arc welding supplies - 07 847 7870 drives/li… · purchase a copy of _safety in welding &...
TRANSCRIPT
Ranger ® 305D (AU)
OPERATOR’S MANUAL
IM10053November, 2010
Safety Depends on YouLincoln 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 THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
For use with machines having Code Numbers: 11692
• 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
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
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FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
____________________________________________________1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
bE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY bY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND MAGNETIC FIELDSmay be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline EnginesAR
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ii iiSAFETY
ARC RAYS can burn.4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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iiiSAFETYiii
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:•Away from areas where they may be struck or subjected tophysical damage.
•A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.
Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour 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 L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’ interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
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vv
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration- 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.• For On-Line Registration: Go to our WEb SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric 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. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.
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vi vi TAbLE OF CONTENTSPage
Installation.......................................................................................................................Section ATechnical Specifications.......................................................................................................A-1
Safety Precautions ........................................................................................................A-2Location and Ventilation................................................................................................A-2Stacking ........................................................................................................................A-2Angle of Operation ........................................................................................................A-2Lifting.............................................................................................................................A-2High Altitude Operation .................................................................................................A-2High Temperature Operation ........................................................................................A-2Cold Weather Operation ...............................................................................................A-2Towing...........................................................................................................................A-3Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3Oil ..................................................................................................................................A-3Fuel ...............................................................................................................................A-3Engine Coolant..............................................................................................................A-4Battery Connections......................................................................................................A-4Muffler Outlet Pipe ........................................................................................................A-4Spark Arrester ...............................................................................................................A-4Remote Control .............................................................................................................A-4
Electrical Connections..........................................................................................................A-4Machine Grounding.......................................................................................................A-4Welding Terminals ........................................................................................................A-5Welding Output Cables .................................................................................................A-5Cable Installation...........................................................................................................A-5
Electrical Device Used with the Ranger 305D (AU) .............................................................A-6Auxiliary Power Receptacles and Plugs...............................................................................A-7Standby Power Connections ................................................................................................A-7Premises Wiring ...................................................................................................................A-8Connection of Lincoln Electric Wire Feeders...............................................................A-9,A-10
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Operation.........................................................................................................................Section bSafety Precautions ..............................................................................................................B-1General Description..............................................................................................................B-1For Auxiliary Power ..............................................................................................................B-1Engine Operation..................................................................................................................B-1Add Fuel ...............................................................................................................................B-1 Break in Period.....................................................................................................................B-1Welder Controls .............................................................................................................B-2,B-3Engine Controls....................................................................................................................B-3
Starting and Stopping the Engine .................................................................................B-4Welding Operation................................................................................................................B-4
Duty Cycle ..............................................................................................................B-4,B-5Constant Current (Stick) Welding..................................................................................B-5Downhill Pipe (Stick) Welding .......................................................................................B-5Tig Welding ...................................................................................................................B-5Typical Current Ranges for Tungsten Electrodes .........................................................B-5Wire Welding-CV...........................................................................................................B-6Arc Gouging ..................................................................................................................B-6Auxiliary Power Operation.............................................................................................B-7Simultaneous Welding and Auxiliary Power Loads.......................................................B-7Extension Cord Recommendations...............................................................................B-7
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Accessories .....................................................................................................Section CField Installed Options / Accessories ...............................................................................C-1
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vii viiTAbLE OF CONTENTSMaintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1Routine Maintenance ............................................................................................D-1Engine Maintenance Components ........................................................................D-1Kubota Diesel Engine............................................................................................D-1
Engine Oil Change..........................................................................................D-2Engine Oil Refill Capacities.............................................................................D-2Engine Oil Filter Change.................................................................................D-2Air Cleaner Service .........................................................................................D-2Service Instructions And Installation Tips for Engine Air Filter .......................D-3
Cooling System .....................................................................................................D-4Fan Belt...........................................................................................................D-4Fuel .................................................................................................................D-4Bleeding the Fuel System ...............................................................................D-4Fuel Filter ........................................................................................................D-5Engine Adjustment ..........................................................................................D-5Battery Maintenance .......................................................................................D-5Servicing Optional Spark Arrestor ...................................................................D-5
Welder / Generator Maintenance ........................................................................D-6Storage ...........................................................................................................D-6Cleaning..........................................................................................................D-6Brush Removal and Replacement ..................................................................D-6GFCI Testing and Resetting Procedure..........................................................D-6
________________________________________________________________________Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.............................................................................E-2 thru E-6
________________________________________________________________________ Diagrams and Dimension Print ......................................................................Section F
________________________________________________________________________Parts List.................................................................................................................P-646
________________________________________________________________________
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RANGER® 305D (AU)
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up torated capacity. When welding, available auxiliary power will be reduced.
* Top of enclosure add 6in. (152mm) for exhaust pipe.** Engine warranty may vary outside of the USA. (See Engine warranty for details)
A-1INSTALLATION A-1
TECHNICAL SPECIFICATIONS - Ranger® 305D (AU) (K2922-1)
Make/Model Description Speed (RPM) Displacement Starting Capacitiescu. 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. (3.2L)
Kubota** (14 KW)D722 Net intermittent Full Load 3500 2.64 x 2.68 (Group 58; 550 Radiator Coolant:
3600 RPM (67 x 68 mm) cold crank amps) 3.85Qts. (3.6L)naturally aspirated Low Idle 2450 Battery Charger
water cooled (3.6L)Diesel Engine
INPUT - DIESEL ENGINE
RATED OUTPUT @ 104° F (40° C) - WELDER
HEIGHT WIDTH DEPTH WEIGHT
30.00* in. 21.50 in 52.25 in.
762.0 mm 546.0 mm 1327.0 mm
LUbRICATION EMISSIONS FUEL SYSTEM GOVERNORFull Pressure Certified to EPA Tier 4 Mechanical Fuel Pump, Auto air bleed Mechanicalwith Full Flow Filter Compliant system Electric shutoff solenoid Indirect fuel injector Governor
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTIONLow noise Muffler: Shutdown on low oil
Single Element Automatic Idler Top outlet can be rotated. pressure & engineMade from long life, aluminized steel. temperature
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)
Welding Process
DC Constant CurrentDC Pipe CurrentTouch-Start™TIG
DC Constant Voltage
Output Range
20 TO 305 AMPS40 TO 300 AMPS20 TO 250 AMPS14 TO 29 VOLTS
Max. Weld OCV@Rated Load RPM
60 Volts
Welding OutputCurrent/Voltage/Duty Cycle
305A / 29V / 100%300A / 29V / 100%250A / 30V / 100%300A / 29V / 100%
Auxiliary Power 1
7200 Watts Continuous, 60 Hz 240 Volts
Sound LevelsSound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m )
PHYSICAL DIMENSIONS
ENGINE
RECEPTACLES AUXILIARY POWER CIRCUIT bREAKER OTHER CIRCUIT bREAKERS
(2) 240VAC Receptacles Two 15AMP for Two Receptacles 15AMP for Battery Charging Circuit 15AMP for 42V Wire Feeder Power
RECEPTACLES AND CIRCUIT bREAKERS
RATED OUTPUT @ 104° F (40° C).- GENERATOR
698 lbs. (317kg.)
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LIFTINGThe Ranger® 305D (AU) weighs approximately775lbs.(352kg.) with a full tank of fuel (698 lbs. lessfuel). A lift bail is mounted to the machine and shouldalways be used when lifting the machine.
HIGH ALTITUDE OPERATIONAt higher altitudes, output derating may be necessary. For max-imum rating, derate the machine 2.5% to 3.5% for every 1000 ft.(305m). Due to new EPA and other local emissions regulations,modifications to the engine for high altitude are restricted withinthe United States and some other European Countries. Useabove 6000 ft.(1828 m) may be limited due to poor engine per-formance or excessive exhaust smoke. An authorized Kubotaengine field service shop should be contacted to determine ifany adjustments can be made for operation in higher elevationslocally.
HIGH TEMPERATURE OPERATIONAt temperatures above 104°F(40°C), Welder output derating isnecessary. For maximum output ratings, derate the welder out-put 2 volts for every 50°F(10°C) above 104°F(40°C).
