Lincoln Electric RANGER 405D Operating Manual
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Lincoln Electric RANGER 405D Operating Manual

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IMA 608D
September 2004
OPERATING MANUAL
RANGER 405D
Part No. KA1453
Multi Process DC Welder & three phase 15 kVA
Auxiliary Power Generator - Diesel Engine driven
Engine - Kubota / Perkins
SAFETY DEPENDS ON YOU
Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be
increased by proper installation and thoughtful operation on your part. Read and observe the general safety
precautions on page 2 and follow specific installation and operating instructions included in this manual.
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
A.B.N. 36 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS

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  • Page 1 Engine - Kubota / Perkins SAFETY DEPENDS ON YOU Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation on your part. Read and observe the general safety precautions on page 2 and follow specific installation and operating instructions included in this manual.

  • Page 2: Arc Welding Safety Precautions

    This can create fire hazards or including the material safety data sheet (MSDS) and overheat lifting chains or cables until they fail. follow your employer’s safety practices. h. Also see Item 7c. e. Also see Item 7b. Page 2 Ranger 405D IMA 608D...
  • Page 3 3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric. 4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Field Service Shop. (The “Lincoln Service Directory” listing these shops geographically is available on request.)

  • Page 4: Welding Power Sources

    Only ‘ACROSS THE ARC’ type wire feeders with a internal contactor fitted should be used in this configuration. Arc air gouging is not recommended in CV. Due to ‘CV MODE’ not offering VRD protection. Page 4 Ranger 405D IMA 608D...

  • Page 5: Welding, Emf & Pacemakers

    (This is also a good you and your pacemaker. practice to eliminate a common problem on welding - a poor work connection. • Do not work next to the welding power source. IMA 608D Ranger 405D Page 5...

  • Page 6: Instructions For Electromagnetic Compatibility

    • for using with other Lincoln Electric/LiquidArc equipment. as filtering the mains supply. Consideration should be given to • designed for industrial and professional use.
  • Page 7 IMA 608D Ranger 405D Page 7...
  • Page 8 Page 8 Ranger 405D IMA 608D...

  • Page 9: Product Description

    PRODUCT DESCRIPTION The Ranger 405D is a diesel engine driven alternator power source for multi-process DC welding and for 115/230-240/400-415VAC auxiliary* and standby power. It is housed in a sound reduced enclosure for quiet operation. Auxiliary outlets and circuit breakers depend on model purchased.

  • Page 10: Engine Coolant

    Fill the fuel tank with clean, fresh diesel fuel. The capacity is 45 litres. See engine Operator’s Manual for specific fuel recom- Battery Connection Instructions mendations. Do not allow the Ranger 405D to run out of fuel. This necessitates bleeding the injector system. The Ranger is shipped with the negative battery cable disconnected.

  • Page 11: Installation Instructions

    Use in open, well ventilated areas or vent exhaust outside. • Do not operate with doors open or guards off. • Stop engine before servicing. M OV I NG PA RTS can injure Keep away from moving parts. IMA 608D Ranger 405D Page 11...

  • Page 12: High Frequency Generator For Tig Welding Applications

    A T12246 BYPASS CAPA C I TOR A S S E M B LY M U S T B E 25/35mm Cable: No trim I N S TALLED IN THE RANGER 405D TO PROTECT T H E 50mm Cable: Trim at “A”...

  • Page 13: Safety Instructions

    Allows machine maintenance procedures to be adhered to by machines being used in environments with high-risk of electric recording engine operating hours. shock. Fuel Gauge Provides indication of the amount of fuel in the fuel tank. IMA 608D Ranger 405D Page 13...

  • Page 14: Starting And Stopping The Engine

    Check fuel gauge to pressure to build up. Therefore if a fault is still present the engine ascertain fuel level in fuel tank (never allow Ranger 405D to will stop again after approx 10 seconds.

  • Page 15: Welder Operation

    TIG Welding The Ranger 405D can be used for a variety of DC tungsten inert gas (TIG) welding applications. Arc initiation may be by “scratch” starting, or by use the K930 Hi-Freq unit. Scratch starting is not...

  • Page 16: Controls And Settings

    All welder and engine controls are located on the case front panel. Refer to diagram and the explanations that follow. 1. Output Control Dial 5. VRD Operation Indicator On the front panel of the Ranger 405D are two indicator lights. A red light when lit indicates voltage >32V and a green light when Increase/Decrease of output “...
  • Page 17 Australian Standard AS3000. 10. Hour Meter The hour meter displays the total time that the engine has been running. This meter is a useful indicator for scheduling preventive maintenance. IMA 608D Ranger 405D Page 17...

