows 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
12. 77 WORK ELECTRODE gt GND o POWER SOURCE FRAME CONNECTION 21 WIRE FEEDER VOLTMETER CONNECTION ELECTRODE CABLE CONNECTS TO WORK TERMINAL OF POWER SOURCE TO WIRE FEED UNIT TO WORK id REMOTE OUTPUT CONTROL CAUTION _ ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET DESIRED POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION N C INSULATE EACH UNUSED LEAD INDIVIDUALLY N D FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT USE ISOLATION TO WIRE RELAY TO CLOSE LEADS 2 amp 4 K867 _ 5 FEEDER N E REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW 523732 7 RANGER 300 DLX 691 10 K488 K487 SPOOL GUN CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEA Keep away from moving
13. 023103 all pii gt Q ES libus e bony 32 0222 ge tox 38055389 10 Le 57 E 81 pi lOHLNOO 3LOW3H 1 0 LOH yom TES MOTO wr Oxo 8 1 90199109 NOILISOd NI NMOHS HOLIMS 10 ET avt i 1 pan 9r vor HOLIMS NOLIISOd 310NN3H s esT MOTD HART 1509 Fy Ninwoust EHS 830455 Bhd 71373 HOLIMS 9 Wa 3000138 9NIHSV T3 7 95 96 30000 1 1509 ANSYYND uii WIRING DIAGRAM 83130 8 HOLIMS 1081409 WNINYAL ONITTEM suolovdo
14. 2 Allow the electrode and work to cool completely 3 Remove the work clamp from the work TABLE B 2 AC TIG WELDING TIG ELECTRODE RANGE SETTINGS Tungsten Diameter Switch Settings Welding Current Tungsten Diameter Switch Settings Welding Current 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 with a pure tungsten electrode DC WIRE FEED WELDING CV WITH RANGER 300 DLX 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 also Lincore amp 33 and 55 hardfacing electrodes can be used Cable length and other conditions can affect the ultimate results of this application Request Lincoln publi cation 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 L 50 and L 56 You must use a blended shielding gas such as C25 75 Argon 25 CO2 Request Lincoln publication GS 100 for additional information 3 Set the IDLER CONTROL to AUTO for the LN 25 HIGH for the LN 7 or
15. 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 the following table Ambient Temperature Viscosity Grades Above 25 C 77 F SAE 10W 30 SAE10W 40 or SAE30 0 C 32 F to 25 C 77 F SAE 10W 30 SAE10W 40 or SAE20 Below 0 C 32 F SAE 10W 30 SAE10W 40 or SAE10 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 OIL LEVEL DIP STICK 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 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 over tighten the new filter 5 Refill the engine with the proper amoun
16. m 6 TWNINSL 018 UND ONTHSYLE WIRING DIAGRAM SL 1 15 NEL UN OH 1 ain0 NS HIM wes NOLLISOd NI NHOHS HOLIMS TOHIN OO 2 TVNIWNSL TL peior it s AINVIOd TS 9 XI MO AONYA NVSOZIG OMA M RANGER 300 D AND 300 DLX LINCOLN E DIMENSION PRINT F 10 F 10 2 0 6
17. For attaching optional remote control equipment to the RANGER 300 D DLX Includes contactor closure circuit on the Ranger 300 DLX amp 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 RANGER 300 D AND 300 DLX LINCOLN 4 OPERATION B 4 4 i2 IA 70 1 FIGURE 2 DIESEL ENGINE CONTROLS ENGINE CONTROLS See Figure B 2 for the location of the following fea tures 1 GLOW PLUG PUSH BUTTON Activates glow plugs to preheat engine for starting 2 IDLER CONTROL SWITCH The idler switch has two positions HIGH and AUTO When in HIGH position the engine will run continuously at high speed for approximate ly 8 seconds and then go to high speed When in AUTO lt gt idle position the idler operates as follows a Welding Low idle with Ranger 300 DLX in the WELDING TERMINALS ALWAYS ON mode o with a Ranger 300D When the electrode touches work the welding arc is initiated and the engine to acc
18. See the Maintenance section of this manual and the Engine Operators 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 A CAUTION Remove all loads connected to the AC power recepta cles 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 plas tic fuel filter housing is in the open position lever in the vertical position See Figure B 3 ON B OFF 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 s 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 6 Press the GLOW PLUG button to pre heat the cylinders per the following table Ambient Temperature Pre Heat Time Above 50 F 10 C NOT REQUIRED 50 F 10 C to 23 F 5 C Approximately 5 seconds Below 23 F 5 C A CAUTION Never press the Glow Plug button
19. Voltage and permissible watts decrease as CONTROL is adjusted to settings less than 10 It is recommended that at settings less than 10 only incandescent lighting loads be connected to the auxiliary power receptacles RANGER 300 D AND 300 DLX LINCOLN B 14 OPERATION B 14 120 240 VOLT DUAL VOLTAGE Maximum Current Draw from Optional 120V RECEPTACLE GFCI Duplex Receptacles Weldin 240 V LOAD FROM EACH HALF OF TOTAL FROM TOTAL FROM The 120 240 volt receptacle can supply up to 50 amps FULL EACH 120V ONE 120V BOTH 1909 of 240 volt power to a two wire circuit up to 50 amps RECEPTACLE DUPLEX DUPLEX DUPLEXES of 120 volt power from each side of the three wire cir cuit up to 100 amps total Do not connect the 115 volt circuits in parallel Current sensing for the auto 15 AMPS 15 AMPS 30 AMPS GND 35 AMPS 15 AMPS 15 AMPS 30 AMPS 120 V 240 V 120 V matic idle feature is in both legs of the three wire cir cuit as shown below FIGURE B 5 120V DUPLEX RECEPTACLES The 120V 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 120V Duplex Receptacles No Welding 240 V LOAD FROM EACHHALF OF TOTAL FROM TOTAL FROM FULL KVA EACH 120V ONE 120V BOTH 120V RECEPTACLE DUPLEX DUPLEX DUPLEXES 15 AMPS 30 AMPS 60 AMPS 20 5 15 AMPS 30 AMPS 60 AMPS 30
20. 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 LIFTING The RANGER 300 weighs approximately 1150 105 522 kg A lift bail is mounted to the machine frame and should always be used when lifting the machine ADDITIONAL SAFETY PRECAUTIONS A WARNING FALLING EQUIPMENT can cause injury Do lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity e Be sure machine is stable when lifting The recommended undercarriage for use with this equipment for in plant and yard towing by a vehicle is Lincoln s K953 1 If the user adapts a non Lincoln undercarriage 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 undercarriage vs weight of Lincoln equipment and likely additional attach ments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the under carriage to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced INSTALLATION A 3 4 Typical condi
21. AC power at the same time within machine total capacity Compatible with GFCI s ground fault circuit inter rupters OTHER FEATURES e Insonorized for extremely quiet operation 99L W A and 74 db A 23 ft 7m Kubota 3 cylinder liquid cooled diesel engine Designed for long life easy maintenance and excel lent 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 radi ator and makes it easy to check coolant level Battery with 495 cold cranking amps Straight through ventilation cooling air for welder alternator enters front of machine and is exhausted out rear Large capacity 10 gallon 38 1 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 bas
