Lincoln Electric RANGER 300 D Operator's Manual
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Lincoln Electric RANGER 300 D Operator's Manual

Lincoln Electric RANGER 300 D Operator's Manual

Lincoln electric welder user manual
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See also: Service Manual
RANGER 300 D and 300 DLX
For use with machines having Code Numbers:
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
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:
• 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
RETURN TO MAIN MENU
™
10399; 10400; 10850
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2003 Lincoln Global Inc.
IM571-A
February, 2003

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Summary of Contents for Lincoln Electric RANGER 300 D

  • Page 1 RANGER 300 D and 300 DLX For use with machines having Code Numbers: 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.

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 SAFETY...
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    120 V Duplex Receptacles ...B-14 Accessories ...Section C General Options / Accessories ...C-1 TIG Welding Options / Accessories...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 Page...
  • Page 8 Fuel ...D-3 Bleeding The Fuel System...D-3 Air Filter...D-3 Tightening the Fan Belt...D-3 Cooling System...D-3 Battery Maintenance ...D-4 Welder / Generator Maintenance ...D-5 Storage ...D-5 Cleaning...D-5 Brush Removal and Replacement ...D-5 Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1 Troubleshooting Guide...E-2 thru E-4...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS - Ranger 300 D (K1522-1), Ranger 300 DLX (K1522-2) Make/Model Description Kubota 3 cylinder DH905 26.0 HP @ Diesel Engine 3600 RPM Welding Output DC Constant Current 300 amps AC Constant Current 300 amps DC Constant Voltage (300 D) 200 amps...

  • Page 10: Location And Ventilation

    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 CAUTION...

  • Page 11: High Altitude Operation

    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 Operator’s Manual. RANGER 300 D AND 300 DLX CAUTION WARNING...

  • Page 12: Fuel

    An optional spark arrester kit (K903-1) is available for your RANGER 300. See the ACCESSORIES section of this manual for more infor- mation. An incorrect spark arrester may lead to damage to the engine or reduce performance. ------------------------------------------------------------------------ RANGER 300 D AND 300 DLX CAUTION CAUTION...

  • Page 13: Electrical Connections

    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. ACCESSORIES section of this manual for more infor- mation.

  • Page 14: Auxiliary Power Receptacles, Plugs, And Hand-Held Equipment

    Under high heat a breaker may tend to trip at lower loads than it would normally. CAUTION Never bypass the circuit breakers. Without overload protection, the RANGER 300 D/DLX could overheat and/or cause damage to the equipment being used. ------------------------------------------------------------------------ INSTALLATION...
  • Page 15 120 VOLT 50AMP 240 VOLT DOUBLE POLE CIRCUIT 240 VOLT BREAKER NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE WARNING RANGER 300 D AND 300 DLX GROUNDED CONDUCTOR NEUTRAL LOAD PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT PROTECTION NOTE: No. 6 COPPER CONDUCTOR CABLE SEE...

  • Page 16: Operation

    • Single side engine service with easy to open access door. • Copper alternator windings and high temperature insulation for dependability and long life. • Powder painted case and base for outstanding cor- rosion protection. RANGER 300 D AND 300 DLX Allows...

  • Page 17: Additional Features

    (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.

  • Page 18: Welder/Generator Controls

    12. 6 PIN AMPHENOL: For attaching optional remote control equipment to the RANGER 300 D/DLX (Includes contactor closure circuit on the Ranger 300 DLX & remote control circuit).

  • Page 19: Engine Controls

    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. Pressing RANGER 300 D AND 300 DLX...

  • Page 20: Engine Operation

    (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 WARNING WARNING...

  • Page 21: Starting The Engine

    Check the fuel gauge to make sure that there is an adequate fuel level (NEVER ALLOW THE RANGER 300 D/DLX TO RUN OUT OF FUEL). OPERATION 6. Press the “GLOW PLUG” button to pre-heat...

  • Page 22: Break-In Period

    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...

  • Page 23: Ac/Dc Stick (Constant Current) Welding

    Reattach the flange nuts and leave them on the terminals. ACTUAL RANGER 300 D AND 300 DLX O U T P U T T E R M I N A L S FIGURE B.4...

  • Page 24: Ac/Dc Tig (Constant Current) Welding

    This can result in damage to the switch. 100 - 180 amps AFTER YOU FINISH WELDING: 60 - 120 amps 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...

  • Page 25: Dc Wire Feed Welding (Cv) With Ranger 300D

    70 - 130 .068” 40 - 90 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 shielding gas such as C25 (75% Argon - 25% CO2).

  • Page 26: Summary Of Welding Processes And Machine Settings

    AUTO REMOTE REMOTE HIGH REMOTE REMOTE HIGH AT WELDER REMOTE RANGER 300 D AND 300 DLX B-11 ELECTRODE TO START WELDING WHEN NOT WELDING Touch electrode to work. Welding starts immediately and engine goes to high idle. Press Amptrol. Welding COLD starts immediately.
  • Page 27 B-12 SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS SUMMARY OF WELDING PROCESSES FOR RANGER 300 D CONTROL PROCESS CABLE & DIAGRAM STICK - CC CARBON ARC GOUGING - CC TIG - CC K930-1 TIG MODULE / S23732-10 K936-1 CONTROL CABLE...

