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Lincoln Electric RANGER 305D IM730 manual

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Table of contents for the manual

  • Page 1

    Ranger 305 D OPERA TOR’S MANUAL IM730 August, 2004 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[...]

  • 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 skin[...]

  • Page 4

    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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

  • Page 6

    v v Thank You 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. Pay[...]

  • Page 7

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

  • Page 8

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

  • Page 9

    RANGER 305D 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. * Top of enclosure add 6in. (152mm) for exhaust pipe. ** Engine warranty may vary outside of the USA. (See Engine warranty for details)[...]

  • Page 10

    LIFTING The RANGER 305D weighs approximately 775lbs.(352kg.) with a full tank of fuel. A lift bail is mounted to the machine and should always be used when lifting the machine. • Lift only with equipment of ade- quate lifting capacity. • Be sure machine is stable when lift- ing. • Do not lift this machine using lift bail if it is equipped wit[...]

  • Page 11

    A-3 INST ALLA TION RANGER 305D A-3 TOWING The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. 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 equipment.[...]

  • Page 12

    A-4 INST ALLA TION RANGER 305D A-4 SP ARK ARRESTER Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. [...]

  • Page 13

    The 240 VAC output can be split to provide two sepa- rate 120 VAC outputs with a max permissible current of 44 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity. The 120 V auxiliary power receptacles should only be used with three wire gro[...]

  • Page 14

    A-6 INST ALLA TION RANGER 305D A-6 CONNECTION OF RANGER 305D T O PREMISES WIRING W ARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that: • The installation complies with the National Electrical Code and all other applicable electrical codes. • The p[...]

  • Page 15

    A-7 INST ALLA TION RANGER 305D A-7 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the RANGER 305D • Shut the welder off. • Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. • Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as requi[...]

  • Page 16

    A-8 INST ALLA TION RANGER 305D A-8 Connection of PRINCE XL SPOOL GUN to the Ranger 305D Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module. • Shut the Welder off. • For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the[...]

  • Page 17

    B-1 OPERA TION RANGER 305D B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer ’ s manual sup- plied with your welder. It includes important safety pre- cautions, detailed engine starting, operating and main- tenance instructions, and parts lists. -------------------------------------[...]

  • Page 18

    B-2 OPERA TION B-2 WELDING CONTROLS (Figure B.1) 1. OUTPUT CONTROL: The OUTPUT dial is used to preset the output voltage or current as dis- played on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV-WIRE modes and when a remote control is con- nected to the 6-Pin or 14-Pin Connector, the auto- sensing circuit[...]

  • Page 19

    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 20

    B-4 OPERA TION B-4 15. ENGINE AL TERNA TOR TROUBLE LIGHT -The engine alternator light is off when battery charging system is functioning normally. If light turns on, the alternator or the voltage regulator may not be operating correctly. The light may also come on due to the battery not holding a charge. It is normal for the light to be on while in[...]

  • Page 21

    TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH 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 22

    RANGER 305D B-6 OPERA TION B-6 When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-pin Connector the OUT- PUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol. The ARC CONTROL is not active in the TIG mode. The Ranger 305D can be used in a wide variety of DC TIG welding applications. In gener[...]

  • Page 23

    Permissible Auxiliary Current in -Amps @ 240 VAC 44 31 24 19 12 3 B-7 OPERA TION B-7 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. The auxiliary power of the RANGER 305D consists of two[...]

  • Page 24

    C-1 ACCESSORIES C-1 FIELD INST ALLED OPTIONS / ACCESSORIES K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.).Order: K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hit[...]

  • Page 25

    D-1 MAINTENANCE D-1 RANGER 305D 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 mainte- nance requiring their removal is complete. If g[...]

  • Page 26

    D-2 MAINTENANCE D-2 Engine Oil Change Drain the engine oil while the engine is warm to assure rapid and complete draining. • 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 and pull through the hole in the battery access panel on the welder. • Remove the ca[...]

  • Page 27

    D-3 MAINTENANCE D-3 RANGER 305D Service Instructions & Installation T ips For Engine Air Filter Release the 1 Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they donít hinder filter removal/installation. Most latches are spring loaded to fold back when [...]

  • Page 28

    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 29

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

  • Page 30

    D-6 MAINTENANCE D-6 RANGER 305D WELDER / GENERA T OR MAINTENANCE STORAGE: Store the RANGER 305D 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: It ’ s nor- mal for the brushes and slip rings t[...]

  • Page 31

    E-1 TROUBLESHOOTING E-1 RANGER 305D 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 repair poss[...]

  • Page 32

    E-2 TROUBLESHOOTING E-2 RANGER 305D 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 PROBLEMS (S[...]

  • Page 33

    E-3 TROUBLESHOOTING E-3 RANGER 305D 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 PROBLEMS (S[...]

  • Page 34

    E-4 TROUBLESHOOTING E-4 RANGER 305D 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 PROBLEMS (S[...]

  • Page 35

    E-5 TROUBLESHOOTING E-5 RANGER 305D 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 PROBLEMS (S[...]

  • Page 36

    E-6 TROUBLESHOOTING E-6 RANGER 305D 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 PROBLEMS (S[...]

  • Page 37

    F-1 DIAGRAMS F-1 RANGER 305D[...]

  • Page 38

    F-2 DIAGRAMS F-2 RANGER 305D[...]

  • Page 39

    F-3 DIAGRAMS F-3 RANGER 305D[...]

  • Page 40

    F-4 DIAGRAMS F-4 RANGER 305D[...]

  • Page 41

    F-5 DIAGRAMS F-5 RANGER 305D[...]

  • Page 42

    F-6 DIAGRAMS F-6 RANGER 305D or ser vice t his equi pm ent. On ly qualified personnel should install,use Keep away from m oving parts. Keep guards in place. MOVING PARTS can injure W ARNING Do not touch electrically live parts. before servicing. Disconnect NEGATIVE (-) Bat te ry lead Do not operate with panels open. ELECTRIC SH OCK can kill 14 PIN [...]

  • Page 43

    F-7 DIAGRAMS F-7 RANGER 305D[...]

  • Page 44

    F-8 DIAGRAMS F-8 RANGER 305D[...]

  • Page 45

    F-9 DIAGRAMS F-9 RANGER 305D[...]

  • Page 46

    F-10 DIAGRAMS F-10 RANGER 305D[...]

  • Page 47

    F-11 DIAGRAMS F-11 RANGER 305D[...]

  • Page 48

    F-12 DIAGRAMS F-12 RANGER 305D 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 numbe[...]

  • Page 49

    F-13 DIAGRAMS F-13 RANGER 305D DIMENSION PRINT RANGER 305D M19772 A.05 *29.0 *11.3 *CE NTER OF GR AVI TY 21.06 51.20 17.50 19.50 35.77 29.83 34.24 6.33 11.03 29.57 26.64 52.2 52.00 21.5 30.71 5.57[...]

  • Page 50

    NOTES RANGER 305D[...]

  • Page 51

    NOTES RANGER 305D[...]

  • Page 52

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL[...]

  • Page 53

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 54

    • 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 •[...]