Cold weather starting:With a fully charged battery and the proper weight oil,the engine should start satisfactorily even down toabout 5°F (-15°C). If the engine must be frequentlystarted at or below 23°F (-5°C), it may be desirable toinstall cold-starting aides. The use of No. 1D dieselfuel is recommended in place of No. 2D at tempera-tures below 23°F (-5°C). Allow the engine to warm upbefore applying a load or switching to high idle.Note: Extreme cold weather starting may requirelonger glow plug operation.
Under no conditions should ether or other startingfluids be used with this engine!--------------------------------------------------------------------------------
WARNING
A-2INSTALLATION
RANGER® 305D (AU)
A-2
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 toavoid restricting the cooling air outlets. Also, locate thewelder so that the engine exhaust fumes are properlyvented to an outside area.
STACKING
Ranger® 305D (AU) machines cannot be stacked.
ANGLE OF OPERATIONEngines are designed to run in the level conditionwhich is where the optimum performance is achieved.The maximum angle of continuous operation is 20degrees in all directions, 35 degrees Intermittent (lessthan 10 minutes continuous) in all directions. If theengine is to be operated at an angle, provisions mustbe made for checking and maintaining the oil level atthe normal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effectivefuel capacity will be slightly less than the specified 12gallons (45ltrs.).
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------
ELECTRIC SHOCK can kill.• Do not touch electrically live parts or
electrode with skin or wet clothing.• Insulate yourself from work and
ground• Always wear dry insulating gloves.
------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or
guards off.• Stop engine before servicing.• Keep away from moving parts.
------------------------------------------------------------------------See additional warning information atfront of this operator’s manual.
WARNING
• Lift only with equipment of ade-quate lifting capacity.
• be sure machine is stable when lift-ing.
• Do not lift this machine using liftbail if it is equipped with a heavyaccessory such as trailer or gascylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
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WARNINGAR
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PRE-OPERATION ENGINE SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.
• Stop engine and allow to cool before fueling• Do not smoke when fueling.• Fill fuel tank at a moderate rate and do not over-
fill.• Wipe up spilled fuel and allow fumes to clear
before starting engine.• Keep sparks and flame away from tank.------------------------------------------------------------------------
OIL The Ranger® 305D (AU) is shipped with the enginecrankcase filled with high quality SAE 10W-30 Oil thatmeets classification CG-4 or CH-4 for diesel engines.Check the oil level before starting the engine. If it isnot up to the full mark on the dip stick, add oil asrequired. Check the oil level every four hours of run-ning time during the first 50 running hours. Refer tothe engine Operator’s Manual for specific oil recom-mendations and break-in information. The oil changeinterval is dependent on the quality of the oil and theoperating environment. Refer to the Engine Operator’sManual for more details on the proper service and
maintenance intervals.
FUELDIESEL FUEL ONLY-Low sulphur fuel or ultra lowsulphur fuel in U.S.A. and Canada.
• Fill the fuel tank with clean, fresh fuel. Thecapacity of the tank is 12 gals. (45.4ltrs). Whenthe fuel gauge reads empty the tank containsapproximately 2 gals. (7.6ltrs.) of reserve fuel.
NOTE: A fuel shut off valve is located on the pre-filter/sediment filter. Which should be inthe closed position when the welder is notran for extended periods of time.
--------------------------------------------------------------------------------
A-3INSTALLATION
RANGER® 305D (AU)
A-3
TOWINGThe recommended trailer for use with this equipment for road,in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. Ifthe user adapts a non-Lincoln trailer, he must assume responsi-bility that the method of attachment and usage does not resultin a safety hazard nor damage the welding equipment. Some ofthe factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment andlikely additional attachments.
2. Proper support of, and attachment to, the base of the weld-ing equipment so there will be no undue stress to the frame-work.
3. Proper placement of the equipment on the trailer to insurestability side to side and front to back when being movedand when standing by itself while being operated or ser-viced.
4. Typical conditions of use, i.e., travel speed; roughness of sur-face on which the trailer will be operated; environmental con-ditions; like maintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
WARNING
WARNING
WARNING
VEHICLE MOUNTING
Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.
• Only transport this Equipment on serviceablevehicles which are rated and designed for suchloads.
• Distribute, balance and secure loads so vehicleis stable under conditions of use.
• Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame ofvehicle.
• Follow vehicle manufacturer’s instructions.--------------------------------------------------------------------------------
WARNING
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A-4INSTALLATION
RANGER® 305D (AU)
A-4
REMOTE CONTROLThe Ranger® 305D (AU) is equipped with a 6-pin anda 14-pin connector. The 6-pin connector is for con-necting the K857 or K857-1 Remote Control or for TIGwelding, the K870 foot Amptrol or the K936-3 handAmptrol. When in the CC-STICK, DOWNHILL PIPE,or CV-WIRE modes and when a remote control isconnected to the 6-pin Connector, the auto-sensingcircuit automatically switches the OUTPUT controlfrom control at the welder to remote control.
When in TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin Connector, theOUTPUT dial is used to set the maximum currentrange of the CURRENT CONTROL of the Amptrol.
The 14-pin connector is used to directly connect awire feeder control cable. In the CV-WIRE mode,when the control cable is connected to the 14-pin con-nector, the auto-sensing circuit automatically makesthe Output Control inactive and the wire feeder volt-age control active
NOTE: When a wire feeder with a built in weldingvoltage control is connected to the 14-pin connec-tor, do not connect anything to the 6-pin connec-tor.
--------------------------------------------------------------------------------
ELECTRICAL CONNECTIONS
MACHINE GROUNDINGBecause this portable engine driven weldercreates its own power, it is not necessary to connectits frame to an earth ground, unless the machine isconnected to premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipmentto which this engine driven welder supplies powermust:
• be grounded to the frame of the welder using agrounded type plug.
• be double insulated.• Do not ground the machine to a pipe that carries
explosive or combustible material.--------------------------------------------------------------------------------
WARNING
ENGINE COOLING SYSTEM
Air to cool the engine is drawn in the base sidesand exhaust through radiator & case back. It isimportant that the intake and exhaust air is notrestricted. Allow a minimum clearance of 2 feet(0.6m) from the case back and 16in.(406mm) fromeither side of the base to a vertical surface.--------------------------------------------------------------------------------
bATTERY CONNECTION
Use caution as the electrolyte is a strong acid thatcan burn skin and damage eyes.--------------------------------------------------------------------------------
The Ranger® 305D (AU) is shipped with the negativebattery cable disconnected. Make certain that theRUN-STOP switch is in the STOP position. Removethe two screws from the rear battery tray using ascrewdriver or a 3/8" socket. Attach the negative bat-tery cable to the negative battery terminal and tightenusing a 1/2" socket or wrench.
NOTE: This machine is furnished with a wet chargedbattery; if unused for several months, the battery mayrequire a booster charge. Be careful to charge the bat-tery with the correct polarity.
MUFFLER OUTLET PIPEUsing the clamp provided secure the outlet pipe to theoutlet tube with the pipe positioned such that it willdirect the exhaust in the desired direction. Tightenusing a 9/16" socket or wrench.
SPARK ARRESTERSome federal, state or local laws may require thatgasoline or diesel engines be equipped with exhaustspark arresters when they are operated in certainlocations where unarrested sparks may present a firehazard. The standard muffler included with this welderdoes not qualify as a spark arrester. When required bylocal regulations, a suitable spark arrester, such asthe K1898-1 must be installed and properly main-tained.
An incorrect spark arrestor may lead to damage tothe engine or adversely affect performance.--------------------------------------------------------------------------------
CAUTION
WARNING
WARNING
WARNING
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TAbLE A.1
CAbLE INSTALLATIONInstall the welding cables to your Ranger® 305D (AU)as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals.3. Connect the electrode holder and work cables to the
weld output terminals. The terminals are identifiedon the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the“work”) is properly connected to the work clamp andcable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output termi-nals to overheat. The terminals may eventuallymelt.
• Do not cross the welding cables at the output ter-minal connection. Keep the cables isolated andseparate from one another.
--------------------------------------------------------------------------------
CAUTION
A-5INSTALLATION
RANGER® 305D (AU)
A-5
When this welder is mounted on a truck or trailer, itsframe must be electrically bonded to the metal frameof the vehicle. Use a #8 or larger copper wire connect-ed between the machine grounding stud and theframe of the vehicle. When this engine driven welderis connected to premises wiring such as that in ahome or shop, its frame must be connected to the sys-tem earth ground. See further connection instructionsin the section entitled "Standby Power Connections"as well as the article on grounding in the latestNational Electrical Code and the local code.
