Lincoln Electric Welder 300 D User Manual

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IM571-A  
RANGER300 D and 300 DLX  
February, 2003  
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:  
OPERATOR’S MANUAL  
Copyright © 2003 Lincoln Global Inc.  
• 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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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
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.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
3.g. Never dip the electrode in water for cooling.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
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 & Number _____________________________________  
Code & 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:  
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.  
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vi  
TABLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Installation Instructions.........................................................................................................A-2  
Location and Ventilation................................................................................................A-2  
Storing...........................................................................................................................A-2  
Stacking ........................................................................................................................A-2  
Tilting.............................................................................................................................A-2  
High Altitude Operation.................................................................................................A-3  
Lifting.............................................................................................................................A-3  
Additional Safety Precautions .......................................................................................A-3  
Pre-Operation Engine Service..............................................................................................A-3  
Oil..................................................................................................................................A-3  
Fuel ...............................................................................................................................A-4  
Engine Coolant..............................................................................................................A-4  
Battery Connections......................................................................................................A-4  
Exhaust Deflector..........................................................................................................A-4  
Spark Arrester...............................................................................................................A-4  
Electrical Connections..........................................................................................................A-5  
Machine Grounding.......................................................................................................A-5  
Welding Cable Connections..........................................................................................A-5  
Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment ........................................A-6  
Circuit Breakers....................................................................................................................A-6  
Premises Wiring ...................................................................................................................A-6  
Operation.........................................................................................................................Section B  
General Description..............................................................................................................B-1  
Design Features...................................................................................................................B-1  
Additional Features ..............................................................................................................B-2  
Recommended Applications.................................................................................................B-2  
Limitations ............................................................................................................................B-2  
Additional Safety Precautions .............................................................................................B-2  
Controls and Settings ..................................................................................................................B-2  
Welder / Generator Controls .........................................................................................B-3  
Engine Controls.............................................................................................................B-4  
Engine Operation .................................................................................................................B-5  
Before Starting the Engine............................................................................................B-5  
Starting the Engine........................................................................................................B-6  
Cold Weather Starting and Operation...........................................................................B-6  
Stoping the Engine........................................................................................................B-6  
Break-In Period .............................................................................................................B-7  
Welding Operation................................................................................................................B-7  
AC / DC Stick (Constant Current) Welding ...................................................................B-8  
AC / DC TIG (Constant Current) Welding .....................................................................B-9  
DC Wire Feed Welding (CV) with Ranger 300 DLX......................................................B-9  
DC Wire Feed Welding (CV) with Ranger 300 D ........................................................B-10  
Carbon Arc Gouging (Constant Current).....................................................................B-10  
Summary of Welding Processes and Machine Settings .............................................B-11  
Auxiliary Power...................................................................................................................B-13  
Simultaneous Welding and Power Loads ...................................................................B-13  
120 / 240 Volt Dual Voltage Receptacle .....................................................................B-14  
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  
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vii  
TABLE OF CONTENTS  
Page  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Kubota Engine Maintenance Schedule .................................................................D-1  
Kubota Engine Maintenance Components............................................................D-1  
Routine and Periodic Engine Maintenance ...........................................................D-2  
Oil....................................................................................................................D-2  
Oil Filter...........................................................................................................D-2  
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  
Connection Diagrams, Wiring Diagrams & Dimension Print.......................Section F  
Parts List.....................................................................................................P-290 Series  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - Ranger 300 D (K1522-1), Ranger 300 DLX (K1522-2)  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
System  
Capacities  
Kubota  
DH905  
Diesel Engine  
3 cylinder  
26.0 HP @  
3600 RPM  
High Idle 3700  
Low Idle 2150  
Full Load 3600  
54.9 cu. in  
(898 cc)  
12VDC battery  
(Group 45, 495  
cold crank amps)  
1 KW Starter  
30 A. Alternator  
w/ built in reg.  
Fuel: 10 gal.  
38 L  
Bore x Stroke  
Oil: 5.4 Qts.  
5.1 L  
2.83” x 2.90”  
(72 mm x 73.6mm)  
Coolant: 5.7 qts.  
5.4 L  
RATED OUTPUT - WELDER  
Welding Output  
Volts at Rated Amps  
Duty Cycle  
Max. OCV @ 3700 RPM  
DC Constant Current 300 amps  
AC Constant Current 300 amps  
DC Constant Voltage (300 D) 200 amps  
DC Constant Voltage (300 DLX) 300 amps  
DC Constant Voltage (300 DLX) 280 amps  
25 volts  
25 volts  
20 volts  
30 volts  
30 volts  
100%  
100%  
100%  
60%*  
100%  
80 volts RMS  
OUTPUT - GENERATOR  
1
Auxiliary Power  
12,000 Watts, 60 Hz  
120/240 Volts  
100 % Duty Cycle  
PHYSICAL DIMENSIONS  
HEIGHT  
37.38 in.  
949.4 mm  
WIDTH  
DEPTH  
WEIGHT  
24.75 in.  
60.50 in.  
1093 lbs. (300 D)  
1133 lbs. (300 DLX)  
480.8 kg. (300 D)  
499.0 kg. (300 DLX)  
628.7 mm  
1528.6 mm  
* 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  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
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”(150mm) beyond the equipment on all sides.  
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.  
STORING  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
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.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
2. Drain the engine oil and refill with fresh 10W30 oil.  
Run the engine for about five minutes to circulate  
oil to all the parts. See the MAINTENANCE section  
of this manual for details on changing oil.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
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.  
• 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.  
-----------------------------------------------------------  
4. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
Only qualified personnel should install,  
use, or service this equipment.  
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.  
LOCATION AND VENTILATION  
Whenever you use the RANGER 300, be sure that  
clean cooling air can flow through the machine’s  
diesel engine and the machine case. Avoid dusty,  
dirty areas. Also, keep the machine away from heat  
sources. Do not place the engine end of the machine  
anywhere near hot engine exhaust from another  
machine or closer than two feet from a wall. And of  
course, make sure that engine exhaust is ventilated to  
an open, outside area.  
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 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.  
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.  
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.  
RANGER 300 D AND 300 DLX  
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A-3  
A-3  
INSTALLATION  
4. Typical conditions of use, i.e., travel speed; rough-  
ness of surface on which the undercarriage will be  
operated; environmental conditions; likely mainte-  
nance.  
HIGH ALTITUDE OPERATION  
It may be necessary to de-rate the welder output at  
higher altitudes. Derate the welder output 0.4% for  
every 100 ft. (30 m) above 500 ft. (150 m). Some  
engine adjustment may be required above 5,000 ft.  
(1,500 m). Contact a Kubota Service Representative.  
(1)  
5. Conformance with federal, state and local laws.  
(1)  
Consult applicable federal, state and local laws regarding  
specific requirements for use on public highways.  
LIFTING  
PRE-OPERATION ENGINE SERVICE  
CAUTION  
The RANGER 300 weighs approximately 1150  
lbs/522 kg. A lift bail is mounted to the machine frame  
and should always be used when lifting the machine.  
READ and UNDERSTAND the engine operating and  
maintenance instructions supplied with this machine.  
ADDITIONAL SAFETY PRECAUTIONS  
------------------------------------------------------------------------  
WARNING  
FALLING EQUIPMENT can cause  
injury.  
