Lincoln Electric IM837-A manual

Ranger 305 D (CE) OPERA TOR’S MANUAL IM837-A June, 2005 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 M[...]

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. ________________________________________________[...]

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[...]

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[...]

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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

v SAFETY v[...]

vi SAFETY vi RANGER 305D (CE) c/o Balmes, 89 - 80 2a 08008 Barcelona SP AIN Measured sound power level: L W A 98 dB (net power Pel = 7.5kW) L W A 96 dB (net power Pel = 7.5k W) 26 April 2005 Dario Gatti,[...]

vii SAFETY vii RANGER 305D (CE)[...]

viii SAFETY viii RANGER 305D (CE)[...]

ix ix 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. P[...]

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

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

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 t o 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 Engine[...]

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[...]

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 equ[...]

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 sur[...]

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[...]

A-6 INST ALLA TION RANGER 305D 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 appro- priate connection diagram in Sec[...]

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. Connection of PRINCE XL SPOOL GUN to the RANGER 305D (CE) Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module. ?[...]

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 manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ----------------------------------------[...]

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 connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit a[...]

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[...]

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 Coo[...]

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 [...]

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[...]

C-1 ACCESSORIES C-1 FIELD INST ALLED OPTIONS / ACCESSORIES K1898-1 SPARK ARRESTOR - Mounts between muf- fler & elbow to eliminate any risk of spark from exhaust. 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. [...]

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. I[...]

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 recommend- ed 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 ba[...]

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

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[...]

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[...]

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: It ’ s nor- mal for the brushes and sl[...]

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 repair[...]

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 PROBLE[...]

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 PROBLE[...]

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 PROBLE[...]

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 PROBLE[...]

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 PROBLE[...]

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

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

F-3 DIAGRAMS F-3 RANGER 305D (CE) or service this equipm ent. Only qualified personnel should install,use Keep aw ay from m oving parts. Keep guards in place. MOVING PARTS can injure W ARNI NG Do not touch electrically live parts. before servicing. Disconnect NEGATIVE (-) Battery lead Do not operate w ith panels open. ELECTRIC SHOCK can kill 14 P I[...]

F-4 DIAGRAMS F-4 RANGER 305D (CE) 2 9/03[...]

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

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 nu[...]

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 nu[...]

F-8 DIAGRAMS F-8 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 nu[...]

F-9 DIAGRAMS F-9 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 nu[...]

F-10 DIMENSION PRINT F-10 RANGER 305D (CE) M M 2 03 35 A. A . 0 2 60.2 1 1529.3 29.6 7 75 3.6 26.5 2 673.6 60.0 0 1524.0 59.2 0 1503.7 17.5 0 444.5 19.5 0 495.3 21.0 6 53 4.9 21.5 0 54 6.1 29.8 3 757.6 34.2 4 869.8 35.7 7 908.4 6.33 160.9 11.0 3 280.2 29.6 3 75 2.6 17.0 0 431.8 CE NTER OF GR AVITY[...]

NOTES RANGER 305D (CE)[...]

NOTES RANGER 305D (CE)[...]

NOTES RANGER 305D (CE)[...]

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 P ARA E[...]

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 P ARA 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 [...]

• 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 •[...]