22. 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 per sonal 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 7 1 sure the machine is 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 a 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 Check and fill the engine fuel 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 RANGER 300 D AND 300 DLX LINCOLN B 6 OPERATION B 6 NOTE DO NOT allow the RANGER 300 to run out of fuel If it does you will have to bleed the injec tion system
23. H E 1 Additional Features aa oa 2 Recommended 2 2 Additional Safety Precautions B 2 Contos and S SUING RR B 2 Welder Generator B 3 Engine Controls RHET B 4 Engine Operaatio E utor EE En ede EDEN Dee B 5 Before Starting the B 5 Starting the 2149 i e 6 Cold Weather Starting and B 6 SOPIN the ENGINE corp cr data cats ceeds t epe ERENER B 6 Break IM Period 125 caetero a enero abe B 7 Welding Operation ERR B 7 AC DC Stick Constant Current B 8 AC DC TIG Constant Current Welding eene B 9 DC Wire Feed Welding CV with Ranger 300 B 9 DC Wire Feed Welding CV with Ranger 300 D B 10 Carbon Arc Gouging Constant B 10 Summary of Welding Processes and Machine Settings B 11 RE
24. 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 A CAUTION During break in subject the RANGER 300 to moder ate 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 Low Idle No Load 2000 RPM High Idle No Load 3700 RPM 30 gallons hour 1 0 liters hour 60 gallons hour 2 2 liters hour AC CC Weld Output 1 gallons hour 1 300 Amps 25 Volts 4 2 liters hour 1 2 gallons hour 4 6 liters hour DC CC Weld Output 300 Amps 25 Volts 90 gallons hour 3 6 liters hour DC CV Weld Output 300 Amps 28 Volts 1 3 gallons hour 4 9 liters hour Auxiliary Power 12 000 kVA DLX model only WELDING OPERATION A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts electrode with skin or wet cloth
25. Idler may not respond with less than a 100 watt load Set idler to High Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Reset CB8 If it continues to trip con tact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 300 D AND 300 DLX LINCOLN 8 E 4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual No welding power output wrong position Faulty welding alternator or faulty 2 PC board Welder has output but no control Control switch is in wrong posi 1 Poor remote kit connection Faulty remote kit Faulty control potentiometer or 4 faulty PC board No auxiliary power Open circuit breakers Faulty connections to 2 receptacles GFCI tripped Faulty welding alternator or faulty 4 PC board Wire feeder does not work when 1 Wire Feeder Power circuit breaker 1 connected to welder 14 pin amphe open nol DLX models only Faulty wiring in control cable Faulty wire feeder when welding without welding terminal control cable Refer to Operation chapter for proper switch function C
26. LN 8 and start the diesel engine 4 Set the RANGE switch to either HIGH MEDIUM HIGH MEDIUM LOW or LOW CV red depend ing on your wire size and speed 5 Set the POLARITY SWITCH to either WIRE FEED DC or WIRE FEED 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 appli cation 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 RANGER 300 D AND 300 DLX LINCOLN B 10 DC WIRE FEED WELDING CV WITH RANGER 300D 1 Connect an LN 25 with internal contactor to the Ranger 300D 2 The only Innershield electrode recommended for use with the Ranger 300D is NR211MP The elec trode sizes and welding ranges that can be used with the Ranger 300D are shown in the following table Wire Speed in min Approximate Current Range Electrode Diameter 70 110 60 120 amps 70 130 120 170 amps 035 068 40 90 125 210 amps The Ranger 300 D is recommended for limited MIG welding GMAW gas metal arc welding The recom mended electrodes are 030 and 035 L 50 and L 56 They must be used with a blended
27. ON WELDER CONTROL PANEL OR OTHER 115 VOLT AC SUPPLY RATED AT A MINIMUM OF 500 VOLT AMPERES LEADS 21 AND GND DO NOT APPEAR ON LN 7 S WITH CODES BELOW 7026 WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATOR S MANUAL IF LN 7 IS EQUIPPED WITH A METER KIT EXTEND LEAD 21 USING 14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION AN S16586 LENGTH REMOTE VOLTAGE SENSING WORK LEAD MAY BE ORDERED FOR THIS PURPOSE CONNECT IT DIRECTLY TO THE WORK PIECE INDEPENDENT OF THE WELDING WORK CABLE FOR CONVENIENCE THIS EXTENDED 21 LEAD SHOULD BE TAPED TO THE WELDING WORK LEAD TAPE UP BOLTED CONNECTION WHERE LEAD 21 IS EXTENDED IDLER SWITCH ON POWER SOURCE MUST BE IN HIGH IDLE POSITION IF AN OPTIONAL K857 REMOTE OUTPUT CONTROL IS USED CONNECT IT TO THE RANGER 300 D AMPHENOL CONNECTOR NOTE PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION WHEN REMOTE OUTPUT CONTROL IS USED CAUTION ANY SPEED UP OF THE 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 ABOVE 140 VOLTS THE LN 7 CONTROL CIRCUIT WILL BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN ENGINE WELDER OPERATING MANUAL 23732 11 RANGER 300 D AND 300 DLX LINCOLN n Jequunu epoo
28. Only qualified personnel should install usd or service this equipment before servicing Do not touch electrically live parts OPTIONAL K857 REMOTE CONTROL 14 AMPHENOL RANGER 300 DLX ONLY 6PIN AMPHENOL O LN 25 WIRE FEEDER WORK CLIP LEAD p A WORK TO WORK ELECTRODE X TO WORK N ELECTRODE CABLE N A WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B USE POLARITY SWITCH TO SELECT DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION N C IF REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION N D ON RANGER 300 DLX THE WELDING TERMINALS SWITCH MUST BE IN THE ALWAYS ON POSITION N E PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 523732 1 RANGER 300 D amp RANGER 300 DLX LN 25 ACROSS THE CONNECTION DIAGRAM WITH OPTIONAL K444 1 REMOTE CONTROL A WARNING ELECTRIC SHOCK can kill 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 usd or service this equipment 14 PIN AMPHENOL RANGER 300 DLX ONLY 6 PIN AMPHENOL Do not operate with panels open Disconnect NEGATIVE BATTERY LEAL OPT
29. Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PSB RET BRAY FE e HMDS RK SHA AGS Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgehause oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CHRRIARRARS SHAE Ro 20 Sel Sepe Asal WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ie BIR Chinese Qai dul jua Jaial os uui BALL ge cal sd ue Aia Ao pha J gail e Ads cuts gall l y e gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K ETISRIUCESU CL TRHORERMEI HS 85 ET REL BE EE Rr de FH B SR 0 AXIS SAAD FAIS HHR EFS
30. 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 auxil iary 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 in to the 50 amp 120 240 volt recep tacle on the RANGER 300 case front RANGER 300 D AND 300 DLX LINCOLN 8 A 7 INSTALLATION A 7 Figure A 1 CONNECTION OF RANGER 300 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER 120 VOLT 60 2 3 Wire COMPANY Service METER NEUTRAL BUS LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE 50AMP OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE 50 AMP 120 240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14 50 1 50 AMP 120 240 VOLT bs O NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS A WARNING Connection of Ranger 300 to premises wiring must be done by a licensed ele
31. attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 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 X Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN SAFETY 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 wor
32. local Lincoln Authorized Field Service Facility Do not touch electrically live parts such as output A WARNING ELECTRIC SHOCK can kill terminals or internal wiring ENGINE EXHAUST can kill 40 outside Use in open well ventilated areas or vent exhaust MOVING PARTS can injure Stop engine before servicing 26 Do not operate with doors open or guards off AR Keep away from moving parts Remove guards only when necessary and replace when work requiring removal is complete Only qualified personnel should install use or service this equipment A CAUTION If for any reason you not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 300 D AND 300 DLX LINCOLN 8 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Major Physical or Electrical Damage 1 Contact your Local Lincoln Authorized is Evident Field Service Facility Engine will not crank 1 Battery is low 1 Charge Battery Loose battery cable connections 2 Inspect clean and tighten Faulty engine starter motor 3 Contact authorized Kubota Service Shop Engine will crank but not start Fuel shut off valve i
33. parts before servicing Only qualified personnel should install us Do not touch electrically live parts or service this equipment 115V RECEPTACLE K488 SG CONTROL MODULE RANGER K487 25 SPOOL GUN gt EPIN WIDE FEEDER N REMOTE K691 10 RECEPTACLE INPUT CABLE TO WORK ELECTRODE O ELECTRODE CABLE TO WORK TO CONTROL MODULE BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE LINCOLN CONTACT CLOSURE POSITION BEFORE ATTEMPTING TO OPERATE CONTROL MODULE INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND OR POWER SOURCE ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION PLACE WELDING TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N C IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIO
34. to protect your skin and that of your helpers from the arc rays 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 3 FUMES AND GASES can be dangerous 5 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 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 prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathin
35. 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 A WARNING 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 A WARNING we 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 e CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting nega tive 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 e Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery BATTERY ACID can burn eyes and skin 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 bat tery cable disconnected Before you operat
36. 08 8 130 y 5 su S yz 9000 3002 0202 i i 310 143038 HOLIMS TIONIS 70 521 385538410 9102 Soma MOTD 9002 yee gu 8 NOLLISOd 4 NI NMOHS 1 ore N HOLIMS x ou luis 759 vee 4 HOLMS 33010 HOLIMS 9S esT uo 019 1154 as 2 NoLLISOd 88 NINMOHS da 30483 3onvo 303 n and email 920 95 0 98 YOSNAS ANAYHNO ov ANSHYND 9NIHSV 1 u39uvHo YNOH ININA UOIDV3U 5 Y eae non F daas 708 HOLMS 630081937
37. 5 with a rating of 495 cold cranking amps RANGER 300 D AND 300 DLX LINCOLN 8 D 5 MAINTENANCE CHARGING THE BATTERY When you charge jump replace or otherwise con nect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The RANGER 300 positive battery termi nal 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 co can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer 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 par ticularly dirty areas OUTPUT RANGE SELECTOR AND POLARITY SWITCHES Switch contacts should not be greased To keep con tacts clean rotate the switch though its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly Inspect the brush
38. A BEHE TT gl Qui al gll oig Gail LINCOLN 5 World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
39. ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B USE POLARITY SWITCH TO SELECT DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION N D PLACE IDLER SWITCH IN HIGH POSITION 623732 4 RANGER 300 D AND 300 DLX LINCOLN CONNECTION DIAGRAMS F 3 RANGER 300 DLX LN 742 CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open e Keep guards in place Disconnect NEGATIVE BATTERY LEA e Keep away from moving parts before servicing Only qualified personnel should install use e Do not touch electrically live parts or service this equipment TO LN 742 INPUT 14 PIN CABLE PLUG AMPHENOL N NC K592 CONTROL CABLE TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT CAUTION TO WORK ANY INCREASE OF THE HIGH IDLE
40. DLX LINCOLN 8 A 5 ELECTRICAL CONNECTIONS See Figure B 1 in the OPERATION section of this manual for location of the 115 and 230 volt recepta cles weld output terminals circuit breakers and ground stud MACHINE GROUNDING QD 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 protec tion against electrical shock connect a heavy gauge wire 8 AWG or larger from the ground stud located on the bottom of the output panel See Figure B 1 to a suitable earth ground such as a metal pipe driven into the ground A WARNING 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 trail er the machine generator ground stud MUST be securely connected to the metal frame of the vehicle See Figure B 1 The ground stud is marked with the ground symbol If the RANGER 300 is connected to premises wiring such as a home or shop it must be properly connect ed to the system earth ground 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
41. ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B N C N D N E USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 823732 5 RANGER 300 DLX LN 8 CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 8 INPUT CABLE PLUG 5 Gols K595 CONTROL CABLE 14 AMPHENOL TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK ANY INCREASE OF T
42. ES AND MACHINE SETTINGS 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 TABLE B 4 SUMMARY OF WELDING PROCESSES FOR RANGER 300 D CONTROL CABLE amp DIAGRAM 523732 10 23732 1 23732 2 YES 23732 11 OUTPUT CONTROL SWITCH AT WELDER REMOTE AT WELDER ELECTRODE WHEN NOT WELDING AT COLD WELDER RANGER 300 D AND 300 DLX LINCOLN TO START WELDING 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 B 13 OPERATION B 13 AUXILIARY POWER The Ranger 300 can provide up to 12 000 watts of 120 240 volts AC Single phase 60 HZ power for con tinuous use The front of the machine includes three receptacles for connecting AC power Plugs one 50 amp 120 240 volt NEMA 14 50R receptacle and two 15 amp 120 volt NEMA 5 15R receptacles Do not connect any plugs that connect to the power recepta cles 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 auxil iary power