WARNING  
Do not lift this machine using lift  
bale if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
• 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.  
Lift only with equipment of adequate lifting  
capacity.  
Be sure machine is stable when lifting.  
• Wipe up spilled fuel and allow the fumes to clear  
before starting the engine.  
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:  
• Keep sparks and flame away from the fuel tank.  
------------------------------------------------------------------------  
OIL  
The RANGER 300 is shipped with the engine filled  
with SAE 10W-30 oil. CHECK THE OIL LEVEL  
BEFORE YOU START THE ENGINE. If it is not full,  
add enough oil to fill it to the full mark.  
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.  
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.  
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.  
RANGER 300 D AND 300 DLX  
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A-4  
A-4  
INSTALLATION  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
FUEL  
Fill the fuel tank with clean No. 2, diesel fuel only. Do  
not fill to the top of the filler neck to allow room for  
expansion.  
a) Installing new batteries.  
b) Using a booster.  
Use correct polarity — Negative Ground.  
The RANGER 300 has a 10 gallon (38 liter) fuel tank  
with a top fill and fuel gauge mounted on the control  
panel. See the OPERATION and MAINTENANCE  
sections of this manual for more details about fuel.  
The RANGER 300 is shipped with the negative bat-  
tery cable disconnected. Before you operate the  
machine, make sure the Engine Switch is in the OFF  
position and attach the disconnected cable securely to  
the negative (-) battery terminal.  
ENGINE COOLANT  
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.  
WARNING  
HOT COOLANT can burn skin.  
• Do not remove cap if radiator is hot.  
EXHAUST DEFLECTOR  
------------------------------------------------------------------------  
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.  
CAUTION  
Shut off the machine and allow the muffler to cool  
before touching the muffler.  
------------------------------------------------------------------------  
BATTERY CONNECTIONS  
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.  
WARNING  
GASES FROM BATTERY can explode.  
Keep sparks, flame and cigarettes  
SPARK ARRESTER  
away from battery.  
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.  
To prevent EXPLOSION when:  
INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and connect  
to new battery last.  
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.  
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.  
CAUTION  
BATTERY ACID can burn eyes and  
An incorrect spark arrester may lead to damage to the  
engine or reduce performance.  
------------------------------------------------------------------------  
skin.  
Wear gloves and eye protection and  
be careful when working near battery.  
Follow instructions printed on battery.  
------------------------------------------------------------------------  
RANGER 300 D AND 300 DLX  
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A-5  
A-5  
INSTALLATION  
ELECTRICAL CONNECTIONS  
TOTAL COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
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.  
Cable Size for  
Cable Length  
300 Amps  
100% Duty Cycle  
1/0 AWG  
0-50 Ft. (0-15 meters)  
MACHINE GROUNDING  
1/0 AWG  
2/0 AWG  
2/0 AWG  
3/0 AWG  
50-100 Ft. (15-39 meters)  
100-150 Ft. (30-46 meters)  
150-200 Ft. (46-61 meters)  
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.  
200-250 Ft. (61-76 meters)  
Table A.1  
CABLE INSTALLATION  
Install the welding cables to your RANGER 300 as fol-  
lows. See Figure B.1 for location of parts.  
WARNING  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
------------------------------------------------------------------------  
1. The diesel engine must be OFF to install welding  
cables.  
2. Remove the flanged nuts from the output terminals.  
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.  
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.  
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.  
5. Be certain that the metal piece you are welding (the  
“work”) is properly connected to the work clamp and  
cable.  
WELDING CABLE CONNECTIONS  
6. Check and tighten the connections periodically.  
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.  
CAUTION  
• 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 sepa-  
rate from one another.  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
------------------------------------------------------------------------  
Lincoln Electric offers a welding accessory kit with the  
properly specified welding cables. See the  
ACCESSORIES section of this manual for more infor-  
mation.  
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A-6  
A-6  
INSTALLATION  
AUXILIARY POWER RECEPTACLES,  
PLUGS, AND HAND-HELD EQUIPMENT  
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.  
The control panel of the RANGER 300 features three  
auxiliary power receptacles: See Figure B.1.  
• Two 15 amp, 120 volt duplex (double outlet) recepta-  
cles.  
• One 50 amp 120/240 volt simplex (single outlet)  
receptacle.  
WARNING  
Only a licensed, certified, trained electrician should  
install the machine to a premises or residential elec-  
trical system. Be certain that:  
Through these receptacles the machine can supply up  
to 12,000 rated continuous watts of single-phase, 60  
Hz AC power.  
• The installation complies with the National Electrical  
Code and all other applicable electrical codes.  
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.  
• 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.  
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  
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.  
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.  
2. Take the necessary steps to assure that the load is  
limited to the capacity of the RANGER 300 by  
installing a 50 amp 240 volt double pole circuit  
breaker. Maximum rated load for the 240 volt 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.  
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.  
------------------------------------------------------------------------  
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.  
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A-7  
A-7  
INSTALLATION  
Figure A.1  
CONNECTION OF RANGER 300 TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
COMPANY  
METER  
240 Volt  
60 Hz.  
3-Wire  
Service  
120 VOLT  
120 VOLT  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
GROUND  
50AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE  
SIZE RECOMMENDATIONS.  
WARNING  
Connection of Ranger 300 to premises wiring  
must be done by a licensed electrician and must  
comply with the National Electrical Code and all  
other applicable electrical codes.  
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B-1  
B-1  
OPERATION  
FOR AUXILIARY POWER:  
GENERAL DESCRIPTION  
• 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 AC power at the same time (within  
machine total capacity).  
• Compatible with GFCI's (ground fault circuit inter-  
rupters).  
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.  
OTHER FEATURES:  
• Insonorized for extremely quiet operation (99LW(A)  
and 74 db(A) @ 23 ft (7m)).  
• Kubota 3-cylinder, liquid cooled, diesel engine.  
Designed for long life, easy maintenance 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.  
The Ranger 300 machines are housed in a heavy  
gauge steel 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.  
• 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.  
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.  
• Large capacity 10 gallon (38 l) fuel tank.  
• Automatic idler reduces engine speed when not  
welding or drawing auxiliary power. Machine always  
starts in low idle. Reduces fuel consumption and  
extends engine life.  
• Compact size fits many smaller trucks.  
• Single side engine service with easy to open access  
door.  
• 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.  
• Copper alternator windings and high temperature  
insulation for dependability and long life.  
• Powder painted case and base for outstanding cor-  
rosion protection.  
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B-2  
B-2  
OPERATION  
ADDITIONAL FEATURES  
RANGER 300 D (K1522-1):  
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.  
• 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 & L-56 using blended Argon shielding gas.  
“Auto-Idle” functions when using an LN-25 with an  
internal contactor.  
• 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 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.  
• 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.  
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.  
RECOMMENDED APPLICATIONS  
WELDER  
CONTROLS AND SETTINGS  
The RANGER 300 provides excellent constant current  
AC/DC welding output for stick (SMAW) welding and  
for TIG welding, and it offers constant voltage output  
for DC semiautomatic wire feed welding.  
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.  
GENERATOR  
The RANGER 300 gives AC generator output for  
medium use demands.  