In general, if the machine is to be grounded, it shouldbe connected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going into theground for at least ten feet and having no insulatedjoints, or to the metal framework of a building whichhas been effectively grounded.
The National Electrical Code lists a number of alter-nate means of grounding electrical equipment. Amachine grounding stud marked with the symbolis provided on the front of the welder.
WELDING TERMINALSThe Ranger® 305D (AU) is equipped with a toggleswitch for selecting "hot" welding terminal when in the"WELD TERMINALS ON" position or "cold" weldingterminal when in the "REMOTELY CONTROLLED"position.
WELDING OUTPUT CAbLES With the engine off connect the electrode and workcables to the output studs. The welding process dic-tates the polarity of the electrode cable. These con-nections should be checked periodically and tightenedwith a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengthsfor rated current and duty cycle. Length refers to thedistance from the welder to the work and back to thewelder. Cable diameters are increased for long cablelengths to reduce voltage drops.
TOTAL COMbINED LENGTH OFELECTRODE AND WORK CAbLES
Cable Length
0-100Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for 305 Amps
100% Duty Cycle1 / 0 AWG
2 / 0 AWG
3 / 0 AWG
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A-6INSTALLATION
RANGER® 305D (AU)
A-6
TABLE lll
ELECTRICAL DEVICE USE WITH THE RANGER® 305D (AU).
Type Common Electrical Devices Possible Concerns
Resistive Heaters, toasters, incandescent NONElight bulbs, electric range, hot pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltageappliances with electrical control. regulation can cause the capaci-
tative elements to fail. Surgeprotection, transient protection,and additional loading is recom-mended for 100% fail-safe oper-
ation. DO NOT RUN THESE
DEVICES WITHOUT ADDI-
TIONAL RESISTIVE TYPE
LOADS.
Inductive Single-phase induction motors, These devices require largedrills, well pumps, grinders, small current inrush for starting. refrigerators, weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain
maximum output torque, butthey SHOULD BE SAFE fromany frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-complicated electrical equipment. er along with transient and
surge protection is required, and
liabilities still exist. DO NOT
USE THESE DEVICES WITH A
RANGER® 305D (AU)
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connectedto the RANGER® 305D (AU).
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AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the Ranger® 305D(AU) is 7.2KW of 60Hz single phase power protectedby an RCD (Residual Current Device) and 2 singlephase 15 amp circuit breakers. The auxiliary powercapacity in watts equivalent to volt-amperes at unitypower factor.
This model has:1 Residual Current Device (RCD) protection (30mA). 2 x 1 phase 15 amp Circuit Breakers.2 x 1 phase 240 volt 15 amp per outlet.
Note: The single-phase outlets are from differentphases and cannot be paralleled.
The auxiliary power receptacles should only be usedwith three grounded type plugs or approved doubleinsulated tools. The current rating of any plug usedwith the system must be at least equal to the currentcapacity of the associated receptacle.
STANDbY POWER CONNECTIONS
The Ranger® 305D (AU) is suitable for temporary,standby or emergency power using the engine manu-facturer’s recommended maintenance schedule.
The Ranger® 305D (AU) can be permanentlyinstalled as a standby power unit for 240 volt (60Hz).Connections must be made by a licensed electricianwho can determine how the 240 VAC power can beadapted to the particular installation and comply withall applicable electrical codes. The following informa-tion can be used as a guide by the electrician formost applications.
1 Install an isolation switch between the power com-pany meter and the premises disconnect. (TheRanger® 305D (AU) and the power company sup-plies must not be connected together).
Switch rating must be the same or greater than thecustomer’s premises disconnect and service overcurrent protection.
2. Take necessary steps to assure load is limited tothe capacity of the Ranger® 305D (AU). Loadingabove the rated output will reduce output voltagebelow the allowable -10% of rated voltage whichmay damage appliances or other motor-drivenequipment and may result in overheating of theRanger® 305D (AU) engine.
A-7INSTALLATION
RANGER® 305D (AU)
A-7
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1. Shut the welder off.
2. For electrode Positive, connect the electrodecable from the LN-25 to the "+" terminal of thewelder and work cable to the "-" terminal of thewelder. For electrode Negative, connect the elec-trode cable from the LN-25 to the "-" terminal ofthe welder and work cable to the "+" terminal ofthe welder.
3. Attach the single lead from the front of the LN-25to work using the spring clip at the end of the lead.This is a control lead to supply current to the wirefeeder motor; it does not carry welding current.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELDTERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially andadjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.When not welding, the Ranger® 305D (AU)engine will be at the low idle speed. If you areusing an LN-25 with an internal contactor, theelectrode is not energized until the gun trigger isclosed.
8. When the gun trigger is closed, the current sens-ing circuit will cause the Ranger® 305D (AU)engine to go to the high idle speed, the wire willbegin to feed and the welding process started.When welding is stopped, the engine will revert tolow idle speed after approximately 12 secondsunless welding is resumed.
If you are using an LN-25 without an internal con-tactor, the electrode will be energized when theRanger® 305D (AU) is started.--------------------------------------------------------------------------------
Connection of LN-742, Spool Gun (K487-25) andCobramatic to Ranger® 305D (AU)
• Shut the welder off.
• Connect per instructions on the appropriate connec-tion diagram in Section F.
CAUTION
A-8INSTALLATION
RANGER® 305D (AU)
A-8
CONNECTION OF LINCOLN ELECTRICWIRE FEEDERS
Connection of LN-15 to the Ranger® 305D (AU)
These connections instructions apply to both the LN-15 Across The-Arc and Control Cable models. TheLN-15 has an internal contactor and the electrode isnot energized until the gun trigger is closed. When thegun trigger is closed the wire will begin to feed and thewelding process is started.
• Shut the welder off.
• For electrode Positive, connect the electrode cableto the "+" terminal of the welder and work cable tothe "-" terminal of the welder. For electrodeNegative, connect the electrode cable "-" terminal ofthe welder and work cable to the "+" terminal of thewelder.
• Across The-Arc Model:
Attach the single lead from the front of the LN-15 towork using the spring clip at the end of the lead. Thisis a control lead to supply current to the wire feedermotor; it does not carry welding current.
Set the "WELD TERMINALS" switch to "WELD TER-MINALS ON"
• Control Cable Model:
Connect Control Cable between Engine Welder andFeeder.
Set the "WELD TERMINALS" switch to "REMOTELYCONTROLLED".
• Set the MODE switch to the "CV-WIRE " position.• Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode polaritybeing used.
• Set the "ARC CONTROL" knob to "0" initially andadjust to suit.
• Set the "IDLE" switch to the "AUTO" position.
Connection of the LN-25 to the Ranger® 305D (AU)
Shut off welder before making any electrical con-nections.--------------------------------------------------------------------------------The LN-25 with or without an internal contactor maybe used with the Ranger® 305D (AU). See the appro-priate connection diagram in Section F.
WARNING
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b-1OPERATION
RANGER® 305D (AU)
b-1
SAFETY PRECAUTIONS
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.--------------------------------------------------------------------------------
ELECTRIC SHOCK can kill.• Do not touch electrically live parts or
electrode with skin or wet clothing.• Insulate yourself from work and
ground• Always wear dry insulating gloves.
• Always operate the welder with the hinged doorclosed and the side panels in place.
• Read carefully the Safety Precautions pagebefore operating this machine. Always followthese and any other safety procedures includedin this manual and in the Engine InstructionManual.
GENERAL DESCRIPTION
The Ranger® 305D (AU) is a diesel engine poweredDC multi-process welding power source and 240 voltAC power generator. The engine drives a generatorthat supplies three phase power for the DC weldingcircuit and single phase power for the AC auxiliaryoutlets. The DC welding control system uses state ofthe art Chopper Technology (CT tm) for superior weld-ing performance.
FOR AUXILIARY POWER:Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn.
The auxiliary power of the Ranger® 305D (AU) con-sists of two 15 Amp-240 VAC receptacles. Also referto the AUXILIARY POWER OPERATION section laterin this chapter.
ENGINE OPERATIONBefore Starting the Engine:• Be sure the machine is on a level surface.• Open top & side engine doors and remove the
engine oil dipstick and wipe it with a clean cloth.Reinsert the dipstick and check the level on the dip-stick.
• Add oil (if necessary) to bring the level up to the fullmark. Do not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if nec-essary).