43. G 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 gt skin d e Wear gloves and eye protection and be careful when working near battery e 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 discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 1113 kg of baking soda and 1 quart 0 946 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 bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumula tion on the battery can lead to more rapid discharge and early battery failure 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 4
44. HE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL CAUTION N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B USE POLARITY SWITCH TO SELECT DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION N C PLACE IDLER SWITCH IN HIGH POSITION 23732 6 RANGER 300 D AND 300 DLX LINCOLN CONNECTION DIAGRAMS F 4 RANGER 300 DLX TO K867 CONTROL CABLE ADAPTER CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK can Kill ma MOVING PARTS can injure e Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEA Keep away from moving parts before servicing Only qualified personnel should or service this equipment Do not touch electrically live parts 14 PIN NG AMPHENOL 81 o 82 o NOT USED ON RANGER POWER SOURCES SPARE o K867 UNIVERSAL 2 o CONNECT TOGETHER FOR ADAPTER PLUG 2 WELDING OUTPUT ND PEE 42 VAC 42 31
45. IONAL 444 1 j REMOTE CONTROL ELECTRODE LN 25 WIRE FEEDER WORK CLIP LEAD N LA x WORK TO WORK TO WORK x ELECTRODE CABLE N A WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B USE POLARITY SWITCH TO SELECT DESIRED ELECTRODE POLARITY POSITION RANGE SWITCH TO A WIRE WELDING CV POSITION N C IF REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION N D ON RANGER 300 DLX THE WELDING TERMINALS SWITCH MUST BE IN THE ALWAYS ON POSITION N E PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 823732 2 RANGER 300 D AND 300 DLX LINCOLN F 2 CONNECTION DIAGRAMS F 2 RANGER 300 DLX LN 25 WITH K624 1 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY Keep away from moving parts before servicing AS Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 25 INPUT 14 PIN CABLE PLUG AMPHENOL 0 K626 XX INPUT CABLE ASSEMBLY TO WORK ELECTRODE 7 _ ELECTRODE CABLE TO WIRE FEED UNIT CAUTION TO WORK ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SET
46. LECT DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A STICK WELD POSITION N C PLACE OUTPUT CONTROL SWITCH IN REMOTE CONTROL POSITION N D PLACE IDLER SWITCH IN HIGH IDLE POSITION CRM after 9 23 97 523732 10 RANGER 300 D AND 300 DLX LINCOLN F 6 CONNECTION DIAGRAMS RANGER 300 D LN 7 K240 CONTACTOR KIT WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure e Do not operate with panels open e Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use e Do not touch electrically live parts or service this equipment CONTROL CABLE N D CONNECT THE CONTROL CABLE NU GROUND LEAD TO THE FRAME Ms B _ wA Pe KIT TERMINAL MARKED NEAR THE TERMINAL STRIP OR i i i i NOTE 600 AMP CAPACITY AN UNPAINTED FRAME SCREW 2 i N F amp N G i i AUTO POWER i i EQUIP SOURCE F 6 6 PIN AMPHENOL i ELECTRODE CABLE TO LN 7 TO WORK WELDER STANDARD OUTPUT TERMINALS USE POWER SOURCE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE OUTPUT SELECTOR SWITCH ON THE POWER SOURCE TO THE CV POSITION 3 CONDUCTOR 16 POWER CORD PHYSICALLY SUITABLE FOR THE INSTALLATION AND PLUG RATED AT 115 VOLTS 15 AMPERES AC PLUG INTO 115 VOLT AC RECEPTACLE
47. LS 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 of 14 pin amphenol con nector 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 6 WIRE FEEDER POWER CIRCUIT BREAKER Opens the wire feeder circuit and disables the feeder if a fault is detected in the circuit 7 15 AMP 120 VOLT DUPLEX RECEPTACLES Connection point for supplying 120 volt power to oper ate 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 con nection point for the electrode holder 11 GROUND STUD Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure 12 6 PIN AMPHENOL
48. 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 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 volt or 240 volt supply not both at the same time RANGER 300 SIMULTANEOUS WELDING AND POWER LOADS OUTPUT SET 10 9 Output Welding Permissible Permissible Permissible Selector Output Power Watts Auxiliary Current in Auxiliary Current in Setting Amps Uni ty Power Amperes 2 120V Amperes 2 240V Factor 300 NONE 225 180 140 100 75 50 1 CV LOW 300 DLX CV 300 D CV MED LOW 300 DLX CV MED HIGH 300 DLX CV HIGH 300 DLX 3000 4800 6400 8000 9000 0 000 4000 9600 3000 8800 2000 8000 0 6000 NOTE
49. N N D PLACE IDLER SWITCH IN HIGH IDLE POSITION CAUTION 823732 8 RANGER 300 D AND 300 DLX LINCOLN F 5 CONNECTION DIAGRAMS F 5 RANGER 300 DLX K930 1 TIG MODULE CONNECTION DIAGRAM A WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment gt Ped K930 1 REGULATOR MODULE FLOWMETER gt GAS INPUT FITTING RANGER 300 DLX K936 1 5 K870 FOOT AMPTROL CONTROL CABLE ARGON GAS CYLINDER OR me TO WORK 7 K963 1 HAND AMPTROL 14 PIN OR AMPHENOL K814 ARC START SWITCH ELECTRODE Nc M 455 CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B USE POLARITY SWITCH TO SELECT DE
50. NS HEIGHT WIDTH DEPTH WEIGHT 37 38 in 24 75 in 60 50 in 1093 Ibs 300 D 1133 16 300 DLX 949 4 mm 628 7 mm 1528 6 mm 480 8 kg 300 D 499 0 kg 300 DLX 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 1 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 RANGER 300 D AND 300 DLX LINCOLN 8 A 2 SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill e 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 Whe
51. RANGER 300 0 and 300 DLX For use with machines having Code Numbers 10399 10400 10850 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased SSS eee OPERATOR S MANUAL E D EU p e 9001 Designed an arci Maruti Under to ISO 9001 Requirements CERTIFICATE NUMBER 30273 Copyright 2003 Lincoln Global Inc World s Leader in Welding and Cutting Products e 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 WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Di
52. S DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria EUR fE 24758 else e SUAS MAS sis PARAH ASA power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor
53. SIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A STICK WELD POSITION N C PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N D PLACE OUTPUT CONTROL SWITCH IN REMOTE CONTROL POSITION N E PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 823732 9 RANGER 300 D K930 1 TIG MODULE WITH K938 1 CONTACTOR KIT CONNECTION DIAGRAM A WARNING ma MOVING PARTS can injure Keep guards in place Keep away from moving parts before servicing Only qualified personnel should install us Do not touch electrically live parts or service this equipment REGULATOR zQ FLOWMETER ARGON GAS CYLINDER INPUT FITTING RANGER 300 D K963 3 K870 FOOT AMPTROL CONTROL CABLE n TO WORK A a K963 1 HAND AMPTROL MIX OR K814 ARC START SWITCH AMPHENOL ELECTRODE U CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B USE POLARITY SWITCH TO SE