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B-3  
B-3  
OPERATION  
5. WELDING TERMINALS SWITCH (DLX Model Only)  
The toggle switch labeled “WELDING TERMINALS  
ALWAYS ON” and “WELDING TERMINALS  
REMOTELY CONTROLLED” is used to control the  
operation of the RANGER 300 DLX output contactor.  
With the switch in the “WELDING TERMINALS  
ALWAYS ON” position, the contactor is closed at low  
and high idle.  
2
4
3
5
1
6
14  
7
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.  
E
F
8
12  
13  
6. WIRE FEEDER POWER CIRCUIT BREAKER: Opens  
the wire feeder circuit and disables the feeder if a fault  
is detected in the circuit.  
10  
11  
9
7. 15 AMP, 120 VOLT DUPLEX RECEPTACLES:  
Connection point for supplying 120 volt power to oper-  
ate one or two electrical devices.  
FIGURE B.1  
OUTPUT PANEL CONTROLS  
8. 50 AMP, 120/240 VOLT RECEPTACLE: Connection  
point for supplying 240 volt power to operate one  
electrical device.  
WELDER/GENERATOR CONTROLS  
See Figure B.1 for the location of the following features:  
9. WELD OUTPUT TERMINAL (TO WORK) WITH  
FLANGE NUT: Provides the connection point for the  
work cable.  
1. OUTPUT RANGE SELECTOR: Selects continuous  
current output for constant current stick or TIG appli-  
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.  
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.  
2. FINE OUTPUT CONTROL: Allows fine adjustment of  
current or voltage within the selected output range.  
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).  
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.  
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.  
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.  
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B-4  
B-4  
OPERATION  
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.  
4
6
5
8
b) 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.  
1
9
2
E
F
3
3. START PUSH-BUTTON: When the push-  
button is held, the starter motor cranks over  
the engine - release the Button once the engine  
starts.  
7
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.  
FIGURE B.2  
DIESEL ENGINE CONTROLS  
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.  
ENGINE CONTROLS  
See Figure B.2 for the location of the following fea-  
tures:  
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.  
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.  
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.  
When in “AUTO” (  
/
) idle position, the  
idler operates as follows:  
a) Welding  
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.  
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  
accelerates to full speed.  
Low idle and in the “WELDING TERMINALS  
REMOTELY CONTROLLED” mode - Pressing  
the gun trigger or Amptrol closes the Ranger 300  
DLX output contactor and causes the engine to  
accelerate to full speed.  
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B-5  
B-5  
OPERATION  
7. WATER TEMPERATURE LIGHT: Remains  
off under normal operating temperatures. If  
the red light turns on, the engine protection system  
will stop the engine. The light will remain on when  
the engine is over temperature and the “Engine”  
switch is in the “ON” position (engine not running)  
but will go off as the engine cools.  
ENGINE OPERATION  
WARNING  
DO NOT RUN THE ENGINE AT EXCESSIVE  
SPEEDS. The maximum allowable high idle speed  
for the RANGER 300 is 3700 RPM, no load. Do NOT  
adjust the governor screw on the engine. Severe 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.  
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.  
BEFORE STARTING THE ENGINE  
Check the engine oil level:  
See Figure D.1 for location of dipstick.  
1. Be sure the machine is on a level surface.  
2. Remove the engine oil dipstick and wipe it with a  
clean cloth. Reinsert the dipstick and check the  
level on the dipstick.  
3. Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill.  
4. Replace the dipstick.  
Check and fill the engine fuel tank:  
WARNING  
DIESEL fuel can cause fire or  
explosion.  
• Stop engine when fueling.  
• Do not smoke when fueling.  
• Do not overfill tank.  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
1. Remove the fuel tank cap.  
2. Fill the tank approximately 4 inches (100 mm) from  
the top of the filler neck to allow for fuel expansion  
(observe the fuel gauge.) DO NOT FILL THE  
TANK TO THE POINT OF OVERFLOW.  
3. Replace the fuel tank cap and tighten securely.  
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B-6  
B-6  
OPERATION  
NOTE: DO NOT allow the RANGER 300 to run out of  
fuel. If it does, you will have to bleed the injec-  
tion system. See the Maintenance section of  
this manual and the Engine Operators Manual  
for instructions on bleeding the fuel injection  
system.  
6. Press the “GLOW PLUG” button to pre-heat  
the cylinders per the following table:  
Pre-Heat Time  
Ambient Temperature  
Above 50°F (10°C)  
50°F (10°C) to 23°F(-5°C)  
Below 23°F (-5°C)  
NOT REQUIRED  
Approximately 5 seconds  
Approximately 10 seconds  
CAUTION  
USE DIESEL FUEL ONLY  
Purchase diesel fuel in quantities that will be used  
within 30 days, to assure freshness.  
------------------------------------------------------------------------  
STARTING THE ENGINE  
CAUTION  
Never press the Glow Plug button continuously for  
more than 20 seconds.  
------------------------------------------------------------------------  
CAUTION  
7. Release the "GLOW PLUG" button and  
press the “START” button to crank the  
engine. Release when the engine starts.  
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.  
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 in 60 seconds or  
stops running the “ENGINE” switch must be  
switched to “OFF” and then switched back to “ON”  
before attempting to restart the engine. This resets  
the engine protection circuit.  
COLD WEATHER STARTING AND  
OPERATION.  
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.  
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.  
3. Check for proper oil level on the oil dipstick. Close  
engine compartment door.  
4. Set “IDLER” switch to “AUTO”.  
/
STOPPING THE ENGINE  
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).  
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  
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B-7  
B-7  
OPERATION  
BREAK-IN PERIOD  
WELDING OPERATION  
WARNING  
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.  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturers  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
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.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground  
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.  
Always wear dry insulating gloves.  
------------------------------------------------------------------------  
FUMES AND GASES can be dangerous.  
Keep your head out of fumes.  
Use ventilation or exhaust to remove  
fumes from breathing zone.  
------------------------------------------------------------------------  
TABLE B.1  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
TYPICAL RANGER 300 FUEL CONSUMPTION  
Do not operate with doors open or  
.30 gallons/hour  
(1.0 liters/hour)  
Low Idle - No Load  
2000 RPM  
guards off.  
Stop engine before servicing.  
Keep away from moving parts.  
------------------------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
.60 gallons/hour  
(2.2 liters/hour)  
High Idle - No Load  
3700 RPM  
1.1 gallons/hour  
(4.2 liters/hour)  
Keep flammable material away.  
AC CC Weld Output  
300 Amps @ 25 Volts  
------------------------------------------------------------------------  
ARC RAYS can burn.  
1.2 gallons/hour  
(4.6 liters/hour)  
DC CC Weld Output  
300 Amps @ 25 Volts  
Wear eye, ear and body protection.  
.90 gallons/hour  
(3.6 liters/hour)  
DC CV Weld Output  
300 Amps @ 28 Volts*  
------------------------------------------------------------------------  
See additional warning information  
throughout this operators manual.  
1.3 gallons/hour  
(4.9 liters/hour)  
Auxiliary Power,  
12,000 kVA  
* DLX model only  
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  
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B-8  
B-8  
OPERATION  
AC/DC STICK (CONSTANT CURRENT)  
WELDING  
1. Remove the flange nuts from output terminals and  
place the work and electrode welding cables over  
the terminals. See Figure B.4. Replace and tight-  
en the flange nuts securely. Be sure the connec-  
tions are tight.  
