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Lincoln Electric 11587 manual

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Table of contents for the manual

  • Page 1

    Ranger ® 305D (CE) OPERA T ORʼS MANUAL IM971-A June, 2010 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ- ING TH[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

  • Page 4

    iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 5

    iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

  • Page 6

    v SAFETY v                                                                               [...]

  • Page 7

    vi SAFETY vi THE LINCOLN ELECTRIC COMPANY EC DECLARATION OF CONFORMITY Manufacturer and technical docum entation holder: The Lincoln Electric Company Address: 22801 St. Clair Ave. Cleveland Ohio 44117-1199 USA EC Company: Lincoln Electric Europe S.L. Address: c/o Balmes, 89 - 80 2a 08008 Barcelona SPAIN Hereby declare that machine: Welding Equipmen[...]

  • Page 8

    vii SAFETY vii Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implem[...]

  • Page 9

    viii SAFETY viii Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the[...]

  • Page 10

    ix ix Thank Y ou 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. [...]

  • Page 11

    x x T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications ....................................................................................................... A-1 Safety Precautions ...........................[...]

  • Page 12

    xi xi T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ..............................................................[...]

  • Page 13

    RANGER® 305D (CE) (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. (2) To top of enclosure, add 152mm (6 “) to top of exhaust elbow. (3) Engine warranty may vary outside of the USA. (See Eng[...]

  • Page 14

    LIFTING The machine weighs approximately 374 kg. (824 lbs) with a full tank of fuel. A lift bail is mounted to the machine and should always be used when lifting the machine. HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For max- imum rating, derate the machine 2.5% to 3.5% for every 305m (1000ft.). Due to new EPA a[...]

  • Page 15

    A-3 INST ALLA TION RANGER® 305D (CE) A-3 TOWING Check with distributor for the recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle. If the user adapts a non-Lincoln trailer, he must assume responsi- bility that the method of attachment and usage does not result in a safety hazard nor damage the welding e[...]

  • Page 16

    A-4 INST ALLA TION RANGER® 305D (CE) A-4 ENGINE COOLING SYSTEM Air to cool the engine is drawn in the base sides and exhaust through radiator & case back. It is important that the intake and exhaust air is not restricted. Allow a minimum clearance of 0.6m (2 feet) from the case back and 40cm (16”) from either side of the base to a vertical s[...]

  • Page 17

    CABLE INSTALLATION Install the welding cables to your machine as follows: 1. The diesel engine must be OFF to install welding cables. 2. Remove the flanged nuts from the output termi- nals. 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 secu[...]

  • Page 18

    A-6 INST ALLA TION RANGER 305D (CE) A-6 Connection of the LN-25 to the RANGER® 305D (CE). Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ The LN-25 with or without an internal contactor may be used with the RANGER® 305D (CE). See the appropriate connection diagra[...]

  • Page 19

    A-7 INST ALLA TION RANGER® 305D (CE) A-7 Connection of LN-742 and Cobramatic to RANGER® 305D (CE). • Shut the welder off. • Connect per instructions on the appropriate connec- tion diagram in Section F.[...]

  • Page 20

    B-1 OPERA TION RANGER® 305D (CE) B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ---------------------------------------[...]

  • Page 21

    B-2 OPERA TION B-2 WELDING CONTROLS (Figure B.1) 1. OUTPUT CONTROL: The OUTPUT dial is used to pre- set the output voltage or current as displayed on the digi- tal meters for the four welding modes. When in the CC- STICK, or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto- sensing circuit automaticall[...]

  • Page 22

    B-3 OPERA TION B-3 4. ARC CONTROL : The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, and has different functions in these modes. This control is not active in the TIG mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp a[...]

  • Page 23

    B-4 OPERA TION B-4 15. ELECTRIC FUEL GAUGE- Provides accu- rate, reliable indication of how much fuel is in the tank. . 16. ENGINE HOUR METER – Displays the total time that the engine has been running. This meter is useful for scheduling prescribed maintenance. 17. ENGINE PROTECTION LIGHT - A warning indicator light for Low Oil Pressure and/or [...]

  • Page 24

    TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORC H Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5) 1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel Tungsten Tungsten .010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6 0.020 (.50) 5-20 (3) 5-10[...]