  • Page 18: Remote Control Receptacle

    Amphenol Receptacle machine, switch to “ ” position. For remote control, switch to “ The Ranger 405D has one 14pin amphenol located on the ” position, in this position control is at the wire feeder (if so control panel. The receptacle is for connecting wire feeders,...
  • Page 19 INSTALLATION INSTRUCTIONS IMA 608D Ranger 405D Page 19...
  • Page 20 Page 20 Ranger 405D IMA 608D...
  • Page 21 IMA 608D Ranger 405D Page 21...
  • Page 22 Page 22 Ranger 405D IMA 608D...
  • Page 23 IMA 608D Ranger 405D Page 23...

  • Page 24: Electrical Design

    • Do not ground the Ranger 405D to a pipe that carries explosive or combustible material. When the Ranger 405D is mounted on a truck or trailer, its frame must be electrically bonded to the metal frame of the vehicle. Use a 10mm (#8) or larger copper wire connected between the machine grounding stud and the frame of the vehicle.

  • Page 25: Auxiliary Power Operation

    KA1453-6, 1 x 400V 3ø, 1 x 230V & 1 x 115V 1ø outlets CA U T I O N Caution: Certain electrical devices need some extra care so they can be powered by the Ranger 405D. Refer to Table for these devices. Type...

  • Page 26: Engine Maintenance Intervals

    Consult your local KUBOTA/PERKINS Dealer for this service. Replace only if necessary. Every Year or every 6 times of cleaning ◊ Emission related critical part. Owner is responsible for proper maintenance Please see Engine Owners Manual for Warranty Statement in detail. Page 26 Ranger 405D IMA 608D...

  • Page 27: Run-In Period

    It IS permissible to use oil that meets S and C grade service classifications.) Any engine will use a small amount of oil during its "run-in" period. For the diesel engine on the Ranger 405D, run-in is about 50 SAE 10W30 is recommended for general, all temperature use, - running hours.

  • Page 28: Air Cleaner

    2. Avoid Dislodging Dust from the Filter Gently pull the filter off the outlet tube and out of the housing. Avoid knocking the filter against the housing. Page 28 Ranger 405D IMA 608D...

  • Page 29: Cooling System

    COOLING SYSTEM FUEL At the end of each day’s use, refill the Ranger 405D fuel tank to W A R N I NG minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the fuel to expand.

  • Page 30: Battery Maintenance

    Keep sparks, flame and cigarettes away MAINTENANCE from battery. To prevent Explosion when: STORAGE: Store the Ranger 405D in clean, dry protected areas. • Installing a new battery - disconnect negative cable from old battery first and connect to new battery last CLEANING: Blow out the generator and controls periodically with •...

  • Page 31: Slip Rings

    320 grit sanding stone. Slip rings must be clean and other auxiliary circuit which operates at free from oil and grease. a voltage not exceeding extra low voltage Between separate welding circuits IMA 608D Ranger 405D Page 31...
  • Page 32 ENGINE SERVICE RECORD FOR RANGER 405D SERIAL 800 HOUR SERVICE 50 HOUR 1ST SERVICE Agent Name Agent Name Date Hourmeter Date Hourmeter Tick completed operations Tick completed operations • Change fuel filter element • Change of engine oil • Change of engine oil •...
  • Page 33 ENGINE SERVICE RECORD FOR RANGER 405D SERIAL 1600 HOUR SERVICE 2400 HOUR SERVICE Agent Name Agent Name Date Hourmeter Date Hourmeter Tick completed operations Tick completed operations • Check fuel injection nozzle pressure • Change of engine oil • Change fuel filter element •...
  • Page 34 INSULATION & RESISTANCE RECORD FOR RANGER 405D SERIAL Agent Name Agent Name Date Date INSULATION TESTING INSULATION TESTING Record Test Results Record Test Results • Earth continuity (< 1Ω) Ω • Earth continuity (< 1Ω) Ω • Auxiliary and Earth (>10MΩ) MΩ...
  • Page 35 INSULATION & RESISTANCE RECORD FOR RANGER 405D SERIAL Agent Name Agent Name Date Date INSULATION TESTING INSULATION TESTING Record Test Results Record Test Results • Earth continuity (< 1Ω) Ω • Earth continuity (< 1Ω) Ω • Auxiliary and Earth (>10MΩ) MΩ...
  • Page 36 Refer PCB Trouble Shooting page 18 V) Faulty rotor/weld control PCB Refer PCB Trouble Shooting page 18 VI) Faulty relay R1 and/or R2 Replace VII) Faulty idler solenoid Repair/replace V I I I ) Faulty throttle linkages Repair/replace Page 36 Ranger 405D IMA 608D...