E
F
2. Select the appropriate electrode. See “Welding  
Tips 1" included with your RANGER 300.  
OUTPUT TERMINALS  
3. Attach the work clamp securely to the work you are  
welding.  
4. Insert the electrode into the electrode holder.  
FIGURE B.4  
WELDING CIRCUIT CONNECTIONS  
5. Set the IDLER CONTROL to AUTO and start the  
diesel engine.  
AFTER YOU FINISH WELDING:  
1. Stop the engine.  
6. Set the RANGE switch to a setting equal to or  
slightly lower than the welding current recommend-  
ed for the electrode being used. For the best weld-  
ing performance, always set the RANGE switch to  
the lowest CC-blue setting that will give the desired  
weld current. This will assure that the OUTPUT  
dial is set towards the high end of the dial. If the  
OUTPUT dial is set at 10 and the welding current  
is to low, move the RANGE switch to the next high-  
est setting.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
4. Remove any remaining piece of electrode from the  
electrode holder.  
5. If you are finished using the RANGER 300 for  
welding, disconnect the welding cables from the  
weld output terminals. Reattach the flange nuts  
and leave them on the terminals.  
7. Set the POLARITY switch to the desired polarity  
(CC-blue setting).  
8. Set the OUTPUT control. For stick welding,  
always use a setting between 5 and 10 on the dial  
(blue range).  
9. Strike an arc and begin welding. The OUTPUT  
control can be adjusted while welding.  
CAUTION  
DO NOT change the RANGE switch setting while  
welding. This can result in damage to the switch.  
------------------------------------------------------------------------  
RANGE SETTING  
ON MACHINE  
ACTUAL  
CURRENT RANGE  
50  
75  
30 to 50 AMPS  
50 to 75 AMPS  
100  
140  
180  
225  
300  
70 to 100 AMPS  
95 to 140 AMPS  
110 to 180 AMPS  
130 to 225 AMPS  
160 to 300 AMPS  
RANGER 300 D AND 300 DLX  
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B-9  
B-9  
OPERATION  
AC/DC TIG (CONSTANT CURRENT)  
WELDING  
DC WIRE FEED WELDING (CV)  
WITH RANGER 300 DLX  
1. Connect the K930-1 TIG Module to the RANGER 300.  
Follow the installation instructions provided with the kit.  
1. Connect one of the following: the LN-25, LN-7 or  
LN-8 Wire Feeder.  
2. Refer to the instruction manual with the TIG module (IM  
528) for operation with a RANGER 300. And proper  
machine settings.  
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® 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.  
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.  
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.  
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.  
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.  
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:  
3. Set the IDLER CONTROL to “AUTO” for the LN-25  
“HIGH” for the LN-7 or LN-8 and start the diesel  
engine.  
1. Stop the engine.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
4. Set the RANGE switch to either HIGH, MEDIUM  
HIGH, MEDIUM LOW, or LOW (CV-red) depend-  
ing on your wire size and speed.  
TABLE B.2  
AC TIG WELDING  
TIG ELECTRODE / RANGE SETTINGS  
5. Set the POLARITY SWITCH to either WIRE FEED  
DC+ or WIRE FEED DC (red), depending on the  
electrode.  
Pure (EWP)  
Tungsten Diameter  
Range”  
Switch Settings  
Appropriate  
Welding Current  
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.  
(1)  
1/8”  
3/32”  
1/16”  
75, 100 or 140  
50, 75 or 100  
50, 75 or 100  
Range”  
100 - 200 amps  
50 - 100 amps  
45 - 150 amps  
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.  
1% Thoriated  
Tungsten Diameter  
Appropriate  
Welding Current  
Switch Settings  
1/8”  
3/32”  
1/16”  
100, 140 or 180  
160 - 250 amps  
100 - 180 amps  
60 - 120 amps  
50, 100 or 140  
50 or 100  
AFTER YOU FINISH WELDING:  
1. Stop the engine.  
(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.  
2. Allow the work to cool completely.  
3. Remove the work clamp from the work.  
RANGER 300 D AND 300 DLX  
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B-10  
B-10  
OPERATION  
AFTER YOU FINISH WELDING:  
DC WIRE FEED WELDING (CV)  
WITH RANGER 300D  
1. Stop the engine  
1. Connect an LN-25 with internal contactor to the  
Ranger 300D.  
2. Allow the work to cool completely  
3. Remove the work clamp from the work  
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:  
CARBON ARC GOUGING  
(CONSTANT CURRENT)  
Electrode  
Diameter  
Wire Speed  
in. / min.  
Approximate  
Current Range  
1. The recommended electrode ia a 3/16” (4.8 mm)  
dia. carbon  
.035”  
.045”  
.068”  
70 - 110  
70 - 130  
40 - 90  
60 - 120 amps  
120 - 170 amps  
125 - 210 amps  
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:  
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). 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:  
1. Stop the engine  
2. Allow the electrode and work to cool completely  
3. Remove the work clamp from the work  
Electrode  
Diameter  
Wire Speed  
in. / min.  
Approximate  
Current Range  
.030”  
.035”  
150 - 450  
100 - 350  
80 - 170 amps  
80 - 190 amps  
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.  
RANGER 300 D AND 300 DLX  
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B-11  
B-11  
OPERATION  
SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS  
TABLE B.3  
SUMMARY OF WELDING PROCESSES FOR RANGER 300 DLX  
CONTROL  
CABLE &  
DIAGRAM  
IDLE  
MODE  
OUTPUT  
WELDING ELECTRODE  
TO START WELDING  
PROCESS  
CONTROL TERMINALS WHEN NOT  
SWITCH  
SWITCH  
WELDING  
Touch electrode to work.  
Welding starts immediately  
and engine goes to high idle.  
AUTO  
AUTO  
AUTO  
AUTO  
AT  
WELDER  
ALWAYS  
ON  
HOT  
STICK - CC  
CARBON ARC  
GOUGING - CC  
NO  
Press Amptrol. Welding  
starts immediately.  
TIG - CC  
K930-1 TIG MODULE /  
K936-1 CONTROL CABLE  
YES  
S23732-9  
REMOTE  
REMOTE  
REMOTE  
REMOTE  
COLD  
COLD  
COLD  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately  
and engine goes to high idle.  
WIRE FEED - CV,  
LN-25 WITH 42V  
REMOTE CON-  
TROL KIT  
YES  
S23732-3  
Press gun trigger, LN-25  
contactor closes. Welding  
starts immediately and engine  
goes to high idle.  
WIRE FEED - CV,  
LN-25 WITH  
INTERNAL  
NO  
S23732-1  
S23732-2  
AT  
WELDER  
ALWAYS  
ON  
CONTACTOR  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately  
and engine goes to high idle.  
WIRE FEED - CV,  
LN-742  
YES  
S23732-5  
AUTO  
HIGH  
HIGH  
REMOTE  
REMOTE  
REMOTE  
REMOTE  
REMOTE  
COLD  
COLD  
COLD  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately.  
WIRE FEED - CV,  
LN-7 or LN-8  
YES  
S23732-4  
S23732-6  
AT WELDER  
Press gun trigger, Ranger  
300 DLX contactor closes.  
Welding starts immediately.  