• See Engine Owner’s Manual for specific oil andcoolant recommendations.
ADD FUEL
¥ Stop engine while fueling.¥ Do not smoke when fueling.¥ Keep sparks and flame awayfrom tank.
¥ Do not leave unattended whilefueling.¥ Wipe up spilled fuel and allowfumes to clear before startingengine.
¥ Do not overfill tank, fuelexpansion may cause over-flow.
DIESEL FUEL ONLY-Low sulphur fuel or ultra lowsulphur fuel in U.S.A. and Canada.--------------------------------------------------------------------------------
• Remove the fuel tank cap.
• Fill the tank approximately 4 inches (100mm) fromthe top of the filler neck to allow for fuel expansion .DO NOT FILL THE TANK TO THE POINT OFOVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recom-mendations.
bREAK-IN PERIOD
Any engine will use a small amount of oil during its“break-in” period. For the diesel engine on theRanger® 305D (AU), break-in is about 50 runninghours.
Check the oil every four hours during break-in.Change the oil after the first 50 hours ofoperation,every 100 hours thereafter. Change the oilfilter at the second oil change.
During break-in, subject the Ranger® 305D (AU) tomoderate loads. Avoid long periods running atidle. before stopping the engine, remove all loadsand allow the engine to cool several minutes.--------------------------------------------------------------------------------
WARNING
WARNING
CAUTION
DIESEL FUELcan cause fire.
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FIGURE B.1
FIGURE B.1
b-2OPERATIONb-2
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 weldingmodes. When in the CC-STICK, DOWNHILL PIPEor CV-WIRE modes and when a remote control isconnected to the 6-Pin or 14-Pin Connector, theauto-sensing circuit automatically switches theOUTPUT CONTROL from control at the welder tothe remote control.
In the CV-WIRE mode, when the wire feeder con-trol cable is connected to the 14-Pin Connector, theauto-sensing circuit automatically makes OUTPUTCONTROL inactive and the wire feeder voltagecontrol active.
When in the TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin Connector, theOUTPUT dial is used to set the maximum currentrange of the CURRENT CONTROL of the Amptrol.
2. DIGITAL OUTPUT METERS-The digital
meters allow the output voltage (CV-WIRE mode)or current (CC-STICK,DOWN HILL PIPE and TIGmodes) to be set prior to welding using the OUT-PUT control dial. During welding, the meter dis-play the actual output voltage (VOLTS) and cur-rent (AMPS). A memory feature holds the displayof both meters on for seven seconds after weldingis stopped. This allows the operator to read theactual current and voltage just prior to when weld-ing was ceased.
While the display is being held the left-most deci-mal point in each display will be flashing. Theaccuracy of the meters is +/- 3%.
3. WELD MODE SELECTOR SWITCH-(Provides four selectable welding modes)CV-WIREDOWNHILL PIPECC-STICKTOUCH START TIG
RANGER® 305D (AU)
1
10
7
4
9
5
8
11
12
13
6
15
14
17
16
2
3
FIGURE b.1
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b-3OPERATIONb-3
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 isnot active in the TIG mode.
CC-STICK mode: In this mode, the ARC CONTROL dialsets the short circuit current (arc-force) during stick weldingto adjust for a soft or crisp arc. Increasing the dial from –10(soft) to +10 (crisp) increases the short circuit current andprevents sticking of the electrode to the plate while welding.This can also increase spatter. It is recommended that theARC CONTROL be set to the minimum number withoutelectrode sticking. Start with a setting at 0.
DOWNHILL PIPE mode: In this mode, the ARC CONTROLdial sets the short circuit current (arc-force) during stickwelding to adjust for a soft or a more forceful digging arc(crisp). Increasing the number from –10 (soft) to +10 (crisp)increases the short circuit current which results in a moreforceful digging arc. Typically a forceful digging arc is pre-ferred for root and hot passes. A softer arc is preferred for filland cap passes where weld puddle control and deposition("stacking" of iron) are key to fast travel speeds. It is recom-mended that the ARC CONTROL be set initially at 0.
CV-WIRE mode: In this mode, turning the ARC CONTROLclock wise from –10 (soft) to +10 (crisp) changes the arcfrom soft and washed-in to crisp and narrow. It acts as aninductance/pinch control. The proper setting depends on theprocedure and operator preference. Start with a setting of 0.
5. WELD OUTPUT TERMINALS WITH FLANGENUT- Provides a connection point for the electrode and
work cables.
6. GROUND STUD- Provides a connection point for
connecting the machine case to earth ground.
7. 14-PIN CONNECTOR- For attaching wire feeder con-
trol cables to the Ranger® 305D (AU). Includes contactorclosure circuit, auto-sensing remote control circuit, and120V and 42V power. The remote control circuit operatesthe same as the 6 Pin Amphenol.
8. 6-PIN CONNECTOR- For attaching optional remote
control equipment. Includes auto-sensing remote controlcircuit.
9. WELD TERMINALS CONTROL SWITCH- In the
WELD TERMINALS ON position, the output is electricallyhot all the time. In the REMOTELY CONTROLLED posi-tion, the output is controlled by a wire feeder or amptroldevice, and is electrically off until a remote switch is
depressed.
10. WIRE FEEDER VOLTMETER SWITCH:Matches the polarity of the wire feeder voltmeter tothe polarity of the electrode.
ENGINE CONTROLS: (Figure b.2)
11. RUN/STOP SWITCH - RUN position energizes
the engine prior to starting. STOP position stops theengine. The oil pressure interlock switch preventsbattery drain if the switch is left in the RUN positionand the engine is not operating.
12. GLOW PLUG PUSH bUTTON -
• When pushed activates the glow plugs. Glow plugshould not be activated for more than 20 secondscontinuously.
13. START PUSH bUTTON -
Energizes the starter motor to crank the engine.
14. IDLER SWITCH- Has two positions as follows:
1) In the HIGH position, the engine runs at the highidle speed controlled by the engine governor.
2) In the AUTO position, the idler operates as follows:• When switched from HIGH to AUTO or after starting
the engine, the engine will operate at full speed forapproximately 12 seconds and then go to low idlespeed.
• When the electrode touches the work or power isdrawn for lights or tools (approximately 100 Wattsminimum), the engine accelerates and operates atfull speed.
• When welding ceases or the AC power load isturned off, a fixed time delay of approximately 12seconds starts. If the welding or AC power load isnot restarted before the end of the time delay, theidler reduces the engine speed to low idle speed.
• The engine will automatically return to high idlespeed when there is welding load or AC power loadreapplied.
RANGER® 305D (AU)
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b-4OPERATIONb-4
15. ELECTRIC FUEL GAUGE- The electric fuel
gauge gives accurate and reliable indication as tohow much fuel is in the fuel tank.
16. ENGINE HOUR METER- Displays the total
time that the engine has been running. This meteris useful for scheduling prescribed maintenance.
17. ENGINE PROTECTION LIGHT- A warning
indicator light for Low Oil Pressure and/or CoolantOver Temperature. The light is off when the sys-tems are functioning properly. The light turns onwhen the RUN-STOP switch is in the “ON” posi-tion prior to starting the engine. If the EngineProtection or Battery Charging Lights do “not”turn off shortly after starting the engine shut offthe engine immediately and determine the cause.
AUXILIARY POWER CONTROLS(Items 18-21)
18. CIRCUIT bREAKERSThese circuit breakers provide separate overloadcurrent protection for each 240V receptacles, the42VAC in the 14-Pin connector and battery cir-cuit overload protection.
19. 240 VAC RECEPTACLESThese two 240VAC receptacles provide up to 15amp total rating each and are IP66 rated. Referto the AUXILIARY POWER RECEPTACLESsection in the installation chapter for further infor-mation about these receptacles. Also refer to theAUXILIARY POWER OPERATION section laterin this chapter.
20. RCD:“Residual Current Device” provides protectionfrom active to ground contact.
RCD will not protect against electrical shockresulting from contact with active and neutralwires.
21. VRD INDICATOR LIGHTS:
(Part of Optional VRD Kit)
Indicates OCV voltage across the output termi-nals. Also indicates operation of VRD in CCmode. A Green light indicates OCV below 30Vand a red light indicates OCV above 30V.
During welding both lights will flash, depending onthe type of Consumable being used.