  • Page 25

    AUXILIAR Y POWER: Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn. Simultaneous Welding and Auxiliary Power Loads While welding, the amount of 3-phase Auxiliary power available is reduced. (See table A.4) R[...]

  • Page 26

    C-1 ACCESSORIES C-1 FIELD INST ALLED OPTIONS / ACCESSORIES K704 ACCESSORY SET - Includes (10m) 35 ft. of electrode cable and (9.m) 30 ft. of work cable, head- shield, work clamp electrode holder. Cables are rated at 400 amps, 100% duty cycle. K857 (7.6m) 25 ft. or K857-1 (30.4m) 100 ft. REMOTE CONTROL - Portable control provides same dial range as [...]

  • Page 27

    D-1 MAINTENANCE D-1 RANGER® 305D (CE) SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.[...]

  • Page 28

    D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Locate oil drain hose and valve in bottom of base[...]

  • Page 29

    D-3 MAINTENANCE D-3 RANGER® 305D (CE)[...]

  • Page 30

    D-4 MAINTENANCE D-4 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in the radiator and recovery bottle. Add 50/50 antifreeze / water solution if the level is close to or below the "LOW&quo[...]

  • Page 31

    D-5 MAINTENANCE D-5 FUEL FIL TER 1. Check the fuel filter and fuel pre-filter for water accu- mulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre- filter. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Servic[...]

  • Page 32

    D-6 MAINTENANCE D-6 RANGER® 305D (CE) WELDER / GENERA T OR MAINTENANCE STORAGE: Store the RANGER® 305D (CE) in clean, dry protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: Itʼs nor- mal for the brushes and s[...]

  • Page 33

    E-1 TROUBLESHOOTING E-1 RANGER® 305D (CE) 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. CAUTION This Troubleshooting Guide is provided to help you locate and repa[...]

  • Page 34

    E-2 TROUBLESHOOTING E-2 RANGER® 305D (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROB[...]

  • Page 35

    E-3 TROUBLESHOOTING E-3 RANGER® 305D (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROB[...]

  • Page 36

    E-4 TROUBLESHOOTING E-4 RANGER® 305D (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROB[...]

  • Page 37

    E-5 TROUBLESHOOTING E-5 RANGER® 305D (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROB[...]

  • Page 38

    E-6 TROUBLESHOOTING E-6 RANGER® 305D (CE) Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROB[...]

  • Page 39

    F-1 DIAGRAMS F-1 RANGER® 305D (CE)[...]

  • Page 40

    F-2 DIAGRAMS F-2 RANGER® 305D (CE)[...]

  • Page 41

    F-3 DIAGRAMS F-3 RANGER® 305D (CE)[...]

  • Page 42

    F-4 DIAGRAMS F-4 RANGER® 305D (CE)[...]

  • Page 43

    F-5 DIAGRAMS F-5 RANGER® 305D (CE)[...]

  • Page 44

    F-6 DIAGRAMS F-6 RANGER® 305D (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code [...]

  • Page 45

    F-7 DIAGRAMS F-7 RANGER® 305D (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code [...]

  • Page 46

    F-8 DIMENSION PRINT F-8 RANGER® 305D (CE) A M21086 60.21 1529.3 29.67 753.6 60.00 1524.0 59.20 1503.7 17.50 444.5 19.50 495.3 21.06 534.9 21.50 546.1 29.83 757.6 34.24 869.8 11.03 280.2 29.63 752.6 17.00 431.8 CEN TER O F GRA VITY 35.08 891.03 26.52 673.6 6.33 160.9[...]

  • Page 47

    NOTES RANGER® 305D (CE)[...]

  • Page 48

    NOTES RANGER® 305D (CE)[...]

  • Page 49

    NOTES RANGER® 305D (CE)[...]

  • Page 50

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A T E N ÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INSTR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PR A CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABR[...]

  • Page 51

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A T E N ÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INSTR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P ARTES DE USO , E SIG A A S PRÁ TIC A S DE SEGUR ANÇ A DO EMPREGADOR. • Keep your head out of fumes. • Use ventilation or exhaust[...]

  • Page 52

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]