K487-15 WIRE FEED-  
CV SPOOL GUN / K488  
CONTROL MODULE  
YES  
S23732-8  
RANGER 300 D AND 300 DLX  
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B-12  
B-12  
OPERATION  
SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS  
TABLE B.4  
SUMMARY OF WELDING PROCESSES FOR RANGER 300 D  
CONTROL  
CABLE &  
DIAGRAM  
IDLE  
MODE  
OUTPUT  
CONTROL  
SWITCH  
ELECTRODE  
WHEN NOT  
WELDING  
TO START WELDING  
PROCESS  
Touch electrode to work.  
Welding starts immediately  
and engine goes to high idle.  
AUTO  
AUTO  
AUTO  
HIGH  
AT  
WELDER  
HOT  
HOT  
STICK - CC  
CARBON ARC  
GOUGING - CC  
NO  
Press Amptrol. Welding  
starts immediately.  
TIG - CC  
K930-1 TIG MODULE /  
K936-1 CONTROL CABLE  
YES  
S23732-10  
REMOTE  
Press gun trigger, LN-25  
contactor closes. Electrode  
touches work, welding starts  
immediately and engine goes  
to high idle.  
WIRE FEED - CV,  
LN-25 /  
INTERNAL  
NO  
S23732-1  
S23732-2  
AT  
WELDER  
COLD  
COLD  
CONTACTOR  
Press gun trigger, K240  
contactor closes. Welding  
starts immediately.  
WIRE FEED - CV,  
LN-7 / K240  
CONTACTOR KIT  
YES  
S23732-11  
AT  
WELDER  
RANGER 300 D AND 300 DLX  
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B-13  
B-13  
OPERATION  
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.  
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.  
SIMULTANEOUS WELDING AND POWER  
LOADS  
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.  
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).  
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  
RANGER 300 SIMULTANEOUS WELDING AND POWER LOADS  
(OUTPUT CONTROL SET AT 10)  
TABLE B.5  
Welding  
Output  
Amps  
Permissible  
Power Watts  
(Unity Power  
Factor)  
Permissible  
Auxiliary Current in Auxiliary Current in  
Amperes @ 120V  
Permissible  
Output  
Selector  
Setting  
Amperes @ 240V  
300  
225  
180  
140  
100  
75  
0
300  
225  
180  
140  
100  
75  
NONE  
3000  
4800  
6400  
8000  
9000  
10,000  
0
13  
20  
27  
33  
38  
42  
25  
40  
53  
60  
60  
60  
50  
50  
200  
60  
17  
40  
CV LOW (300 DLX)  
CV (300 D)  
4000  
9600  
33  
60  
225  
80  
13  
27  
CV MED. LOW  
(300 DLX)  
3000  
8800  
25  
60  
250  
100  
8
33  
CV MED. HIGH  
(300 DLX)  
2000  
8000  
17  
60  
300  
150  
0
25  
CV HIGH  
(300 DLX)  
0
6000  
0
50  
NOTE: Voltage and permissible watts decrease as "CONTROL" is adjusted to settings less than 10. It is recommended that  
at settings less than 10, only incandescent lighting loads be connected to the auxiliary power receptacles.  
RANGER 300 D AND 300 DLX  
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B-14  
B-14  
OPERATION  
120/240  
RECEPTACLE  
VOLT  
DUAL  
VOLTAGE  
Maximum Current Draw from Optional 120V  
GFCI Duplex Receptacles - No Welding  
EACH HALF OF TOTAL FROM  
TOTAL FROM  
BOTH 120V  
DUPLEXES  
240 V LOAD FROM  
FULL KVA  
RECEPTACLE  
The 120/240 volt receptacle can supply up to 50 amps  
of 240 volt power to a two wire circuit, up to 50 amps  
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-  
EACH 120V  
DUPLEX  
ONE 120V  
DUPLEX  
30 AMPS  
30 AMPS  
0
0
15 AMPS  
15 AMPS  
0
15 AMPS  
15 AMPS  
0
35 AMPS  
50 AMPS  
GND  
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  
EACH HALF OF TOTAL FROM  
TOTAL FROM  
BOTH 120V  
DUPLEXES  
240 V LOAD FROM  
FULL KVA  
RECEPTACLE  
EACH 120V  
DUPLEX  
ONE 120V  
DUPLEX  
60 AMPS  
60 AMPS  
40 AMPS  
20 AMPS  
0
0
15 AMPS  
15 AMPS  
15 AMPS  
15 AMPS  
0
30 AMPS  
30 AMPS  
30 AMPS  
20 AMPS  
0
20 AMPS  
30 AMPS  
40 AMPS  
50 AMPS  
RANGER 300 D AND 300 DLX  
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C-1  
C-1  
ACCESSORIES  
The TIG Module is supplied without accessories, Arc  
Start switches, Amptrols, cables, torches and mount-  
ing brackets must be purchased separately.  
GENERAL OPTIONS /  
ACCESSORIES  
The following options/accessories are available for  
your RANGER 300 from your local Lincoln Distributor.  
K939-1 Docking Kit - For mounting the K930-1 TIG  
Module on top of the Ranger 300.  
K953-1 Two-Wheeled Trailer - For in-plant or yard  
towing of the RANGER 300. Suitable for road towing  
with optional Fender and Light Kit. Load capacity is  
2,100 lbs.  
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.  
K802-R Power Plug Kit - Provides four 15 amp, 115  
volt plugs and one 50 amp, dual voltage (115/230V),  
full kVA plug.  
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.  
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.  
K963 Hand Amptrol - Remote output control on  
RANGER 300 D/DLX and contactor control on Ranger  
300 DLX.  
• GC500 work clamp.  
• Cooltong® 300 insulated electrode holder.  
K870 Foot Amptrol - Remote output control on  
RANGER 300 D/DLX and contactor control on Ranger  
300 DLX.  
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.  
SEMIAUTOMATIC FCAW AND MIG  
WELDING (RANGER 300 DLX)  
OPTIONS / ACCESSORIES  
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.  
LN-25 Wire Feeder - This portable unit provides  
CC/CV for flux-cored arc welding (FCAW) and metal  
inert gas welding (MIG).  
K896-1 GFCI Receptacle Kit - Includes two UL  
approved 120 volt ground fault circuit interrupter  
receptacles (duplex type) with covers and installation  
instructions. Each receptacle is rated 15 amps, but  
the maximum total current from each GFCI duplex is  
limited to 20 amps. The GFCI receptacles replace the  
two factory installed 120 volt duplex receptacles.  
LN-7 or LN-8 Wire Feeder - Semiautomatic constant  
speed wire feeders.  
NOTE: Gas-shielded welding requires a Magnum  
Gun. Gasless welding requires an Innershield Gun.  
K487-25 Magnum Spool Gun - A lightweight, 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.  
TIG WELDING OPTIONS /  
ACCESSORIES  
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.  
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.  
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C-2  
C-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.  
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D-1  
D-1  
MAINTENANCE  
KUBOTA ENGINE MAINTENANCE  
SCHEDULE  
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 moving parts.  
TABLE D.1  
FREQUENCY  
MAINTENANCE REQUIRED  
Daily or Before  
Starting Engine  
• Fill fuel tank.  
• Check oil level.  
• Check air cleaner for dirty, loose,  
or damaged parts.  
• Check air intake and cooling  
areas, clean as necessary.  
