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Lincoln Electric RANGER 305D IM730 Operator's Manual

Lincoln electric welding system user manual.
RETURN TO MAIN MENU
IM730
Ranger 305 D
August, 2004
10926
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 © 2004 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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   Summary of Contents for Lincoln Electric RANGER 305D IM730

  • Page 1

    RETURN TO MAIN MENU IM730 Ranger 305 D August, 2004 10926 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 ...

  • Page 2

    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. 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. 3.b.

  • Page 4

    WELDING 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 sparks and hot 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 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.

  • Page 6

    The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

  • Page 7: Table Of Contents

    Welding Terminals ...A-4 Welding Output Cables ...A-4 Cable Installation...A-5 Auxiliary Power Receptacles and Plugs ...A-5 Standby Power Connections ...A-5 Premises Wiring ...A-6 Connection of Lincoln Electric Wire Feeders ...A-7 ________________________________________________________________________________ Operation...Section B Safety Precautions ...B-1 General Description...B-1 For Auxiliary Power ...B-1 Engine Operation...B-1...

  • Page 8: Table Of Contents

    Maintenance...Section D Safety Precautions ...D-1 Routine Maintenance ...D-1 Engine Maintenance Components ...D-1 Kubota Diesel Engine ...D-1 Engine Oil Change...D-2 Engine Oil Refill Capacities...D-2 Engine Oil Filter Change...D-2 Air Cleaner Service ...D-2 Service Instructions And Installation Tips for Engine Air Filter ...D-3 Cooling System ...D-4 Fan Belt...D-4 Fuel ...D-4...

  • Page 9: Technical Specifications

    TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2) Make/Model Description 3 cylinder 4 stroke 18.8 HP Kubota** (14 KW) D722 Net intermittent 3600 RPM naturally aspirated water cooled engine RATED OUTPUT @ 104° F (40° C) - WELDER Welding Process Current/Voltage/Duty Cycle DC Constant Current DC Pipe Current Touch-Start™TIG...

  • Page 10: Safety Precautions, Location And Ventilation, Stacking, Angle Of Operation, Lifting, High Altitude Operation

    SAFETY PRECAUTIONS WARNING 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. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. •...

  • Page 11: Towing, Pre-operation Engine Service, Fuel, Battery Connections, Muffler Outlet Pipe

    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: Spark Arrester, Remote Control, Electrical Connections, Machine Grounding, Welding Terminals, Welding Output Cables

    SPARK 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: Cable Installation, Standby Power Connections

    TABLE A-1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Length 0-100Ft. (0-30meters) 100-150 Ft. (30-46m meters) 150-200 Ft. (46-61 meters) CABLE INSTALLATION Install the welding cables to your RANGER 305D as follows. 1. The diesel engine must be OFF to install welding cables.

  • Page 14: 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 15: Connection Of Lincoln Electric Wire Feeders

    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 "+"...

  • Page 16

    WARNING Connection of the LN-25 to the RANGER 305D 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. See the appropriate connection diagram in Section F. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the RANGER 305D.

  • Page 17: General Description, Safety Precautions, For Auxiliary Power, Engine Operation, Engine Break In, Add Fuel, Fuel

    DIESEL FUEL ONLY ----------------------------------------------------------------------- BREAK-IN PERIOD Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal.

  • Page 18

    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 automatically switches the OUTPUT CONTROL from control at the welder to the remote...

  • Page 19: 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 20

    15. ENGINE ALTERNATOR 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.

  • Page 21: Duty Cycle, Downhill Pipe (stick) Welding, Tig Welding

    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. The Ranger 305D can be used with a broad range of DC stick electrodes.

  • Page 22: Wire Welding-cv, Arc Gouging

    Start with the dial set at 0. Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain applications with this machine. Also additional information WWW.Lincolnelectric.com...

  • Page 23: Auxiliary Power, Simultaneous Welding And Auxiliary Power Loads

    AUXILIARY 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 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle.

  • Page 24: Cold Weather Operation, Field Installed Options / Accessories

    FIELD INSTALLED 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 Hitch K959-2 Fender &...

  • Page 25: Routine Maintenance, Safety Precautions, Engine Maintenance Components

    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 necessary to perform maintenance and replace them when the mainte- nance requiring their removal is complete.

  • Page 26: Engine Oil Change, Engine Oil Refill Capacities

    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.

  • Page 27

    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 donít 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.

  • Page 28: Cooling System, Fan Belt, Fuel, Bleeding The Fuel System

    COOLING SYSTEM WARNING HOT COOLANT • 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"...

  • Page 29: Fuel Filter, Engine Adjustment, Battery Maintenance, Servicing Optional Spark Arrestor

    FUEL FILTER 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. OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3650 RPM, no load.

  • Page 30: Welder / Generator Maintenance, Storage, Cleaning, Brush Removal And Replacement

    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 31: How To Use Troubleshooting Guide

    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 32

    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 33

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine shuts down while under a load. Engine runs rough. Battery does not stay charged. Engine alternator trouble light is on while machine is running. Engine will not idle down to low speed.

  • Page 34

    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 35

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welding power output. Welder has output but no control. Wire feeder does not work when control cable is connected to 14 pin connector. No auxiliary power. 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 36

    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.

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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    DIAGRAMS RANGER 305D...

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

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

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    F-12 DIAGRAMS 1 1 1 1 BLACK WHITE RANGER 305D ENHANCED DIAGRAM BLACK WHITE F-12...

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    F-13 F-13 DIAGRAMS RANGER 305D...

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    NOTES RANGER 305D...

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    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 ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE 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...

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