54. TING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY POSITION THE RANGE SWITCH TO A WIRE WELDING CV POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N B WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N C IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION N D PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 23732 3 RANGER 300 DLX LN 7 CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAN e Keep away from moving parts before servicing ANS Only qualified personnel should install use e Do not touch electrically live parts or service this equipment TO LN 7 INPUT X CABLE PLUG 7 584 CONTROL CABLE eee OPTIONAL K857 REMOTE CONTROL 14 PIN AMPHENOL SED ENOL TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION
55. UMMARY OF WELDING PROCESSES FOR RANGER 300 DLX CONTROL PROCESS CABLE amp DIAGRAM OUTPUT WELDING ELECTRODE CONTROL TERMINALS WHEN NOT TO START WELDING SWITCH SWITCH WELDING Touch electrode to work AT ALWAYS HOT Welding starts immediately WELDER ON and engine goes to high idle Press Amptrol Welding REMOTE REMOTE COLD starts immediately Press gun trigger Ranger REMOTE REMOTE COLD 300 DLX contactor closes Welding starts immediately and engine goes to high idle Press gun trigger LN 25 AT ALWAYS COLD contactor closes Welding WELDER ON starts immediately and engine goes to high idle Press gun trigger Ranger REMOTE REMOTE COLD 300 DLX contactor closes Welding starts immediately and engine goes to high idle REMOTE REMOTE COLD Press gun trigger Ranger 300 DLX contactor closes Welding starts immediately AT WELDER REMOTE COLD Press gun trigger Ranger 300 DLX contactor closes Welding starts immediately TIG CC K930 1 TIG MODULE 23732 9 K936 1 CONTROL CABLE STICK CC CARBON ARC GOUGING CC Y Y WIRE FEED CV LN 25 WITH 42V 23732 3 REMOTE CON TROL KIT ES ES WIRE FEED CV NO LN 25 WITH 23732 1 INTERNAL 23732 2 CONTACTOR WIRE FEED CV YES LN 742 23732 5 WIRE FEED CV YES LN 7 or LN 8 23732 4 23732 6 K487 15 WIRE FEED YES CV SPOOL GUN K488 S23732 8 CONTROL MODULE RANGER 300 D AND 300 DLX LINCOLN B 12 OPERATION B 12 SUMMARY OF WELDING PROCESS
56. 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 three wire grounded neutral generator it can be permanent ly installed as a standby power unit for 240 volt three wire single phase 50 ampere service A WARNING Only a licensed certified trained electrician should install the machine to a premises or residential elec trical 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 con junction 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 1 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 dis connect The switch rating must be the same as or greater than the premises disconnect and service overcurrent protection 2 Take the necessary steps to
57. automatic 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 semi automatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the handle Requires the K488 SG Control Module Includes 50 feet 15 2 meters of power cable 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 RANGER 300 D AND 300 DLX LINCOLN 5 2 ACCESSORIES 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 mounts inside the LN 25 RANGER 300 D AND 300 DLX LINCOLN 8 C 2 D 1 MAINTENANCE D 1 A WARNING 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 movin
58. continuously for more than 20 seconds Approximately 10 seconds 7 Release the GLOW PLUG button and press the START button to crank the 5 engine Release when the engine starts 8 Check that the indicator lights are off If not imme diately stop the engine and investigate the indicat ed 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 60 seconds 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 tem peratures below 23 F 5 C it is recommended that No 1D diesel fuel be used in place of No 2D Allow engine to warm up before applying a load or switching to HIGH idle 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 RANGER 300 D AND 300 DLX LINCOLN B 7 OPERATION B 7 BREAK
59. ctrician and must comply with the National Electrical Code and all other applicable electrical codes RANGER 300 D AND 300 DLX LINCOLN 8 B 1 OPERATION B 1 GENERAL DESCRIPTION The RANGER 300 is a diesel engine driven multi process AC and DC arc welder and AC power genera tor for commercial and residential applications As a generator it can supply up to 12 000 continuous watts of 120 240 volt 60 Hz single phase AC power to operate AC power tools battery chargers and light ing it can also be used to provide standby power As a welder it provides 300 amps of AC current for weld ing with AC stick electrodes or 300 amps of DC cur rent for DC stick welding The RANGER 300 can also perform AC DC TIG welding and DC semiautomatic wire feed welding The engine used on the Ranger 300 machines is the Kubota Super Five water cooled 3 cylinder DH905 engine The DH905 has an offset piston design with built in steel strut and a more rigid crank case 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 vibra tion even at low idle speed The Ranger 300 machines are housed in a heavy gauge stee
60. 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 infor mation INSTALLATION TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 300 Amps 100 Duty Cycle 1 0 AWG Cable Length 0 50 Ft 0 15 meters 1 0 AWG 50 100 Ft 15 39 meters 100 150 Ft 30 46 meters 2 0 AWG 150 200 Ft 46 61 meters 2 0 AWG 200 250 Ft 61 76 meters 3 0 AWG Table A 1 CABLE INSTALLATION Install the welding cables to your RANGER 300 as fol lows See Figure B 1 for location of parts 1 The diesel engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are identi fied 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 CAUTION e Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and
61. e flange nuts from output terminals and place the work and electrode welding cables over the terminals See Figure 4 Replace and tight en the flange nuts securely Be sure the connec tions are tight 3 o 2 Select the appropriate electrode See Welding Tips 1 included with your RANGER 300 H E OUTPUT TERMINALS 3 Attach the work clamp securely to the work you are eH welding 4 Insert the electrode into the electrode holder FIGURE B 4 5 Set the IDLER CONTROL to AUTO and start the WELDING CIRCUIT CONNECTIONS AFTER YOU FINISH WELDING 6 Set the RANGE switch to a setting equal to or slightly lower than the welding current recommend 1 Stop the engine ed for the electrode being used For the best weld ing performance always set the RANGE switch to 2 Allow the electrode and work to cool completely the lowest CC blue setting that will give the desired weld current This will assure that the OUTPUT Remove the work clamp from the work dial is set towards the high end of the dial If the OUTPUT dial is set at 10 and the welding current 4 Remove any remaining piece of electrode from the is to low move the RANGE switch to the next high electrode holder est setting 5 If you are finished using the RANGER 300 for 7 Set the POLARITY switch to the desired polarity welding discon