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.  
Every 50 Hours  
Every 100 Hours  
• Check fuel lines and clamps.  
(1)  
• Clean air filter element.  
• Check battery electrolyte level.  
• Check fan belt tightness.  
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground  
(2)  
Every 200 Hours  
Every 400 Hours  
• Change engine oil.  
(2)  
• Replace oil filter cartridge.  
• Check radiator hoses.  
Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
• Replace fuel filter element.  
Use in open, well ventilated areas or  
(1) Replace air filter element after 600 hours of operation or sooner under  
dusty operating conditions.  
vent exhaust outside.  
(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.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
Refer to your Kubota Operator's Manual for periodic  
maintenance at 500 hours and beyond.  
Do not operate with doors open or  
guards off.  
Stop engine before servicing.  
Keep away from moving parts.  
------------------------------------------------------------------------  
KUBOTA ENGINE MAINTENANCE  
COMPONENTS  
See additional warning information  
throughout this operators manual and  
the Engine manual as well.  
TABLE D.2  
-----------------------------------------------------------  
ITEM  
MAKE AND PART NUMBER  
Oil Filter Element  
Kubota 16271-32092  
Fram PH 3593A  
Air Cleaner Element  
Fuel Filter Element  
Donaldson P148970  
Kubota 15231-43560  
Fram C6921  
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D-2  
D-2  
MAINTENANCE  
OIL FILL CAP  
OIL LEVEL  
DIP STICK  
ROUTINE AND PERIODIC ENGINE  
MAINTENANCE  
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 FILTER  
OIL DRAIN PLUG  
FIGURE D.1  
OIL COMPONENT LOCATIONS  
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.  
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.  
CHANGING THE OIL  
Change the oil filter as follows:  
Change the oil, while the engine is still warm, as fol-  
lows:  
1. Drain the oil from the engine and allow the oil filter  
to drain.  
1. Drain the oil from the drain plug located on the  
engine bottom, as shown in Figure D.1.  
2. Remove the old filter (spin it off) and discard it.  
Wipe off the filter mounting surface and adapter.  
2. Replace the plug and tighten it securely.  
3. Apply a thin coat of new oil to the rubber gasket on  
the new oil filter.  
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:  
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.  
Viscosity Grades  
Ambient Temperature  
Above 25°C (77°F)  
0°C (32°F) to 25°C(77°F)  
Below 0°C (32°F)  
5. Refill the engine with the proper amount and type  
of oil as described in the CHANGING THE OIL  
section. Start the engine and check for leaks  
around the filter element. Correct any leaks (usu-  
ally by retightening the filter, but only enough to  
stop leaks) before placing the RANGER 300 back  
in service.  
SAE 10W-30, SAE10W-40 or SAE30  
SAE 10W-30, SAE10W-40 or SAE20  
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.  
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.  
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D-3  
D-3  
MAINTENANCE  
FUEL  
AIR CLEANER  
At the end of each days 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.  
The Kubota diesel engine is equipped with a dry type  
air filter. Never apply oil to it. Service the air cleaner  
as follows:  
Use only fresh, No. 2 grade DIESEL fuel. Do not use  
kerosene.  
1. Remove the dust cup from the bottom of the air  
cleaner housing. Clean out any accumulated dust.  
See the Kubota Engine Operator's Manual for instruc-  
tions on replacing the fuel filter.  
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.  
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:  
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 lbs. (9 Kg) (6  
mm).  
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.  
COOLING SYSTEM  
2. Open the air vent plug on the fuel injection pump  
two turns using a 10mm wrench.  
WARNING  
HOT COOLANT can burn skin.  
3. Move the fuel feed pump lever by hand until fuel  
flows out of the air vent plug.  
Do not remove cap if radiator is  
hot.  
4. Tighten the air vent plug.  
------------------------------------------------------------------------  
AIR VENT PLUG  
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 radiator. 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.  
FUEL FEED PUMP LEVER  
FIGURE D.2  
FUEL BLEEDING COMPONENT LOCATIONS  
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D-4  
D-4  
MAINTENANCE  
To prevent ELECTRICAL DAMAGE when:  
CAUTION  
a) Installing a battery.  
b) Using a booster.  
Always premix the antifreeze and clean tap water  
before adding to the radiator or the overflow tank. It is  
very important that a precise 50/50 solution be used  
with this engine year round. This gives proper cooling  
during hot weather and freezing protection to -34° F (-  
37° C).  
Use correct polarity - Negative Ground.  
To prevent BATTERY DISCHARGE, if you have an  
ignition switch, turn it off when engine is not  
running.  
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.  
------------------------------------------------------------------------  
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 l) of water. Be  
sure the battery vent plugs (if equipped) are tight so  
that none of the solution enters the cells.  
------------------------------------------------------------------------  
Periodically remove the dirt from the radiator fins.  
Periodically check the fan belt and radiator hoses.  
Replace if signs of deterioration are found.  
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.  
BATTERY MAINTENANCE  
WARNING  
GASES FROM BATTERY can explode.  
CHECKING ELECTROLYTE LEVEL  
Keep sparks, flame and cigarettes  
away from battery.  
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.  
To prevent EXPLOSION when:  
INSTALLING A NEW BATTERY disconnect  
negative cable from old battery first and connect to  
new battery last.  
The battery is a group 45, with a rating of 495 cold  
cranking amps.  
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.  
BATTERY ACID can burn eyes and  
skin.  
Wear gloves and eye protection and  
be careful when working near battery.  
Follow instructions printed on battery.  
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D-5  
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 brushes when a generator  
overhaul is necessary.  
WARNING  
Do not attempt to polish slip rings while the engine is  
running.  
------------------------------------------------------------------------  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
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 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.  
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.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled POSSIBLE CAUSElists  
the obvious external possibilities that may contribute  
to the machine symptom.  
WARNING  
ELECTRIC SHOCK can kill.  
Do not touch electrically live parts such as output  
terminals or internal wiring.  
ENGINE EXHAUST can kill.  
Use in open, well ventilated areas or vent exhaust  
outside.  
MOVING PARTS can injure.  
Do not operate with doors open or guards off.  
Stop engine before servicing.  
Keep away from moving parts.  
Remove guards only when necessary and replace when work  
requiring removal is complete.  
Only qualified personnel should install, use or service this  
equipment.  
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.  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
Major Physical or Electrical Damage  
is Evident.  
1. Contact your Local Lincoln Authorized  
Field Service Facility.  
Engine will not "crank".  
1. Battery is low.  
1. Charge Battery.  
2. Loose battery cable connections. 2. Inspect, clean and tighten.  
3. Faulty engine starter motor. 3. Contact authorized Kubota Service  
Shop.  
Engine will "crank" but not start.  
1. Fuel shut off valve is in off posi- 1. Move lever on fuel filter housing to  
tion.  
"ON" (vertical) position.  
2. Out of fuel.  
2. Fill tank and bleed fuel system. See  
MAINTENANCE section  
3. Engine switch in "OFF" position.  
3. Set switch to "ON" position.  
4. High  
(Indicator light lit).  
5. Faulty fuel solenoid or faulty PC 5. Contact your Local Lincoln Authorized  
coolant  
temperature 4. Check engine cooling system.  
board.  
Field Service Facility for technical  
troubleshooting assistance.  
