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IM836-B
Ranger 305D
May, 2007
11121, 11188, 11275
For use with machines having Code Numbers:
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.
OPERATOR'S MANUAL
Copyright © 2007 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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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric RANGER IM836-B
Summary of Contents for Lincoln Electric RANGER IM836-B
- Page 1 RETURN TO MAIN MENU IM836-B Ranger 305D May, 2007 11121, 11188, 11275 For use with machines having Code Numbers: 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 ...
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Page 2: California Proposition 65 Warnings
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can 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. - Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 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.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Welding Terminals ...A-5 Welding Output Cables ...A-5 Cable Installation...A-5 Auxiliary Power Receptacles and Plugs ...A-6 Standby Power Connections ...A-6 Premises Wiring ...A-7 Connection of Lincoln Electric Wire Feeders...A-8,A-9 ________________________________________________________________________________ Operation...Section B Safety Precautions ...B-1 General Description...B-1 For Auxiliary Power ...B-1 Engine Operation...B-1... - Page 8 Fuel ...D-4 Bleeding the Fuel System ...D-4 Fuel Filter ...D-5 Engine Adjustment ...D-5 Battery Maintenance ...D-5 Servicing Optional Spark Arrestor ...D-5 Welder / Generator Maintenance ...D-6 Storage ...D-6 Cleaning...D-6 Brush Removal and Replacement ...D-6 GFCI Testing and Resetting Procedure...D-6 ________________________________________________________________________ Troubleshooting ...Section E...
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Page 9: Installation
(14 KW) D722 Net intermittent 3600 RPM naturally aspirated water cooled Diesel Engine RATED OUTPUT @ 104° F (40° C) - WELDER Welding Process Current/Voltage/Duty Cycle DC Constant Current DC Pipe Current Touch-Start™TIG DC Constant Voltage RATED OUTPUT @ 104° F (40° C) 10,000 Watts Peak, / 9,500 Watts Continuous, 60 Hz 120/240 Volts Sound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m ) -
Page 10: Safety Precautions
Only qualified personnel should install, use, or service this equipment. LOCATION AND VENTILATION The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area. -
Page 11: Towing
2 gals. (7.6ltrs.) of reserve fuel. NOTE: A fuel shut off valve is located on the pre- filter/sediment filter. Which should be in the closed position when the welder is not ran for extended periods of time. ------------------------------------------------------------------------ RANGER 305D... -
Page 12: Battery Connections
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must: • Be grounded to the frame of the welder using a grounded type plug. • Be double insulated. • Do not ground the machine to a pipe that carries explosive or combustible material. -
Page 13: Welding Terminals
When this welder is mounted on a truck or trailer, its frame must be electrically bonded to the metal frame of the vehicle. Use a #8 or larger copper wire connect- ed between the machine grounding stud and the frame of the vehicle. When this engine driven welder... -
Page 14: Standby Power Connections
AUXILIARY POWER RECEPTACLES Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI receptacle can be reset prop- erly. -
Page 15: Premises Wiring
CONNECTION OF RANGER 305D TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT RECEPTACLE... -
Page 16: Connection Of Lincoln Electric Wire Feeders
• 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 welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+"... - Page 17 • 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 welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+"...
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Page 18: Operation
• Insulate yourself from work and ground • Always wear dry insulating gloves. • Always operate the welder with the hinged door closed and the side panels in place. • Read carefully the Safety Precautions page before operating this machine. Always follow... -
Page 19: Welding Controls
CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control. In the CV-WIRE mode, when the wire feeder con-... -
Page 20: Engine Controls
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 arc. -
Page 21: Duty Cycle
STOP position. NOTE: A fuel shut off valve is located on the fuel pre- filter. WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no load in a 10 minute period. -
Page 22: Tig Welding
The Ranger 305D can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows: Constant Current (CC-STICK) Welding The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of elec- trodes, especially low hydrogen. -
Page 23: Wire Welding-Cv
.045 (1.1 mm), Super Arc L-50 and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max MIG 308 LS. Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain appli- cations with this machine. OPERATION... -
Page 24: Auxiliary Power
AUXILIARY POWER: If a GFCI receptacle is tripped, See the MAINTE- NANCE section for detailed information on testing and resetting the GFCI receptacle. 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. -
Page 25: Accessories
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE CONTROL Portable control provides same dial range as the out- put control on the welder. Has a convenient 6 pin plug for easy connection to the welder. K2174-1 COLD WEATHER OPERATIONS KIT- Provides starting aid and enhancement in extreme cold weather. -
Page 26: Maintenance
SAFETY PRECAUTIONS WARNING • 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 27: Engine Oil Change
• 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 cap from the drain valve. Push valve in and twist counterclockwise. Pull to open and drain the oil into a suitable container for disposal. - Page 28 Service Instructions & Installation Tips Release the 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 don t hinder filter removal/installation. Most latches are spring loaded to fold back when open. The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter of the filter endcap.
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Page 29: Cooling System
It is recommended that the fuel shutoff valve be closed during periods of non-use. (For Code 11121) The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that functions when the electric fuel pump is actuated. It is generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system. -
Page 30: Fuel Filter
● CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. -
Page 31: Welder / Generator Maintenance
WARNING • Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equip- ment may result in danger to the technician and machine operator and will invalidate your factory warranty. -
Page 32: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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. -
Page 33: Troubleshooting
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not "crank". Engine will "crank" but not start. Engine shuts down shortly after starting. 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. - Page 34 3. Faulty engine alternator or charg- er module. Consult authorized Engine Service Shop. 1. Idler switch in High idle position. Set switch to Auto. 2. External load on welder or auxil- iary power. Remove all external loads. 3. Faulty PC board or idler sole- noid.
- Page 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not go to high idle when using auxiliary power. Engine will not go to high idle under weld or auxiliary loading. Engine does not develop full power. Engine runs rough. Engine will not go to high idle when attempting to weld or using auxil- iary power.
- Page 36 2. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On" position when welding without control cable. 3. Faulty PC board or welder alterna- tor. 1. Poor remote/control cable connec- tion to 6-pin or 14-pin connector. Check connections.
- Page 37 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The welding arc is “cold.” The weld- ing arc is not stable or is not satis- factory. the engine runs normally. The auxiliary power is normal. 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.
- Page 38 DIAGRAMS RANGER 305D...
- Page 39 DIAGRAMS RANGER 305D...
- Page 40 DIAGRAMS RANGER 305D...
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- Page 44 DIAGRAMS RANGER 305D...
- Page 45 DIAGRAMS RANGER 305D...
- Page 46 DIAGRAMS RANGER 305D...
- Page 47 F-10 F-10 DIAGRAMS RANGER 305D...
- Page 48 ENHANCED F-11 WIRING DIAGRAM F-11 DIAGRAMS RANGER 305D...
- Page 49 ENHANCED F-12 WIRING DIAGRAM F-12 DIAGRAMS RANGER 305D...
- Page 50 F-13 F-13 DIMENSION PRINT RANGER 305D...
- Page 51 NOTES RANGER 305D...
- Page 52 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 53 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATTENTION WARNUNG ATENÇÃO...
- Page 54 • 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...