Lincoln Electric RANGER 305D AU Operator's Manual
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Lincoln Electric RANGER 305D AU Operator's Manual

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Operator's Manual
RANGER
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10053-D
|
Issue
Apr-21 © Lincoln Global, Inc. All Rights
Reserved.
®
305D (AU)
D ate
For use with machines having Code Numbers:
11692, 12193, 12682, 13167
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual RANGER ® 305D (AU) For use with machines having Code Numbers: 11692, 12193, 12682, 13167 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    Cable Installation......................A-5 Electrical Device Used with the Ranger 305D (AU)............. A-6 Auxiliary Power Receptacles and Plugs................A-7 Standby Power Connections....................A-7 Premises Wiring........................A-8 Connection of Lincoln Electric Wire Feeders...............A-9,A-10 ________________________________________________________________________________ Operation.........................Section B Safety Precautions ......................B-1 General Description......................B-1 For Auxiliary Power......................B-1 Engine Operation........................B-1...
  • Page 7 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.....................

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - Ranger® 305D (AU) (K2922-1) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (cu. cm.) System 3 cylinder 43.88(789) 12VDC Battery & Fuel: 12 gal. 4 stroke starter (45 Liters) 18.8 HP High Idle 3650 Bore x Stroke inch (mm) Oil: 3.4Qts.

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS gallons (45ltrs.). WARNING LIFTING The Ranger® 305D (AU) weighs approximately 775lbs.(352kg.) with a full tank of fuel (698 lbs. less Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s WARNING manual supplied with your welder. It includes important safety precautions, detailed engine •...

  • Page 10: Towing

    INSTALLATION PRE-OPERATION ENGINE SERVICE -------------------------------------------------------------------------------- READ the engine operating and maintenance instruc- TOWING tions supplied with this machine. The recommended trailer for use with this equipment for road, WARNING 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- •...

  • Page 11: Battery Connections

    INSTALLATION -------------------------------------------------------------------------------- REMOTE CONTROL (1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways. WARNING The Ranger® 305D (AU) is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for con- ENGINE COOLING SYSTEM necting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-3 hand...

  • Page 12: Welding Terminals

    INSTALLATION TABLE A.1 When this welder is mounted on a truck or trailer, its frame must be electrically bonded to the metal frame CABLE INSTALLATION of the vehicle. Use a #8 or larger copper wire connect- Install the welding cables to your Ranger® 305D (AU) ed between the machine grounding stud and the as follows.

  • Page 13: Electrical Device Used With The Ranger 305D (Au

    DO NOT USE THESE DEVICES WITH A RANGER® 305D (AU) The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER® 305D (AU). RANGER® 305D (AU)

  • Page 14: Standby Power Connections

    INSTALLATION AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the Ranger® 305D (AU) is 7.2KW of 60Hz single phase power protected by an RCD (Residual Current Device) and 2 single phase 15 amp circuit breakers. The auxiliary power capacity in watts equivalent to volt-amperes at unity power factor.
  • Page 15 INSTALLATION CONNECTION OF ACROSS THE ARC WIRE FEEDERS FIGURE A.7 TO THE RANGER ® 305D (AU) Weld These connections instructions apply to both the LN-25 Pro and Terminals On Activ8 models. The feeders have an internal contactor and the electrode is not energized until the gun trigger is closed. When the Set Mode to Set to gun trigger is closed the wire will begin to feed and the welding...

  • Page 16: Operation

    OPERATION SAFETY PRECAUTIONS • Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door. WARNING • Check radiator for proper coolant level. (Fill if nec- essary). • See Engine Owner’s Manual for specific oil and Do not attempt to use this equipment until you coolant recommendations.
  • Page 17 OPERATION FIGURE B.1 FIGURE B.1 WELDING CONTROLS (Figure B.1) 2. DIGITAL OUTPUT METERS- The digital meters allow the output voltage (CV-WIRE mode) 1. OUTPUT CONTROL- or current (CC-STICK,DOWN HILL PIPE and TIG The OUTPUT dial is modes) to be set prior to welding using the OUT- used to preset the output voltage or current as dis- PUT control dial.