  • Page 28: Auxiliary Power

    Permissible Power Watts Auxiliary Current in (Unity Power Amperes @ 120V Factor) NONE 3000 4800 6400 8000 9000 10,000 4000 9600 3000 8800 2000 8000 6000 RANGER 300 D AND 300 DLX B-13 Permissible Auxiliary Current in Amperes @ 240V...

  • Page 29: 120 / 240 Volt Dual Voltage Receptacle

    50 AMPS 2 4 0 V TOTAL FROM BOTH 120V DUPLEXES 60 AMPS 60 AMPS 40 AMPS 20 AMPS RANGER 300 D AND 300 DLX B-14 EACH HALF OF TOTAL FROM TOTAL FROM EACH 120V ONE 120V BOTH 120V DUPLEX...

  • Page 30: Accessories

    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.

  • Page 31: Semiautomatic Fcaw And Mig Welding (Ranger 300 D) Options / Accessories

    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).

  • Page 32: Maintenance

    KUBOTA ENGINE MAINTENANCE COMPONENTS ITEM Oil Filter Element Air Cleaner Element Fuel Filter Element RANGER 300 D AND 300 DLX TABLE D.1 MAINTENANCE REQUIRED • Fill fuel tank. • Check oil level. • Check air cleaner for dirty, loose, or damaged parts.

  • Page 33: Routine And Periodic Engine Maintenance

    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 OIL FILL CAP OIL FILTER OIL DRAIN PLUG FIGURE D.1...

  • Page 34: Fuel

    (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 WARNING can burn skin. hot.

  • Page 35: Battery Maintenance

    If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks. The battery is a group 45, with a rating of 495 cold cranking amps. RANGER 300 D AND 300 DLX...

  • Page 36: Welder / Generator Maintenance

    It is normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. WARNING Do not attempt to polish slip rings while the engine is running. ------------------------------------------------------------------------ RANGER 300 D AND 300 DLX...

  • Page 37: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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.
  • Page 38 1. Faulty battery. 2. Loose connections at battery or alternator. 3. Loose fan belt. 4. Faulty engine alternator. CAUTION RANGER 300 D AND 300 DLX RECOMMENDED COURSE OF ACTION 1. Contact your Local Lincoln Authorized Field Service Facility. 1. Charge Battery.
  • Page 39 100 watts. 2. Faulty high speed solenoid or faulty PC board. 1. Faulty high speed solenoid CAUTION RANGER 300 D AND 300 DLX RECOMMENDED COURSE OF ACTION 1. Set switch to Auto. 2. Remove all external loads. 3. Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.
  • Page 40 1. Wire Feeder Power circuit breaker open. 2. Faulty wiring in control cable 3. Faulty wire feeder. CAUTION RANGER 300 D AND 300 DLX RECOMMENDED COURSE OF ACTION 1. Place switch in "Always On" position when welding without welding terminal control cable.
  • Page 41 CONNECTION DIAGRAMS RANGER 300 D & RANGER 300 DLX / LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts.
  • Page 42 Keep away from moving parts. Only qualified personnel should install,use or service this equipment. TO LN-7 INPUT CABLE PLUG K584 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK RANGER 300 D AND 300 DLX 6-20-97 S23732-3 OPTIONAL K857 REMOTE CONTROL 6-20-97 S23732-4...
  • Page 43 Only qualified personnel should install,use or service this equipment. TO LN-8 INPUT CABLE PLUG K595 CONTROL CABLE ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK RANGER 300 D AND 300 DLX TO WIRE FEED UNIT 6-20-97 S23732-5 6-20-97 S23732-6...

  • Page 44: Connection Diagrams

    CONNECTS TO (WORK TERMINAL) OF POWER SOURCE REMOTE OUTPUT CONTROL MIN. K867 WARNING Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. RANGER 300 D AND 300 DLX N.C. N.D. N.E. WIRE FEEDER 6-20-97 S23732-7 K488 SG...

  • Page 45: Connection Diagram

    N.D. PLACE OUTPUT CONTROL SWITCH IN "REMOTE CONTROL" POSITION. N.E. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED. RANGER 300 D / K930-1 TIG MODULE WITH K938-1 CONTACTOR KIT / Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing.
  • Page 46 N.H. IDLER SWITCH ON POWER SOURCE MUST BE IN HIGH IDLE POSITION. N.J. 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.
  • Page 47 WIRING DIAGRAM BLACK 235C BLUE BLUE CURRENT FLASHING BLACK BLACK WHITE WHITE GREEN GREEN BLACK BLACK BLACK GREEN WHITE BLACK BLACK BLACK BLACK BLACK RANGER 300 D AND 300 DLX...
  • Page 48 WIRING DIAGRAM BLACK 235C BLUE BLUE CURRENT FLASHING BLACK BLACK WHITE WHITE GREEN GREEN BLACK BLACK BLACK GREEN WHITE BLACK BLACK BLACK BLACK BLACK RANGER 300 D AND 300 DLX...
  • Page 49 WIRING DIAGRAM 235C BLUE BLUE RENT FLASHING RANGER 300 D AND 300 DLX...
  • Page 50 F-10 F-10 DIMENSION PRINT RANGER 300 D AND 300 DLX...
  • Page 51 NOTES RANGER 300 D AND 300 DLX...
  • Page 52 NOTES RANGER 300 D AND 300 DLX...
  • Page 53 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 54 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 55 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 56 • 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...

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Ranger 300 dlx

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