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Lincoln Electric Ranger 3050 Operator's Manual

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RETURN TO MAIN MENU
IM10053
Ranger
305D (AU)
®
November, 2010
11692
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
Copyright © 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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  • Page 1 RETURN TO MAIN MENU IM10053 Ranger 305D (AU) ® November, 2010 11692 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

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...

  • 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.

  • Page 7: 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 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: 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 10: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING The Ranger® 305D (AU) weighs approximately 775lbs.(352kg.) with a full tank of fuel (698 lbs. less WARNING fuel). A lift bail is mounted to the machine and should always be used when lifting the machine. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s WARNING manual supplied with your welder.

  • Page 11: Towing

    INSTALLATION PRE-OPERATION ENGINE SERVICE TOWING READ the engine operating and maintenance instruc- The recommended trailer for use with this equipment for road, tions supplied with this machine. 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- WARNING bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment.

  • Page 12: Battery Connections

    INSTALLATION REMOTE CONTROL ENGINE COOLING SYSTEM The Ranger® 305D (AU) is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for con- WARNING necting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-3 hand Air to cool the engine is drawn in the base sides Amptrol.

  • Page 13: 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 14: 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 15: 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 16: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION 1. Shut the welder off. CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS 2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the Connection of LN-15 to the Ranger® 305D (AU) welder and work cable to the "-" terminal of the welder.

  • Page 17: Operation

    OPERATION SAFETY PRECAUTIONS • Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door. • Check radiator for proper coolant level. (Fill if nec- WARNING essary). • See Engine Owner’s Manual for specific oil and Do not attempt to use this equipment until you coolant recommendations.

  • Page 18: Welding Controls

    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 19: 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 not active in the TIG mode.
  • Page 20 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 21: 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 22: Tig 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 23: 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 24: 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 25: 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 26: Maintenance

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

  • Page 27: 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 28 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 29: 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 30: 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 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 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 33: Troubleshooting

    TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS POSSIbLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Lincoln is Evident. Authorized Field Service Facility. Engine will not "crank". 1. Battery is low, Charge Battery. 2.
  • Page 34 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 35 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 36 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 37 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 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 DIAGRAMS RANGER® 305D (AU)
  • Page 46 DIAGRAMS RANGER® 305D (AU)
  • Page 47 F-10 F-10 DIAGRAMS Enhanced Diagram RANGER® 305D (AU)
  • Page 48 F-11 F-11 DIMENSION PRINT RANGER® 305D (AU)
  • Page 49 NOTES RANGER® 305D (AU)
  • Page 50 NOTES RANGER® 305D (AU)
  • Page 51 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. • • • WARNING electrode with skin or wet clothing. Insulate yourself from work and • ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el •...
  • Page 52 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or • • • WARNING Use ventilation or exhaust to guards off. • remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- •...
  • Page 53 • 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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