  • Page 18: Engine Controls

    OPERATION 10. WIRE FEEDER VOLTMETER SWITCH: 4. ARC CONTROL - The ARC CONTROL dial is active in Matches the polarity of the wire feeder voltmeter to the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, the polarity of the electrode. and has different functions in these modes. This control is ENGINE CONTROLS: not active in the TIG mode.
  • Page 19 OPERATION 15. ELECTRIC FUEL GAUGE- The electric fuel gauge gives accurate and reliable indication as to how much fuel is in the fuel tank. 16. ENGINE HOUR METER- Displays the total time that the engine has been running. This meter is useful for scheduling prescribed maintenance.

  • Page 20: Duty Cycle

    OPERATION STARTING THE ENGINE NOTE: When starting a Ranger® 305D (AU) for the first time, or after and extended period of time of not 1. Remove all plugs connected to the AC power operating, it will take longer than normal because the receptacles.

  • Page 21: Constant Current (Stick) Welding

    OPERATION It is recommended that the ARC CONTROL be set to the The Ranger® 305D (AU) can be used with a broad range minimum number without electrode sticking. Start with of DC stick electrodes. The MODE switch provides two the dial set at 0. stick welding settings as follows: TIG WELDING Constant Current (CC-STICK) Welding...

  • Page 22: Wire Welding-Cv

    .045 (1.1 mm), Super Arc L-50 and L-56, .035 (0.9 mm) .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 applications with this machine. RANGER® 305D (AU)

  • Page 23: Auxiliary Power Operation

    OPERATION AUXILIARY POWER OPERATION: Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no weld- ing current is being drawn. The auxiliary power of the Ranger® 305D (AU) con- sists of two 15Amp 240VAC single phase receptacles.

  • Page 24: Accessories

    ACCESSORIES FIELD INSTALLED OPTIONS / ACCESSORIES TIG Welding K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS K1783-9 TIG Torch PTA-26V (25ft.) For road, off-road and in-plant and yard towing. K963-3 Hand Amptrol (For highway use, consult applicable federal, state K870 Foot Amptrol and local laws regarding requirements for brakes, lights, fenders, etc.).Order:...

  • Page 25: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS KUBOTA D722 DIESEL ENGINE FREQUENCY MAINTENANCE REQUIRED WARNING • FILL FUEL TANK. • CHECK OIL LEVEL. • Have qualified personnel do all maintenance • CHECK COOLANT LEVEL. • CHECK AIR CLEANER ELE- and troubleshooting work. MENT AND HOUSING FOR DIRTY, LOOSE OR DAMAGED •...

  • Page 26: Engine Oil Change

    MAINTENANCE Oil Filter Change Engine Oil Change • Drain the oil. Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommend- • Remove the oil filter with an oil filter wrench and ed that each time the oil is changed the oil filter be drain the oil into a suitable container.
  • Page 27 MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 28: Cooling System

    MAINTENANCE FUEL COOLING SYSTEM WARNING At the end of each day’s use, refill the fuel tank to min- imize moisture condensation and dirt contamination in HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to expand.

  • Page 29: Fuel Filter

    MAINTENANCE CLEANING THE BATTERY FUEL FILTER Keep the battery clean by wiping it with a damp cloth 1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon- accumulation or sediment. nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 2.

  • Page 30: 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 31: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 1. Contact your local Lincoln Major Physical or Electrical Damage Authorized Field Service is Evident. Facility. Engine will not "crank". 1. Battery is low, Charge Battery. 2.
  • Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant tempera- load. ture. Reduce load if it is exceed- ing machine rating. Add coolant to system if low.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine will not go to high idle when 1. Auxiliary power load is less than using auxiliary power. 100 watts. Idler may not respond with less than a 100 watt load.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION No welding power output. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal. 2. "Weld Terminals" switch in wrong position.
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory.
  • Page 37 DIAGRAMS RANGER® 305D (AU)
  • Page 38 DIAGRAMS RANGER® 305D (AU)
  • Page 39 DIAGRAMS RANGER® 305D (AU)
  • Page 40 DIAGRAMS RANGER® 305D (AU)
  • Page 41 DIAGRAMS RANGER® 305D (AU)
  • Page 42 DIAGRAMS RANGER® 305D (AU)
  • Page 43 DIAGRAMS RANGER® 305D (AU)
  • Page 44 DIAGRAMS RANGER® 305D (AU)
  • Page 45 DIMENSION PRINT RANGER® 305D (AU)
  • Page 46 NOTES RANGER® 305D (AU)
  • Page 47 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 48 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 49 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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