  • Page 37: Troubleshooting Guide

    II) Faulty rotor/weld control PCB Refer PCB Trouble Shooting page 18 III) Faulty choke/inductor Repair/replace IV) Faulty reactors (one per each weld phase) Repair/replace V) Faulty capacitors Replace all 4 capacitors at one time IMA 608D Ranger 405D Page 37...

  • Page 38: Procedure For Replacing Pc Boards

    The weld control circuitry has 2 modes of operation Constant Brief Operating Description Current (CC) and Constant Voltage (CV). The Ranger 405D has 5 separate PCBs. These are: In CC mode, feed back to the control circuitry is provided by a 400 Amp to 50mV shunt, thus maintaining the 1) Watcher/Idler PCB –...
  • Page 39 Operative: Sep 2004 Supersedes: Jul 2004 RANGER 405D Model Index DO NOT attempt to use this Parts List for machine if its code NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed. Contact the Service Department for any COLUMN TO USE IN EACH PARTS LIST FOR EACH code numbers not listed.
  • Page 40 Operative: Sep 2004 Supersedes: Jul 2004 RANGER 405D Model Index DO NOT attempt to use this Parts List for machine if its code NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed. Contact the Service Department for any COLUMN TO USE IN EACH PARTS LIST FOR EACH code numbers not listed.

  • Page 41: Optional Equipment

    Hi-Freq TIG Module ............Order K930-2 IMA 608D Ranger 405D Page 41...
  • Page 42 AP-210C Casework Assembly Operative: Jul 2004 Supersedes: Feb 2002 AG1459B A11.03.04M Page 42 Ranger 405D IMA 608D...
  • Page 43 End Frame Welded Assembly AL2550-5W Lower Front Panel AM3505 Gas Strut (Small) AM3614-1 Control Panel Door (Drop down) AM3542 Control Panel Door (Lift Up) AM3542-1 Control Panel Door (Gas Strut) AM3542-3 Control Panel Door (Gas Strut) AM3542-3W IMA 608D Ranger 405D Page 43...
  • Page 44 AP-210C.2 Casework Assembly Operative: Jul 2004 Supersedes: Feb 2002 AG1459B A11.03.04M Page 44 Ranger 405D IMA 608D...
  • Page 45 Right Hand End Frame Panel AL2556 Right Hand End Frame Panel AL2556W Lower Chassis End Panel AM3447 Lower Chassis End Panel AM3447W Radiator End Cover Panel AL2560-2 Radiator End Cover Panel AL2560-4 Radiator End Cover Panel AL2560-4W IMA 608D Ranger 405D Page 45...

  • Page 46: General Assembly

    AP-210D General Assembly Operative: Jul 2004 Supersedes: Feb 2002 AG1459A A24.3.04M Page 46 Ranger 405D IMA 608D...
  • Page 47 Choke & Bracket Assy AL2698-1 Note 1 Earlier Codes will need to use the gate harness off the original Rectifier Assembly Note 2 Order AG1381-3 Radiator plus AM3665-1, AM3464 x 2, AS1733-3Z x 10 IMA 608D Ranger 405D Page 47...
  • Page 48 AP-210D.3 General Assembly Operative: Jul 2004 Supersedes: Feb 2002 AG1459A A24.3.04M Page 48 Ranger 405D IMA 608D...
  • Page 49 AM3504 Fuel Tank Tray Assy AM3438 Fuel Tank Strap AM3443 Muffler Assy (Vertical outlet) AG1402-3 Heat Shield AM3676 Exhaust Clamp AT3192-2 Exhaust Gasket AT3820-1 Top Radiator Hose (Kubota) K16266-72941 Top Radiator Hose (Perkins) AL2740 IMA 608D Ranger 405D Page 49...
  • Page 50 AP-210F Front End Frame Module Operative: Jul 2004 Supersedes: Feb 2002 AG1403-7 A27.8.03M Page 50 Ranger 405D IMA 608D...
  • Page 51 Output Panel Nameplate AM3610 Output Panel Nameplate AG1458 Toggle Switch T10800-39 14 Pin Connector Base S12021-40 Connector Cap S17062-3 Output Terminal Assy M13896-3 End Frame AL2550-3 End Frame AL2550-5 End Frame AL2550-5 End Frame AL2550-5W IMA 608D Ranger 405D Page 51...