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STARTING THE ENGINE1. Remove all plugs connected to the AC power
receptacles.2. Set IDLER switch to AUTO.3. Set the RUN/STOP switch to RUN.4. Press Glow Plug Button and hold 5 to 10 seconds.5. Press and hold both the “Glow Plug” Button and
START button together until the engine starts or forup to 10 seconds.
6. Release the engine START button immediately
when the engine starts.
7. Release the glow plug button after the EngineProtection Light turns off or after an additional 5seconds maximum.
8. The engine will run at high idle speed for approxi-mately 12 seconds and then drop to low idle speed.Allow the engine to warm up at low idle for severalminutes before applying a load and/or switching tohigh idle. Allow a longer warm up time in coldweather.
NOTE: If the unit fails to start repeat step 4 throughstep 7 after waiting 30 seconds
• Do not allow the starter motor to run continuouslyfor more than 20 seconds.
• Do not push the START button while the engineis running because this can damage the ringgear and/or the starter motor.
• IF the Engine Protection or battery ChargingLights do “not” turn off shortly after starting theengine shut off the engine immediately and determine the cause.
--------------------------------------------------------------------------------
NOTE: When starting a Ranger® 305D (AU) for thefirst time, or after and extended period of time of notoperating, it will take longer than normal because thefuel pump has to fill the fuel system.
STOPPING THE ENGINERemove all welding and auxiliary power loads andallow the engine to run at low idle speed for a fewminutes to cool the engine.
STOP the engine by placing the RUN-STOP switch inthe STOP position.
NOTE: A fuel shut off valve is located on the fuel pre-filter.
WELDER OPERATIONDUTY CYCLE
Duty Cycle is the percentage of time the load is beingapplied in a 10 minute period. For example a 60% dutycycle, represents 6 minutes of load and 4 minutes of no
load in a 10 minute period.
RANGER® 305D (AU)
CAUTION
TYPICAL Ranger® 305D (AU) FUEL CONSUMPTIONKubota D722 Running time for
Gal./Hr (Liters/Hr) 12 gallons-hoursLow Idle - No Load2450 R.P.M. .29 (1.09) 41.77High Idle - No Load3650 R.P.M. .54 (2.06) 22.02DC Weld Output250 Amps @ 28 Volts 1.03 (3.91) 11.62DC Weld Output300 Amps @ 29 Volts 1.18 (4.47) 10.16
7,000 Watts .96 (3.63) 12.50
3,000 Watts .70 (2.67) 17.03
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The Ranger® 305D (AU) can be used with a broad rangeof DC stick electrodes. The MODE switch provides twostick welding settings as follows:
Constant Current (CC-STICK) WeldingThe CC-STICK position of the MODE switch is designedfor horizontal and vertical-up welding with all types ofelectrodes, especially low hydrogen. The output CON-TROL dial adjusts the full output range for stick welding.
The ARC CONTROL dial sets the short circuit current(arc-force) during stick welding to adjust for a soft orcrisp arc. Increasing the number from -10(soft) to+10(crisp) increases the short circuit current and pre-vents sticking of the electrode to the plate while welding.This can also increase spatter. It is recommended thatthe ARC CONTROL be set to the minimum number with-out electrode sticking. Start with the dial set at 0.
DOWNHILL PIPE WeldingThis slope controlled setting is intended for "out-of-posi-tion" and "down hill" pipe welding where the operatorwould like to control the current level by changing the arclength. The output CONTROL dial adjusts the full outputrange for pipe welding. The ARC CONTROL dial sets theshort circuit current (arc-force) during stick welding toadjust for a soft or more forceful digging arc (crisp).Increasing the number from -10(soft) to +10(crisp)increases the short circuit current which results in a moreforceful digging arc.Typically a forceful digging arc is pre-ferred for root and hot passes. A softer arc is preferredfor fill and cap passes where weld puddle control anddeposition (“stacking” of iron) are key to fast travelspeeds. This can also increase spatter.
It is recommended that the ARC CONTROL be set to theminimum number without electrode sticking. Start withthe dial set at 0.
TIG WELDINGThe TOUCH START TIG setting of the MODE switch isfor DC TIG (Tungsten Inert Gas) welding. To initiate aweld, the CONTROL dial is first set to the desired currentand the tungsten is touched to the work. During the timethe tungsten is touching the work there is very little volt-age or current and, in general, no tungsten contamina-tion. Then, the tungsten is gently lifted off the work in arocking motion, which establishes the arc.
When in the TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin connector the OUT-PUT dial is used to set the maximum current range of thecurrent control of the Amptrol.
The ARC CONTROL is not active in the TIG mode. ToSTOP a weld, simply pull the TIG torch away from thework. When the arc voltage reaches approximately 30Volts the arc will go out and the machine will reset thecurrent to the Touch Start level. To reinitiate the arc,retouch the tungsten to the work and lift. Alternatively,the weld can be stopped by releasing the Amptrol or arcstart switch.
The Ranger® 305D (AU) can be used in a wide variety ofDC TIG welding applications. In general the ‘Touch Start’feature allows contamination free starting without the useof a Hi-frequency unit. If desired, the K930-2 TIG Modulecan be used with the Ranger® 305D (AU). The settingsare for reference.
RANGER® 305D (AU)
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES(2)
Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH
Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless SteelTungsten Tungsten
.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #60.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #81/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #103/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-12% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.(3) DCEP is not commonly used in these sizes.(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6 mm)# 5 = 5/16 in. (8 mm)# 6 = 3/8 in. (10 mm)# 7 = 7/16 in. (11 mm)# 8 = _ in. (12.5 mm)#10 = 5/8 in. (16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperaturesand high duty cycles.
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RANGER® 305D (AU)
b-7OPERATIONb-7
Ranger® 305D (AU) settings when using the K930-2TIG Module with an Amptrol or Arc Start Switch:• Set the MODE Switch to the TOUCH START TIG
setting.
• Set the "IDLER" Switch to the "AUTO" position.
• Set the "WELDING TERMINALS" switch to the"REMOTELY CONTROLLED" position. This will keepthe "Solid State" contactor open and provide a "cold"electrode until the Amptrol or Arc Start Switch ispressed.
When using the TIG Module, the OUTPUT control onthe Ranger® 305D (AU) is used to set the maximumrange of the CURRENT CONTROL on the TIG Moduleor an Amptrol if connected to the TIG Module.
WIRE WELDING-CVConnect a wire feeder to the Ranger® 305D (AU)according to the instructions in INSTALLATIONINSTRUCTIONS Section.
The Ranger® 305D (AU) in the CV-WIRE mode, per-mits it to be used with a broad range of flux cored wire(Innershield and Outershield) electrodes and solid wiresfor MIG welding (gas metal arc welding). Welding canbe finely tuned using the ARC CONTROL. Turning theARC CONTROL clockwise from –10 (soft) to +10 (crisp)changes the arc from soft and washed-in to crisp andnarrow. It acts as an inductance/pinch control. Theproper setting depends on the procedure and operatorpreference. Start with the dial set at 0.
Listed below are some wires suitable for use on thismachine:
• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%,NR-212.
• Outershield - 0S-70, 0S-71M, 0S-71 ELITE.• Solid wires for MIG welding - .035 (0.9 mm), and
.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 Distributoror the Lincoln Electric Company for specific wires usedon certain applications with this machine.
ARC GOUGINGThe Ranger® 305D (AU) can be used for limited arcgouging. For optimal performance, set the MODEswitch to CC-STICK and the ARC CONTROL to +10.
Set the OUTPUT CONTROL knob to adjust outputcurrent to the desired level for the gouging electrodebeing used according to the ratings in the followingTable.
Carbon Diameter Current Range (DC, electrode positive)
1/8" 60-90 Amps
5/32" 90-150 Amps
3/16" 200-250 Amps
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AUXILIARY POWER OPERATION:
Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless 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.
The auxiliary power receptacles should only be usedwith three wire grounded type plugs or approved dou-ble insulated tools with two wire plugs.
The current rating of any plug used with the systemmust be at least equal to the current capacity of the
associated receptacle.
NOTE: The 240 V receptacle has two circuits, each ofwhich measure 120 V to neutral but are of oppositepolarities and cannot be paralleled.
Simultaneous Welding and Auxiliary Power LoadsThe above auxiliary power ratings are with no weldingload. Simultaneous welding and power loads arespecified in the following table:
RANGER® 305D (AU)
WeldingOutput-Amps
0100150200250300
Permissible Power-Watts (Unity Power Factor)
72007200560042002300
0
* Each receptacle is limited to 15 amps.