Engine shuts down shortly after 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.  
2. Circuit breaker CB9 located in 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 CB9 is tripped.  
Engine shuts down while under load. 1. High  
coolant  
temperature 1. Reduce load if it is exceeding machine  
rating. Add coolant to system if low.  
Clean fins on radiator if dirty. Tighten  
fan belt if loose.  
(Indicator light lit).  
Battery does not stay charged.  
1. Faulty battery.  
1. Replace  
2. Loose connections at battery or 2. Clean and tighten connections.  
alternator.  
3. Loose fan belt.  
4. Faulty engine alternator.  
3. Tighten. See Maintenance Section.  
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.  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
Engine will not idle down to low 1. Idler switch in High idle position.  
1. Set switch to Auto.  
speed. 2. External load on welder or auxil- 2. Remove all external loads.  
iary power.  
3. Faulty wiring or PC board.  
3. Contact your Local Lincoln Authorized  
Field Service Facility for technical  
troubleshooting assistance.  
Engine will not go to high idle when 1. Poor work lead connection to 1. Make sure work clamp is tightly con-  
attempting to weld. work. nected to clean base metal.  
2. "Welding Terminals" switch is in 2. Set to "Always On" when welding with-  
wrong position.  
out a welding terminal control cable.  
Refer to Operations chapter for proper  
use of this switch.  
3. Faulty high speed solenoid or 3. Contact your Local Lincoln Authorized  
faulty PC board.  
Field Service Facility for technical  
troubleshooting assistance.  
Engine will not go to high idle when 1. Auxiliary power load is less than 1. Idler may not respond with less than a  
using auxiliary power. 100 watts. 100 watt load. Set idler to "High".  
2. Faulty high speed solenoid or 2. Contact your Local Lincoln Authorized  
faulty PC board.  
Field Service Facility for technical  
troubleshooting assistance.  
Engine will not go to high idle and 1. Faulty high speed solenoid  
circuit breaker CB8 located in engine  
compartment is open.  
1. 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.  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
No welding power output.  
1. "Welding Terminals" switch in 1. Place switch in "Always On" position  
wrong position.  
when welding without welding terminal  
control cable. Refer to Operation  
chapter for proper switch function.  
2. Faulty welding alternator or faulty 2. Contact your Local Lincoln Authorized  
PC board.  
Field Service Facility for technical  
troubleshooting assistance.  
Welder has output but no control.  
1. "Control" switch is in wrong posi- 1. Place switch in "Control at Welder"  
tion.  
position to control output at welder.  
Place switch in "Remote" position to  
control output remotely. Refer to  
Operation chapter for proper switch  
function.  
2. Poor remote kit connection.  
3. Faulty remote kit.  
2. Check connections.  
3. Replace if necessary.  
4. Faulty control potentiometer or 4. Contact your Local Lincoln Authorized  
faulty PC board.  
Field Service Facility for technical  
troubleshooting assistance.  
No auxiliary power.  
1. Open circuit breakers.  
1. Reset breakers. If breakers keep trip-  
ping, reduce power draw.  
2. Faulty connections to auxiliary 2. Check connections.  
receptacles.  
3. GFCI tripped.  
3. Clear any ground fault and reset GFCI  
circuit by pressing "Reset" button on  
the 120 V receptacle.  
4. Faulty welding alternator or faulty 4. Contact your Local Lincoln Authorized  
PC board.  
Field Service Facility for technical  
troubleshooting assistance.  
Wire feeder does not work when 1. Wire Feeder Power circuit breaker 1. Reset  
connected to welder 14 pin amphe- open.  
nol (DLX models only).  
2. Faulty wiring in control cable  
3. Faulty wire feeder.  
2. Repair or replace cable  
3. 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.  
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F-1  
F-1  
CONNECTION DIAGRAMS  
RANGER 300 D & RANGER 300 DLX / LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
WITH OPTIONAL K857 REMOTE CONTROL  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
14 PIN  
AMPHENOL  
OPTIONAL K857  
REMOTE CONTROL  
6 PIN  
AMPHENOL  
(RANGER 300 DLX  
ONLY)  
LN-25  
WIRE FEEDER  
WORK CLIP LEAD  
ELECTRODE  
TO WORK  
TO WORK  
TO WORK  
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.  
6-20-97  
S23732-1  
RANGER 300 D & RANGER 300 DLX / LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
WITH OPTIONAL K444-1 REMOTE CONTROL  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
14 PIN  
AMPHENOL  
(RANGER 300 DLX  
ONLY)  
6 PIN  
AMPHENOL  
OPTIONAL K444-1  
REMOTE CONTROL  
LN-25  
WIRE FEEDER  
WORK CLIP LEAD  
ELECTRODE  
TO WORK  
TO WORK  
TO WORK  
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.  
6-20-97  
S23732-2  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-2  
F-2  
CONNECTION DIAGRAMS  
RANGER 300 DLX / LN-25 WITH K624-1 42 VOLT REMOTE OUTPUT  
CONTROL MODULE CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
TO LN-25 INPUT  
CABLE PLUG  
14 PIN  
AMPHENOL  
K626-XX INPUT CABLE ASSEMBLY  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
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. 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.  
6-20-97  
S23732-3  
RANGER 300 DLX / LN-7 CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
TO LN-7 INPUT  
CABLE PLUG  
14 PIN  
AMPHENOL  
K584 CONTROL CABLE  
OPTIONAL K857  
REMOTE CONTROL  
6 PIN  
ELECTRODE  
TO WORK  
AMPHENOL  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
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 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.  
6-20-97  
S23732-4  
RANGER 300 D AND 300 DLX  
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F-3  
F-3  
CONNECTION DIAGRAMS  
RANGER 300 DLX / LN-742 CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Keep guards in place.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
TO LN-742 INPUT  
CABLE PLUG  
14 PIN  
AMPHENOL  
K592 CONTROL CABLE  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
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 SET FOR DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO A WIRE WELDING-CV POSITION.  
N.C. PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.  
N.D. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.  
N.E. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.  
6-20-97  
S23732-5  
RANGER 300 DLX / LN-8 CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
TO LN-8 INPUT  
CABLE PLUG  
K595 CONTROL CABLE  
14 PIN  
AMPHENOL  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
TO WORK  
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 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.  
6-20-97  
S23732-6  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-4  
F-4  
CONNECTION DIAGRAMS  
RANGER 300 DLX TO K867 CONTROL CABLE ADAPTER CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
14 PIN  
AMPHENOL  
N.C.  
81  
82  
NOT USED ON RANGER POWER SOURCES  
SPARE  
2
4
K867 UNIVERSAL  
ADAPTER PLUG  
CONNECT TOGETHER FOR  
N.D.  
WELDING OUTPUT  
41  
42  
31  
32  
GND  
21  
42 VAC  
N.E.  
115 VAC  
ELECTRODE  
TO WORK  
POWER SOURCE FRAME CONNECTION  
WIRE FEEDER VOLTMETER CONNECTION  
CONNECTS TO (WORK TERMINAL) OF POWER SOURCE  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
77  
76  
75  
10K  
REMOTE OUTPUT CONTROL  
TO WORK  
MIN.  
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.  
2
TO  
TO  
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION  
RELAY TO CLOSE LEADS 2 & 4.  