  • Page 52: Control Panel Assembly

    Control Panel Assembly AP-210G Operative: Feb 2002 Supersedes: for Codes 1691 & below) Page 52 Ranger 405D IMA 608D...
  • Page 53 DPDT Toggle Switch T10800-39 SPST Toggle Switch T10800-55 SPDT Toggle Switch T13562 Nameplate AL2575-6 PC Board Assembly L10558-1AA Key Switch K66706-5512 Fuel Gauge AS4302-1 Warning Light Assy AT2996-2 Hourmeter S17475-3 S/T Pan Hd Screw S8025-15 IMA 608D Ranger 405D Page 53...
  • Page 54 Control Panel Assembly AP-210G Operative: Jul 2004 Supersedes: Feb 2002 (for Codes 70001 & above) AL2616-5 A03.09.03M Page 54 Ranger 405D IMA 608D...
  • Page 55 AM3053-177 3/16"UNC Hex Nut AM3055-76 Spacer Tube AT1932 Selector Switch AM3312-2 3/16" Springwasher E106A1 Potentiometer Spacer S18280 Potentiometer T10812-40 Hex Nut (Suppied with Hourmeter) Supplied Lockwasher (Suppied with Hourmeter) Supplied Digital PCB Rework AS4728-1 IMA 608D Ranger 405D Page 55...
  • Page 56 AP-210H Output Rectifier Assembly Operative: Jul 2004 Supersedes: Feb 2002 Page 56 Ranger 405D IMA 608D...
  • Page 57 Reed Switch Assy (includes) AS4767 Reed Switch S12334-50 Clamp T8970-17 Copper Lead AM3646 Reed Switch Plate S11797-14 Support Bracket M13430 Note 1 Use AL2463-4. Earlier codes will need to use the Gate Harness of original Rectifier Assy. IMA 608D Ranger 405D Page 57...

  • Page 58: Australian Model

    AP-210J Auxiliary Output Box Module Operative: Jul 2004 Supersedes: Feb 2002 Australian Model Ref. AL2614-4 European Model Ref. AL2614-1 UK Model Ref. AL2614-2 Page 58 Ranger 405D IMA 608D...
  • Page 59 Plug Outlet 5 Pin 400V AM3567-3 Plug Outlet 3 Pin 110/130V AM3567-4 Output Box Panel AM3515-1 Output Box Panel & Tube AM3566-1 Output Box Panel & Tube AM3566-2 Aux Sensor PCB M18765-1AA Outlet Caution Decal AT4135 IMA 608D Ranger 405D Page 59...

  • Page 60: Rotor Assembly

    Bar & Paddle Assy AM3090 5/16"UNF x 1" Hex Screw H/T AM3053-231 5/16" Springwasher E106A14 Coupling Disc M15012 Rotor Clamping Ring S17896 Disc Clamping Bar S17895 5/16" UNF x 1" Screw H/T AM3053-236 5/16" Springwasher E106A14 Page 60 Ranger 405D IMA 608D...
  • Page 61 Engine / Stator Mount Detail ITEM DESCRIPTION PART NO. QTY. Mount Spacer Tube AT4024-4 " UNC Nyloc Nut AM3055-137 Rebound Retainer Cup AS4614 Rubber Mount S14447 Distributor Washer AT3063-1 " UNC x 2.75" Hex Bolt AM3053-294 IMA 608D Ranger 405D Page 61...
  • Page 62 Capacitor Strap Assy AS4550 Capacitor Insulation AS4552 Resistor 68ohm 50W AS4091 Capacitor Lead AS4551 " UNC Hex Nut AM3055-76 "UNC x 147 Booker Bar AS4469-2 " Ext. Starwasher T9860-10X " Flatwasher S9262-27 Insulating Washer T4479A Page 62 Ranger 405D IMA 608D...
  • Page 63 AM3661-1 1/4"UNC x 5/8" Hex Screw AM3053-174 In-Line Swivel S22070 Throttle Rod AS4324-14 Female Rod End 1/4" UNF AT4090 Spacer AT4137Z 1/4"UNC Hex Nut AM3055-90 1/4" Springwasher E106A2 1/4"UNC x 1.5" Hex Screw AM3053-180 IMA 608D Ranger 405D Page 63...

  • Page 64: Wiring Diagram

    Wiring Diagram Page 64 Ranger 405D IMA 608D...
  • Page 65 Wiring Diagram IMA 608D Ranger 405D Page 65...
  • Page 66 Wiring Diagram Page 66 Ranger 405D IMA 608D...
  • Page 67 Wiring Diagram IMA 608D Ranger 405D Page 67...

  • Page 68: Limited Warranty

    We respond to our customers based on the best information in our One Year* possession at that time. Lincoln Electric is not in a position to warrant or guarantee Ruggerini Engines and Accessories such advice and assumes no liability, with respect to such information or advice. We...

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