Ranger® 305D (AU) Simultaneous Welding and Power Loads
Ranger® 305D (AU) Extension Cord Length Recommendations(Use the shortest length extension cord possible sized per the following table.)
Current(Amps)
15
VoltageVolts240
Load(Watts)3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Conductor size is based on maximum 2.0% voltage drop.
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C-1ACCESSORIESC-1
FIELD INSTALLED OPTIONS /ACCESSORIES
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERSFor road, off-road and in-plant and yard towing.(For highway use, consult applicable federal, stateand local laws regarding requirements for brakes,lights, fenders, etc.).Order:
K957-1 TrailerK958-1 ball HitchK958-2 Lunette Eye HitchK959-2 Fender & Light KitK965-1 Cable Storage Rack
K1789-1 ROLL CAGE - Gives added damage protection.
K1898-1 SPARK ARRESTOR
K704 ACCESSORY SET - Includes 35 ft. (10m) ofelectrode cable and 30 ft. (9.1m) of work cable, head-shield, work clamp electrode holder. Cables are ratedat 400 amps, 100% duty cycle.
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m)REMOTE CONTROLPortable control provides same dial range as the out-put control on the welder. Has a convenient 6 pin plugfor easy connection to the welder.
K2174-1 COLD WEATHER OPERATIONS KIT-Provides starting aid and enhancement in extremecold weather. Includes radiator grill cover, oil panheater, coolant Lester and all hardware required forinstallation.
K32043-2 VRD VOLTAGE REDUCTION DEVICE KIT-Provides reduced Open Circuit Voltage (OCV) in theCC Stick Weld Mode.
TIG Welding
K1783-9 TIG Torch PTA-26V (25ft.)K963-3 Hand AmptrolK870 Foot Amptrol
KP509 Magnum Parts Kit
Spool Gun
K1692-2 Prince XL Spool Gun (25ft.)
K487-25 Magnum Spool GunK488 Magnum Control Module
K691-10 Input Cable)
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RANGER® 305D (AU)
SAFETY PRECAUTIONS
• Have qualified personnel do all maintenanceand troubleshooting work.
• Turn the engine off before working inside themachine or servicing the engine.
• Remove guards only when necessary toperform maintenance and replace them whenthe maintenance requiring their removal iscomplete. If guards are missing from themachine, obtain replacements from a LincolnDistributor. (See Operating Manual Parts List.)
Read the Safety Precautions in the front of thismanual and in the Engine Owner’s Manual beforeworking on this machine.
Keep all equipment safety guards, covers, anddevices in position and in good repair. Keephands, hair, clothing, and tools away from thegears, fans, and all other moving parts whenstarting, operating, or repairing the equipment.
Routine Maintenance
At the end of each day’s use, refill the fuel tank tominimize moisture condensation in the tank. Runningout of fuel tends to draw dirt into the fuel system.Also, check the crankcase oil level and add oil ifindicated.
WARNINGFREQUENCY
DAILY OR BEFORE STARTING ENGINE
MAINTENANCE REQUIRED • FILL FUEL TANK.• CHECK OIL LEVEL.• CHECK COOLANT LEVEL.• CHECK AIR CLEANER ELE-
MENT AND HOUSING FORDIRTY, LOOSE OR DAMAGEDPARTS.
• CHECK AIR INTAKE HOSEFOR CRACKS OR LOOSECONNECTIONS.
• CHECK AIR INTAKE/EXHAUSTAREAS & RADIATOR FORDIRT. CLEAN AS NECESSARY.
• CHECK ALTERNATOR BELTTENSION AND WEAR.
ITEM MAKE AND PART NUMbER
OIL FILTER KUBOTA 70000-15241
AIR FILTER ELEMENT DONALDSON P822686
FUEL FILTER ELEMENT KUBOTA 15231-43560
BATTERY KUBOTA GROUP 58, 550 CCA
BELT KUBOTA 15881-97011
GLOW PLUGS KUBOTA 16851-65512
INLINE FUEL FILTER KUBOTA 12581-43012
ENGINE MAINTENANCE COMPONENTSKUbOTA D722 DIESEL ENGINE
KUbOTA D722 DIESEL ENGINE
Service IntervalsObserve the following for service and maintenance. The lubricatingoil change intervals listed in the table below are for Classes CF,CEand CD lubricating oils of API classification with a low sulfur fuel inuse. If the CF-4 or CG-4 lubricating oil is used with a high-sulfurfuel, change the lubricating oil at shorter intervals than recommend-ed in the table below depending on the operating condition.
Every 50 hoursEvery 75 hours
Every 100 hours
Every 150 hours
Every 200 hoursEvery 400 hoursEvery 500 hours
Every 1 or 2 monthsEvery 800 hoursEvery 1500 hours
Every 3000 hours
Every 2 years
Check of fuel pipes and clamp bands.Change of engine oil
Inspect/Clean air cleaner elementand Vacuator™ valve.Cleaning of fuel filter.Check the battery electrolyte level.Check the fan belt tightness.Check the radiator and hose clamps.Replacement of oil filter cartridge Check the intake air lines.Replacement of Air Filter element. Replacement of fuel filter element.Cleaning of water jacket (radiatorinterior).
Replacement of fan belt.
Recharging of Battery.Check of valve clearance.Check the fuel injection nozzle injec-tion pressure.Check of injection pump.Check of fuel injector timer.Replacement of batteryReplacement of radiator hoses andclamp band.Replacement of fuel pipes andclamps.Change the radiator coolant.(L.L.C.)Replacement of intake air line.
•
*1
•
*1,*2
*3*3
*3*3
*4
@
@
@@@
@@
@@
@
Intervals Items
IMPORTANT
• These jobs should be done after the first 50 hours of operation.
*1 Air cleaner should be inspected/cleaned more often in dusty conditions thanthe normal conditions.
*2 Follow Service Instructions and Installation Tips for air cleaner inSection D.
*3 Consult your local KUBOTA Dealer for this service.*4 Replace only if necessary.@ All these markings are registered as emission related critical parts by KUB-
OTA in the U.S. EPA nonroad emission regulation. As the engine owner,you are responsible for the performance of the required maintenance onthe according to the above instruction.
Please see Engine Owners Manual for Warranty Statement in detail.
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Engine Oil ChangeDrain the engine oil while the engine is warm toassure rapid and complete draining. It is recommend-ed that each time the oil is changed the oil filter bechanged as well.
• Be sure the unit is off. Disconnect the negative bat-tery cable to ensure safety.
• Locate oil drain hose and valve in bottom of baseand pull through the hole in the battery access panelon the welder.
• Remove the cap from the drain valve. Push valve inand twist counterclockwise. Pull to open and drainthe oil into a suitable container for disposal.
• Close the drain valve by pushing in and twistingclockwise. Replace the cap.
• Re-fill the crankcase to the upper limit mark on thedipstick with the recommended oil (see engine oper-ation manual OR engine service items decal ORbelow). Replace and tighten the oil filler cap secure-ly.
• Push oil drain hose and valve back into unit, re-con-nect negative battery cable, and close doors andengine top cover before restarting unit.Wash yourhands with soap and water after handling usedmotor oil. Please dispose of used motor oil in amanner that is compatible with the environment.We suggest you take it in a sealed container to yourlocal service station or recycling center for reclama-tion. DO NOT throw it in the trash; pour it on theground or down a drain.
Engine Oil Refill capacitiesWithout oil filter replacement: • 3.3 U.S. Quart. (2.7 Imp Quart, 3.2 liter)
With oil filter replacement:• 3.4 U.S. Quart. (3.0 Imp Quart, 3.2 liter)
Use motor oil designed for diesel engines that meetsrequirements for API service classif icationCC/CD/CE/CF/CF-4/CG-4 or CH-4.ACEA E1/E2/E3. Always check the API service labelon the oil container to be sure it includes the lettersindicated. (Note: An S-grade oil must not be used in adiesel engine or damage may result. It IS permissibleto use an oil that meets S and C grade service classifi-cations.)SAE 10W30 is recommended for general, all tempera-ture use, 5F to 104F (-15C to 40C).See engine owner’s manual for more specific informa-tion on oil viscosity recommendations.
Oil Filter Change• Drain the oil.