62. e for outstanding cor rosion protection RANGER 300 D AND 300 DLX LINCOLN 8 B 2 OPERATION B 2 ADDITIONAL FEATURES RANGER 300 D K1522 1 One constant voltage wire feed welding range 80 to 200 amps The wire feed setting permits the Ranger 300D to 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 amp L 56 using blended Argon shielding gas Auto ldle functions when using an LN 25 with 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 volt age Built in contactor with front panel selection of cold or hot welding terminals e 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 vol
63. e 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 negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused for several months the bat tery may require a booster charge Be sure to use the correct polarity when charging the battery EXHAUST DEFLECTOR A CAUTION Shut off the machine and allow the muffler to cool before touching the muffler The RANGER 300 is shipped with the exhaust deflec tor detached Install it on the muffler outlet using the clamp supplied Rotate the deflector to the desired direction before tightening the clamp 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 includ ed with the RANGER 300 do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly main tained An optional spark arrester kit K903 1 is available for your RANGER 300 See the ACCESSORIES section of this manual for more infor mation CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance RANGER 300 D AND 300
64. 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 con trol for AC and DC GTAW TIG welding applications It provides contactor control of constant current weld ing power sources having an internal contactor The TIG Module is supplied without accessories Arc Start switches Amptrols cables torches and mount ing 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 300 DLX for connecting the K930 1 TIG Module to a RANGER 300 DLX K936 3 Control Cable Control cable for connecting 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 Semi
65. elerates 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 2 Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn 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 3 START PUSH BUTTON When the push button is held the starter motor cranks over 5 the engine release the Button once the engine starts NOTE If you press the START push button 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 reg ulator 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 aft
66. er one minute to prevent discharging the battery if the engine is not started If this happens the engine protection circuit must be reset by turning the Engine switch to the OFF position and back to the ON posi tion 6 OIL PRESSURE LIGHT Remains off with proper oil pressure If the red light turns on while the engine is running the engine pro tection system will stop the engine It is normal for the light to go on when the Engine Switch is switched to the ON position with the engine not running It will go off after one minute to prevent discharging the battery if the engine is not started If this happens the engine protection circuit must be reset by turning the Engine switch to the OFF position and back to the ON posi tion RANGER 300 D AND 300 DLX LINCOLN B 5 OPERATION B 5 7 WATER TEMPERATURE LIGHT Remains off under normal operating temperatures 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 lives 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 ENGINE OPERATION A WARNING DO NOT RUN THE ENGINE
67. es when a generator overhaul is necessary A WARNING Do not attempt to polish slip rings while the engine is running RANGER 300 D AND 300 DLX LINCOLN 8 D 5 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your
68. esel Engines The Above For Gasoline Engines 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 copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free 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 powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 1 To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 2 MAGNETIC FIELDS be dangerous 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 vaporiz i
69. flows out of the air vent plug 4 Tighten the air vent plug AIR VENT PLUG FIGURE 0 2 FUEL BLEEDING COMPONENT LOCATIONS AIR CLEANER The Kubota diesel engine is equipped with a dry type air filter Never apply oil to it 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 cm2 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 press ing on the belt midway between the pulleys It should deflect bout 25 in under a load of 20 Ibs 9 Kg 6 mm COOLING SYSTEM WARNING 6 HOT COOLANT can burn skin A 4 97 i 0 27 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 or the radia
70. g air is safe 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 SAFETY 7 WELDING SPARKS can gt 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 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 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 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 Pract
71. g 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 e Do not touch electrically live parts or electrode with skin or wet clothing insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off A gt Stop engine before servicing Keep away from moving parts See additional warning information throughout this operator s manual and the Engine manual as well KUBOTA ENGINE MAINTENANCE SCHEDULE TABLE D 1 FREQUENCY 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 Daily or Before Starting Engine Every 50 Hours Check fuel lines and clamps Clean air filter element Check battery electrolyte level Check fan belt tightness Every 100 Hours Every 200 Hours Change engine oil 2 Replace oil filter cartridge Check radiator hoses Every 400 Hours Replace fuel filter element 1 Replace air filter element after 600 hours of operation or sooner under dusty operating conditions
72. hool BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on orders of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only I IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery 10 5 Shipping for North America Only All prepaid orders request UPS shipment please 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment OF PAYMENT Sorry No C O D Orders CHECK ONE Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only Credit Card m Y USE THIS FORM ORDER sooks OR FREE INFORMATIVE CATALOGS Welding School ED 80 New Lessons in Arc Welding Seminar Information Procedure Handbook Twelfth Edition 15 00 PH ___ __ How to Read Shop Drawings 450 H 1 12902819291 Video Inf
73. ices 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode 22238 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders sho
74. idung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra E GUB S Oa E EERTE uc HIE Weal AMI d ous uil chai Quali Y O aual ay gl uit celal AL usu DA dua ule Y wae Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM EA IEEE IIS eis ALD al gll e Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo EROS ISCRBREUCF ez 119 59 s ESSAI dise 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONE
75. ing eInsulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous d Keep your head out of fumes Use ventilation or exhaust to remove 1 On fumes from breathing zone MOVING PARTS can injure Do not operate with doors open or guards off AN Stop engine before servicing Keep away from moving parts a WELDING SPARKS can cause fire or Tx explosion Keep flammable material away ARC RAYS can burn 4 Wear eye ear and body protection 12 See additional warning information throughout this operator s manual 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 semiau tomatic 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 set tings that are best for your selected welding process RANGER 300 D AND 300 DLX LINCOLN 8 OPERATION B 8 AC DC STICK CONSTANT CURRENT e 4 WELDING 1 Remove th
76. kpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material
77. l case that is protected by a durable pow der paint finish The case is completely insonorized for remarkably quiet operation An easy to open hinged door allows access to the engine for single side ser vice The welder alternator has all copper windings and a high temperature insulation system that includes three coats of electrical grade varnish DESIGN FEATURES ALL MODELS FOR WELDING Excellent AC and DC constant current output for stick welding applications 40 to 300 amps constant current output with seven range settings Excellent semi automatic wire feed welding on con stant voltage output range s TIG welding full range on DC and up to 250 amps on AC 100 duty cycle rating on all output ranges Remote control capability standard on all models Amphenol receptacle for easy connection of Lincoln remote control accessories FOR AUXILIARY POWER 12 000 watts of 120 240 volt 60Hz AC auxiliary power Power for tools lights electric pumps and for stand by emergency power Drive a 2 HP motor provided it is started under no load Two 15 amp industrial grade 120 volt duplex recep tacles for up to 60 amps of 120 volt power One 50 amp 120 240 volt dual voltage receptacle for up to 50 amps of 240 volt auxiliary power Allows easy connection to premises wiring Four 15 amp circuit breakers for 120V duplex recep tacles and 2 50 amp circuit breakers for 240V recep tacle Weld and have
78. nce sss ene D 5 Kira cT EI TO D 5 D 5 Brush Removal and D 5 Troubleshooting Section E Safety Precalutioris oes corti ci RR uU uS E 1 How to Use Troubleshooting E 1 Troubleshooting addet 2 thru E 4 Connection Diagrams Wiring Diagrams amp Dimension Print Section F Parts P 290 Series A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Ranger 300 D K1522 1 Ranger 300 DLX K1522 2 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System Kubota 3 cylinder High Idle 3700 54 9 cu in 12VDC battery Fuel 10 gal DH905 26 0 HP Low Idle 2150 898 cc Group 45 495 38 L Diesel Engine 3600 RPM Full Load 3600 LL cold crank amps Bore x Stroke 1 KW Starter Oil 5 4 Qts 30 A Alternator 5 1L 2 83 2 90 w built in reg 72 mm x 73 6mm Coolant 5 7 qts 5 4L RATED OUTPUT WELDER DC Constant Current 300 amps 25 volts AC Constant Current 300 amps 25 volts 80 volts RMS DC Constant Voltage 300 D 200 amps 20 volts DC Constant Voltage 300 DLX 300 amps 30 volts DC Constant Voltage 300 DLX 280 amps 30 volts OUTPUT GENERATOR 12 000 Watts 60 Hz 120 240 Volts 100 Duty Cycle PHYSICAL DIMENSIO
79. nd application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding Sc
80. nect the welding cables from the CC blue setting weld output terminals Reattach the flange nuts and leave them on the terminals 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 A CAUTION DO NOT change the RANGE switch setting while welding This can result in damage to the switch RANGE SETTING ACTUAL ON MACHINE CURRENT RANGE 75 50 to 75 AMPS 100 70 to 100 AMPS 140 95 to 140 AMPS 180 110 to 180 AMPS 225 130 to 225 AMPS RANGER 300 D AND 300 DLX LINCOLN B 9 OPERATION B 9 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 250 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 CON TINUOUS HF AFTER YOU FINISH WELDING 1 Stop the engine
81. never 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 assem bled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices INSTALLATION A 2 A CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150 beyond the equipment on all sides 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 abou
82. ng 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 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not
83. ontact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Place switch in Control at Welder position to control output at welder Place switch in Remote position to control output remotely Refer to Operation chapter for proper switch function Check connections Replace if necessary Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Reset breakers If breakers keep trip ping reduce power draw Check connections Clear any ground fault and reset circuit by pressing Reset button on the 120 V receptacle Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Reset Repair or replace cable Replace with known good one CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 300 D AND 300 DLX LINCOLN 8 CONNECTION DIAGRAMS F 1 RANGER 300 D 8 RANGER 300 DLX LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL A WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure x Do not operate with panels open e Keep guards in place __ Disconnect NEGATIVE BATTERY LEAQ Keep away from moving parts
84. ormation Incentive Management 5 00 IM k Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Price Code Quantity Cost Address Telephone Signature as it appears on Charge Card 0 t luames F Lincoln Arc Welding Foundation Book Information JFLF 515 A New Approach to Industrial Economics 5 00 NA The American Century of John C Lincoln 5 00 Welding Preheat Calculator 300 wC8 Pipe Welding Charis 450 to 9 ea Shipping M LL WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG it is BIR Korean Do touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kle
85. s in off posi 1 Move lever on fuel filter housing to tion ON vertical position Out of fuel 2 Fill tank and bleed fuel system See MAINTENANCE section Engine switch in OFF position 3 Set switch to ON position High coolant temperature 4 Check engine cooling system Indicator light lit Faulty fuel solenoid or faulty PC 5 Contact your Local Lincoln Authorized board Field Service Facility for technical troubleshooting assistance Engine shuts down shortly 1 Low oil level Oil pressure indica 1 Change oil and oil filter and fill to prop starting tor light will flash while engine is er level Start engine and look for running leaks Circuit breaker CB9 located 2 Reset CB9 If it continues to trip con engine compartment is open Oil tact your Local Lincoln Authorized pressure and charging indicator Field Service Facility for technical lights will not be on when engine troubleshooting assistance switch is ON and engine is not running if 9 is tripped Engine shuts down while under load 1 High coolant temperature 1 Reduce load if it is exceeding machine Indicator light lit rating Add coolant to system if low Clean fins on radiator if dirty Tighten fan belt if loose Battery does not stay charged Faulty battery 1 Replace 2 Loose connections at battery 2 Clean and tighten connections alternator Loose fan belt 3 Tighten See Maintenance Section Faulty engine al