WIRE  
FEEDER  
K867  
4
N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.  
6-20-97  
S23732-7  
RANGER 300 DLX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
115V RECEPTACLE  
RANGER  
K488 SG  
CONTROL MODULE  
K487-25  
SPOOL GUN  
14 PIN WIRE FEEDER  
6 PIN REMOTE  
RECEPTACLE  
RECEPTACLE  
K691-10  
INPUT CABLE  
ELECTRODE  
TO WORK  
ELECTRODE CABLE  
TO CONTROL MODULE  
TO WORK  
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.  
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 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" POSITION.  
N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.  
6-20-97  
S23732-8  
RANGER 300 D AND 300 DLX  
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F-5  
F-5  
CONNECTION DIAGRAMS  
RANGER 300 DLX / K930-1 TIG MODULE / CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
REGULATOR  
FLOWMETER  
ARGON GAS  
CYLINDER  
TO GAS  
INPUT  
FITTING  
K870 FOOT AMPTROL  
K936-1  
CONTROL CABLE  
-OR-  
TO WORK  
K963-1 HAND AMPTROL  
-OR-  
14 PIN  
AMPHENOL  
K814 ARC START SWITCH  
ELECTRODE  
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 DESIRED 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.  
6-20-97  
S23732-9  
RANGER 300 D / K930-1 TIG MODULE WITH K938-1 CONTACTOR KIT / CONNECTION DIAGRAM  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
REGULATOR  
FLOWMETER  
ARGON GAS  
CYLINDER  
TO GAS  
INPUT  
FITTING  
K870 FOOT AMPTROL  
-OR-  
K963-3  
CONTROL CABLE  
TO WORK  
K963-1 HAND AMPTROL  
6 PIN  
AMPHENOL  
-OR-  
K814 ARC START SWITCH  
ELECTRODE  
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 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  
S23732-10  
RANGER 300 D AND 300 DLX  
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F-6  
F-6  
CONNECTION DIAGRAMS  
RANGER 300 D / LN-7 / K240 CONTACTOR KIT  
WARNING  
Do not operate with panels open.  
Disconnect NEGATIVE (-) BATTERY LEAD  
before servicing.  
Keep guards in place.  
Keep away from moving parts.  
Only qualified personnel should install,use  
or service this equipment.  
Do not touch electrically live parts.  
CONTROL CABLE  
GND.  
32  
2
TO LN-7  
21  
4
31  
N.D.  
CONNECT THE CONTROL CABLE  
GROUND LEAD TO THE FRAME  
K240 CONTACTOR KIT  
115V (50/60HZ.)  
(NOTE : 600 AMP CAPACITY)  
N.B.  
N.C.  
NEAR  
TERMINAL MARKED  
POWER  
SOURCE  
THE TERMINAL STRIP OR TO  
32  
31  
2
4
AN UNPAINTED FRAME SCREW.  
N.F. & N.G.  
AUTO.  
EQUIP.  
POWER  
SOURCE  
N.J.  
6 PIN AMPHENOL  
ELECTRODE CABLE TO LN-7  
TO WORK  
WORK ELECTRODE  
WELDER STANDARD OUTPUT TERMINALS  
N.A. USE POWER SOURCE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR  
SWITCH ON THE POWER SOURCE TO THE CV POSITION.  
N.B. 3 CONDUCTOR #16 POWER CORD PHYSICALLY SUITABLE FOR THE INSTALLATION AND PLUG RATED AT 115 VOLTS 15 AMPERES AC.  
N.C. PLUG INTO 115 VOLT AC RECEPTACLE ON WELDER CONTROL PANEL OR OTHER 115 VOLT AC SUPPLY RATED AT A MINIMUM  
OF 500 VOLT AMPERES.  
N.D. LEADS #21 AND GND. DO NOT APPEAR ON LN-7’S WITH CODES BELOW 7026.  
N.E. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE  
APPLICATIONS. (SEE OPERATOR’S MANUAL.)  
N.F. 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.  
N.G. TAPE UP BOLTED CONNECTION WHERE LEAD #21 IS EXTENDED.  
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.  
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.  
6-20-97  
S23732-11  
RANGER 300 D AND 300 DLX  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
WIRING DIAGRAM  
B L A C K  
2 3 5 C  
B L U E  
B L U E  
R E D  
F L A S H I N G C U R R E N T  
R E D  
B L A C K  
B L A C K  
W H I T E  
W H I T E  
R 1  
G R E E N  
G R E E N  
B L A C K  
B L A C K  
B L A C K  
G R E E N  
W H I T E  
B L A C K  
B L A C K  
B L A C K  
B L A C K  
R 2  
B L A C K  
RANGER 300 D AND 300 DLX  
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F-8  
F-8  
WIRING DIAGRAM  
B L A C K  
2 3 5 C  
B L U E  
B L U E  
R E D  
F L A S H I N G C U R R E N T  
R E D  
B L A C K  
B L A C K  
W H I T E  
W H I T E  
G R E E N  
G R E E N  
B L A C K  
B L A C K  
B L A C K  
G R E E N  
W H I T E  
B L A C K  
B L A C K  
B L A C K  
B L A C K  
B L A C K  
RANGER 300 D AND 300 DLX  
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F-9  
F-9  
WIRING DIAGRAM  
C
2 3 5  
U E B L  
E U B L  
R E D  
N T E R C U R H I S N A G F L  
A
R E D  
C K B L A  
K C A B L  
E T H W I  
E T W H I  
R 1  
E E N G R  
E E N G R  
C K L A B  
C K B L A  
K C A B L  
N E E G R  
T E W H I  
C K B L A  
C K B L A  
C K B L A  
C K B L A  
R 2  
C K L A B  
RANGER 300 D AND 300 DLX  
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F-10  
F-10  
DIMENSION PRINT  
RANGER 300 D AND 300 DLX  
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NOTES  
RANGER 300 D AND 300 DLX  
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NOTES  
RANGER 300 D AND 300 DLX  
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Now Available...12th Edition  
New Lessons in Arc Welding  
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Lessons, simply written, cover manipulatory techniques;  
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With over 500,000 copies of previous editions published  
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For order value between $50.00 & $99.99  
For order value between $100.00 & $149.00  
For North America invoiced orders over $50.00 & 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.  
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)  
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USE THIS FORM TO ORDER:  
BOOKS OR FREE INFORMATIVE CATALOGS  
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.  
Lincoln Welding School  
Titles:  
Price  
$5.00  
$15.00  
$4.50  
$5.00  
Code  
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PH  
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IM  
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(ED-80)  
New Lessons in Arc Welding  
Procedure Handbook Twelfth Edition”  
How to Read Shop Drawings  
Incentive Management  
A New Approach to Industrial Economics $5.00  
The American Century of John C. Lincoln $5.00  
Seminar Information  
(ED-45)  
Educational Video Information  
(ED-93)  
NA  
AC  
James F. Lincoln Arc Welding  
Foundation Book Information  
Welding Preheat Calculator  
Pipe Welding Charts  
$3.00  
$4.50  
WC-8  
ED-89  
(JFLF-515)  
SUB TOTAL  
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TOTAL COST  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
SpanisAh VISO DE  
PRECAUCION  
French  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à l’écart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
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 INSTRUCCIONES 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant l’entre- N’opérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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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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