• Remove the oil filter with an oil filter wrench anddrain the oil into a suitable container. Discard theused filter. Note: Care should be taken during filterremoval to not disrupt or damage in any way the fuellines.
• Clean the filter mounting base and coat the gasketof the new filter with clean engine oil.
• Screw the new filter on by hand until the gasket con-tacts the mounting base. Using an oil filter wrench,tighten the filter an additional 1/2 to 7/8 of a turn.
• Refill the crankcase with the specified amount of therecommended engine oil. Reinstall the oil filler capand tighten securely.
• Start the engine and check for oil filter leaks.
• Stop the engine and check the oil level. If neces-sary, add oil to the upper limit mark on the dipstick.
• Never use gasoline or low flash point solventsfor cleaning the air cleaner element. A fire orexplosion could result.
• Never run the engine without the air cleaner.
Rapid engine wear will result from contaminants,such as dust and dirt being drawn into theengine.
--------------------------------------------------------------------------------AIR CLEANER
The diesel engine is equipped with a dry type air filter.Never apply oil to it. Service the air cleaner as follows:
Replace the element at least every 200 hours ofoperation and sooner under dusty conditions.
RANGER® 305D (AU)
CAUTION
WARNING
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RANGER® 305D (AU)
Unfasten or unlatch theservice cover. Becausethe filter fits tightly over theoutlet tube to create the critical seal, there willbe some initial resistance, similar to breakingthe seal on a jar. Gently move the end of the filterback and forth to break the seal then rotate whilepulling straight out. Avoid knocking the filteragainst the housing.
Remove the FilterRemove the FilterRotate thefilter whilepullingstraight out.If your air cleaner has a safety filter, replace it every third primaryfilter change. Remove the safety filter as you would the primaryfilter. Make sure you cover the air cleaner outlet tube to avoid anyunfiltered contaminant dropping into the engine.
If your air cleaner is equipped with a Vacuator ValveVisually check and physically squeeze to make sure thevalve is flexible and not inverted, damaged or plugged.
Inspect the new filter carefully, paying attention tothe inside of the open end, which is thesealing area. NEVER install a damagedfilter. A new Donaldson radial sealfilter may have a dry lubricant on theseal to aid installation.If you're servicing the safety filter, this should be seated intoposition before installing the primary filter.Insert the new filter carefully. Seat the filter by hand, making certain it iscompletely into the air cleaner housingbefore securing the cover in place.
If the service cover hits the filter before it is fully in place, removethe cover and push the filter (by hand) further into the air cleanerand try again. The cover should go on with no extra force.Once the filter is in place, secure the service cover.
Make sure that all mounting bands, clamps, bolts, and connectionsin the entire air cleaner system are tight. Check for holes in pipingand repair if needed. Any leaks in your intake piping will send dustdirectly to the engine!
The critical sealing area will stretchslightly, adjust itself and distribute the sealing pressure evenly. Tocomplete a tight seal, apply pressure by hand at the outer rim ofthe filter, not the flexible center. (Avoid pushing on the center of theurethane end cap.) No cover pressure is required to hold the seal.NEVER use the service cover to push the filter into place! Using thecover to push the filter in could cause damage to the housing, coverfasteners and will void the warranty.
Visually inspect the old filter for any signsof leaks. A streak of dust on the clean sideof the filter is a telltale sign. Remove anycause of leaks before installing new filter.
Clean Both Surfaces of the Outlet TubeClean Both Surfaces of the Outlet Tubeand Check the Vacuator™ Valveand Check the Vacuator™ Valve
Inspect the OldInspect the OldFilter for Leak CluesFilter for Leak Clues
Inspect the New Filter for DamageInspect the New Filter for Damage
Insert the New Radial Seal Filter ProperlyInsert the New Radial Seal Filter Properly
Check Connectors for Tight FitCheck Connectors for Tight Fit
NEVER use the service cover toNEVER use the service cover topush the filter into place! Usingpush the filter into place! Usingthe cover to push the filter in couldthe cover to push the filter in couldcause damage to the housing, covercause damage to the housing, coverfasteners and will void the warranty.fasteners and will void the warranty.
CautionCaution
Use a clean cloth to wipe the filter sealing surface and the inside ofthe outlet tube. Contaminant on the sealing surface could hinder aneffective seal and cause leakage. Make sure that all contaminant isremoved before the new filter is inserted. Dirt accidently transferredto the inside of the outlet tube will reach the engine and cause wear. Engine manufacturers say that it takes only a few grams ofdirt to "dust" an engine! Be careful not to damage the sealing areaon the tube. Wipe both sidesof the outlettube clean.Outer edge of theoutlet tube Inner edge of theoutlet tube
Service InstructionsService InstructionsSingle- and Two-Stage Engine Air CleanersSingle- and Two-Stage Engine Air Cleaners
Unfasten or unlatch theservice cover. Becausethe filter fits tightly over theoutlet tube to create the critical seal, there willbe some initial resistance, similar to breakingthe seal on a jar. Gently move the end of the filterback and forth to break the seal then rotate whilepulling straight out. Avoid knocking the filteragainst the housing.
Remove the FilterRemove the Filter
Rotate thefilter whilepullingstraight out.
If your air cleaner has a safety filter, replace it every third primaryfilter change. Remove the safety filter as you would the primaryfilter. Make sure you cover the air cleaner outlet tube to avoid anyunfiltered contaminant dropping into the engine.
If your air cleaner is equipped with a Vacuator ValveVisually check and physically squeeze to make sure thevalve is flexible and not inverted, damaged or plugged.
Inspect the new filter carefully, paying attention tothe inside of the open end, which is thesealing area. NEVER install a damagedfilter. A new Donaldson radial sealfilter may have a dry lubricant on theseal to aid installation.
If you're servicing the safety filter, this should be seated intoposition before installing the primary filter.
Insert the new filter carefully. Seat the filter by hand, making certain it iscompletely into the air cleaner housingbefore securing the cover in place.
If the service cover hits the filter before it is fully in place, removethe cover and push the filter (by hand) further into the air cleanerand try again. The cover should go on with no extra force.
Once the filter is in place, secure the service cover.
Make sure that all mounting bands, clamps, bolts, and connectionsin the entire air cleaner system are tight. Check for holes in pipingand repair if needed. Any leaks in your intake piping will send dustdirectly to the engine!
The critical sealing area will stretchslightly, adjust itself and distribute the sealing pressure evenly. Tocomplete a tight seal, apply pressure by hand at the outer rim ofthe filter, not the flexible center. (Avoid pushing on the center of theurethane end cap.) No cover pressure is required to hold the seal.NEVER use the service cover to push the filter into place! Using thecover to push the filter in could cause damage to the housing, coverfasteners and will void the warranty.
Visually inspect the old filter for any signsof leaks. A streak of dust on the clean sideof the filter is a telltale sign. Remove anycause of leaks before installing new filter.
Clean Both Surfaces of the Outlet TubeClean Both Surfaces of the Outlet Tubeand Check the Vacuator™ Valveand Check the Vacuator™ Valve
Inspect the OldInspect the OldFilter for Leak CluesFilter for Leak Clues
Inspect the New Filter for DamageInspect the New Filter for Damage
Insert the New Radial Seal Filter ProperlyInsert the New Radial Seal Filter Properly
Check Connectors for Tight FitCheck Connectors for Tight Fit
NEVER use the service cover toNEVER use the service cover topush the filter into place! Usingpush the filter into place! Usingthe cover to push the filter in couldthe cover to push the filter in couldcause damage to the housing, covercause damage to the housing, coverfasteners and will void the warranty.fasteners and will void the warranty.
CautionCaution
Use a clean cloth to wipe the filter sealing surface and the inside ofthe outlet tube. Contaminant on the sealing surface could hinder aneffective seal and cause leakage. Make sure that all contaminant isremoved before the new filter is inserted. Dirt accidently transferredto the inside of the outlet tube will reach the engine and cause wear. Engine manufacturers say that it takes only a few grams ofdirt to "dust" an engine! Be careful not to damage the sealing areaon the tube.
Wipe both sidesof the outlettube clean.
Outer edge of theoutlet tube
Inner edge of theoutlet tube
Service InstructionsService InstructionsSingle- and Two-Stage Engine Air CleanersSingle- and Two-Stage Engine Air Cleaners
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COOLING SYSTEM
HOT COOLANT can burn skin.