86. sepa rate from one another RANGER 300 D AND 300 DLX LINCOLN 8 6 INSTALLATION A 6 AUXILIARY POWER RECEPTACLES PLUGS AND HAND HELD EQUIPMENT The control panel of the RANGER 300 features three auxiliary power receptacles See Figure 1 Two 15 amp 120 volt duplex double outlet recepta cles 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 elec trical equipment connected to the generator recepta cles must use a three blade grounded type plug or an Underwriter s Laboratories UL approved double 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 receptacles for overload protection Under high heat a breaker may tend to trip at lower loads than it would normally A CAUTION Never bypass the circuit breakers Without overload protection the RANGER 300 D DLX could overheat
87. shielding gas such as C25 75 Argon 25 2 The 035 diameter electrode gives improved starting compared to 030 diameter The welding ranges that can be used with the Ranger 300D are shown in the following table Electrode Approximate Diameter Current Range Wire Speed in min 3 Set the IDLER control to AUTO 4 Set the RANGER switch to the WIRE FEED CV red setting 5 Set the POLARITY SWITCH to either WIRE FEED DC red or WIRE FEED 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 appli cation 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 OPERATION B 10 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 ia 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 RANGER 300 D AND 300 DLX LINCOLN p OPERATION B 11 SUMMARY OF WELDING d AND MACHINE SETTINGS S
88. t 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 usu ally 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 RANGER 300 D AND 300 DLX LINCOLN 8 D 3 MAINTENANCE D 3 FUEL At the end of each day s use refill the fuel tank to minimize moisture condensation and dirt contami nation in the fuel line Do not overfill leave room 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 instruc tions on replacing the fuel filter 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 A WARNING To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust mani fold 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
89. t 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 radia tor 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 whenev er you use it or store it Any surfaces you place it on other than the ground must be firm non skid and structurally sound 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 RANGER 300 D AND 300 DLX LINCOLN 5 A 3 HIGH ALTITUDE OPERATION It may be necessary to de rate the welder output at higher altitudes Derate the welder output
90. tage 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 per formed using stick welding SMAW TIG welding GTAW MIG GMAW welding and Innershield FCAW welding The RANGER 300 D DLX is not recommended for pipe thawing During welding generator power is limited and out put voltages can drop Therefore DO NOT OPER ATE ANY SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE WELDING See Table B 4 for permissible simultaneous welding and auxiliary power loads ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read and understand all Safety Precautions before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manual Only qualified personnel should install use or service this equipment 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 RANGER 300 D AND 300 DLX LINCOLN B 3 OPERATION B 3
91. ternator 4 Consult authorized Kubota Service Shop CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 300 D AND 300 DLX LINCOLN 8 E 3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 2 External load on welder or auxil 2 iary power 3 Faulty wiring or PC board Engine will not go to high idle when 1 Poor work lead connection attempting to weld work Welding Terminals switch is 2 wrong position Faulty high speed solenoid or 3 faulty PC board Engine will not go to high idle when 1 Auxiliary power load is less than 1 using auxiliary power 100 watts Faulty high speed solenoid or 2 faulty PC board Engine will not go to high idle Faulty high speed solenoid circuit breaker CB8 located in engine compartment is open Remove all external loads Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Make sure work clamp is tightly con nected to clean base metal Set to Always On when welding with out a welding terminal control cable Refer to Operations chapter for proper use of this switch Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance
92. tions of use i e travel speed rough ness of surface on which the undercarriage will be operated environmental conditions likely mainte nance 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways PRE OPERATION ENGINE SERVICE CAUTION READ and UNDERSTAND the engine operating and maintenance instructions supplied with this machine A WARNING Keep hands way 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 7 The RANGER 300 is shipped with the engine filled with SAE 10W 30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE f it is not full add enough oil to fill it to the full mark Always use oil that is rated for diesel engine service API classification of CD CE For more information on oil viscosity and service con ditions see the MAINTENANCE section of this manu al and the engine Operators Manual RANGER 300 D AND 300 DLX LINCOLN 8 A 4 INSTALLATION A 4 FUEL m 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
93. tor Open the radiator cap to allow com plete drainage Tighten the petcock and refill with a 50 50 antifreeze water solution Use an automotive grade low silicate ethylene glycol antifreeze The cooling system capacity is 5 4 quarts 5 1L Replace and tighten the radiator cap RANGER 300 D AND 300 DLX LINCOLN 8 D 4 MAINTENANCE D 4 CAUTION 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 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 BATTERY MAINTENANCE A WARNING 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 nega tive cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USIN
94. uld be located e Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY LINCOLN 8 V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you

Download Pdf Manuals

Related Search

Related Contents

LEON- PCI- UMC Development Board Test Report  四し 弐に  Brivo OnAir Administrator`s Manual  Manual SPIDER PRO 1000  QUEST User Manual  Deutsch Low Solvent - Oce Display Graphics Systems Inc.  Model UHF-R® Wireless Systems User Guide Model UHF-R    manual de instruções rfa341 - 220vca - p286  Models UT550/UT520 Digital Indicating Controllers User`s Manual  

Copyright © All rights reserved. Failed to retrieve file