• Do not remove cap if radiator ishot.
------------------------------------------------------------------------Check the coolant level by observing the level in theradiator and recovery bottle. Add 50/50 antifreeze /water solution if the level is close to or below the"LOW" mark. do not fill above the "FULL" mark.Remove radiator cap and add coolant to radiator. Fillup to the top of the tube in the radiator filler neckwhich includes a connecting hose coming from thethermostat housing.
To drain the coolant, open the petcock at the bottomof the radiator. Open the radiator cap to allow com-plete drainage. (Tighten the petcock and refill with a50/50 antifreeze/water solution.) Use an automotivegrade (low silicate) ethylene glycol antifreeze. Thecooling system capacity is 3.85 quarts (3.6L.).Squeeze upper and lower radiator hoses while fillingto bleed air from system coolant. Replace and tightenthe radiator cap.
Always premix the antifreeze and clean tap waterbefore adding to the radiator. It is very importantthat a precise 50/50 solution be used with thisengine year round. This gives proper cooling dur-ing hot weather and freezing protection to -34° F(-37° C).
Cooling solution exceeding 50% ethylene glycolcan result in engine overheating and damage tothe engine. Coolant solution must be premixedbefore adding to radiator.--------------------------------------------------------------------------------
Periodically remove the dirt from the radiator fins.
Periodically check the fan belt and radiator hoses.Replace if signs of deterioration are found.
TIGHTENING THE FAN bELT
If the fan belt is loose, the engine can overheat andthe battery lose its charge. Check tightness by press-ing on the belt midway between the pulleys. It shoulddeflect about .25 in. under a load of 20 lbs. (9 Kg) (6mm).
FUEL
At the end of each day’s use, refill the fuel tank to min-imize moisture condensation and dirt contamination inthe fuel line. Do not overfill; leave room for the fuel toexpand.
Use only fresh, No. 2 grade DIESEL fuel. Do not usekerosene.
See the Engine Operator's Manual for instructions onreplacing the fuel filter.
bLEEDING THE FUEL SYSTEM
You may need to bleed air from the fuel system if thefuel filter or fuel lines have been detached, the fueltank has been ran empty or after periods of long stor-age. It is recommended that the fuel shutoff valve beclosed during periods of non-use.
The Kubota D722 engine supplied with this welder isequipped with an automatic bleeding mechanism thathelps purge the air from the mechanical fuel pumpsystem. It is generally not necessary to open a ventscrew or fuel line fitting to bleed the fuel system.Operate the priming lever on the pump to assist start-ing after extended periods of non-use or out of fuelconditions.
To avoid personal injury, do not bleed a hotengine. This could cause fuel to spill onto a hotexhaust manifold, creating a danger of fire.--------------------------------------------------------------------------------
bleed the fuel system as follows:
1. Fill the fuel tank with fuel.2. Open the fuel shut off valve (vertical position of
handle) on the Fuel Filter.3. Crank the engine by pressing the start button for
45 seconds.4. Check to see that fuel is flowing through both fuel
filters5. Follow the normal STARTING procedures.
RANGER® 305D (AU)
WARNING
CAUTION WARNING
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D-5MAINTENANCED-5
FUEL FILTER1. Check the fuel filter and fuel pre-filter for water
accumulation or sediment.
2. Replace the fuel filter if it is found with excessivewater accumulation or sediment. Empty fuel pre-fil-
ter.
ENGINE ADJUSTMENTAdjustments to the engine are to be made only by aLincoln Service Center or an authorized Field ServiceShop.
bATTERY MAINTENANCETo access the battery, Disconnect the Negative andthen Positive battery cables. Remove the 2 screwsfrom the battery door using a screwdriver or a 3/8"socket. Remove the 2 nuts from the battery bracketusing a 7/16” wrench or socket. Slide the battery outand remove from welder
GASES FROM bATTERY can explode.l Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
l INSTALLING A NEW bATTERY — disconnectnegative cable from old battery first and con-nect to new battery last.
l CONNECTING A bATTERY CHARGER —remove battery from welder by disconnectingnegative cable first, then positive cable andbattery clamp. When reinstalling, connectnegative cable last. Keep well ventilated.
l USING A bOOSTER — connect positive lead tobattery first then connect negative lead to neg-
ative battery lead at engine foot.bATTERY ACID can burn eyes andskin.
l Wear gloves and eye protectionand be careful when working nearbattery.
l Follow instructions printed on battery.
RANGER® 305D (AU)
OVERSPEED IS HAzARDOUSThe maximum allowable high idle speed for thismachine is 3650 RPM, no load. Do NOT tamperwith governor components or setting or make anyother adjustments to increase the maximumspeed. Severe personal injury and damage to themachine can result if operated at speeds abovemaximum.
CLEANING THE bATTERYKeep the battery clean by wiping it with a damp clothwhen dirty. If the terminals appear corroded, discon-nect the battery cables and wash the terminals with anammonia solution or a solution of 1/4 pound (0.1113kg) of baking soda and 1 quart (0.9461) of water. Besure the battery vent plugs (if equipped) are tight sothat none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat-tery compartment, and surrounding areas with clearwater. Coat the battery terminals lightly with petroleumjelly or a non-conductive grease to retard corrosion.Keep the battery clean and dry. Moisture accumula-tion on the battery can lead to more rapid dischargeand early battery failure.
CHECKING THE ELECTROLYTE LEVELIf battery cells are low, fill them to the neck of the fillerhole with distilled water and recharge. If one cell islow, check for leaks.
CHARGING THE bATTERYWhen you charge, jump, replace, or otherwise con-nect battery cables to the battery, be sure the polarityis correct. Improper polarity can damage the chargingcircuit. The Ranger® 305D (AU) positive (+) batteryterminal has a red terminal cover.
If you need to charge the battery with an externalcharger, disconnect the negative cable first, then thepositive cable before you attach the charger leads.After the battery is charged, reconnect the positivebattery cable first and the negative cable last. Failureto do so can result in damage to the internal chargercomponents.
Follow the instructions of the battery charger manu-facturer for proper charger settings and charging time.
SERVICING OPTIONAL SPARKARRESTOR
Clean every 100 hours.
WARNING
WARNING
• MUFFLER MAY bE HOT
• ALLOW ENGINE TO COOL bEFORE INSTALLINGTHE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLINGTHE SPARK ARRESTER!
------------------------------------------------------------------------
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D-6MAINTENANCED-6
RANGER® 305D (AU)
WELDER / GENERATORMAINTENANCE
STORAGE: Store the Ranger® 305D (AU) in clean,
dry protected areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once aweek in particularly dirty areas.
bRUSH REMOVAL AND REPLACEMENT: It’s nor-mal for the brushes and slip rings to wear and darkenslightly. Inspect the brushes when a generator over-haul is necessary.
• Do not attempt to polish slip rings while theengine is running.
WARNING
• Service and Repair should only be performed byLincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equip-ment may result in danger to the technician andmachine operator and will invalidate your factorywarranty. For your safety and to avoid ElectricalShock, please observe all safety notes and pre-cautions.
CAUTION
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E-1TROUbLESHOOTINGE-1
RANGER® 305D (AU)
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNINGAR
C WEL
DING S
UPPLIE
S - 0
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7870
E-2TROUbLESHOOTINGE-2
RANGER® 305D (AU)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Major Physical or Electrical Damageis Evident.
Engine will not "crank".
Engine will "crank" but not start.
Engine shuts down shortly afterstarting.
1. Contact your local LincolnAuthorized Field ServiceFacility.
1. Battery is low, Charge Battery.2. Loose battery cable connections.
Inspect, clean and tighten terminals.3. Faulty engine starter motor.
Contact authorized local EngineService Shop.
1. Fuel shut off valve on Main FuelFilter in the OFF position. Openvalve (vertical) position of handle.
2. Fuel Filters dirty/clogged. Checkand replace main filter elementand/or Inline Fuel Filter.
3. Out of fuel. Fill tank and bleed fuelsystem.
4. High coolant temperature or lowoil pressure. (indictor lights lit)Check oil and coolant levels. Fill ifrequired. Check for loose or bro-ken fan belt.
5. Faulty fuel shutdown solenoid.Check that shutdown solenoid isfunctioning properly and not bind-ing/ contact authorized engineservice shop.
6. Faulty fuel pump. Check for fuelflow through filters. Contact autho-rized local Engine Service Shop.
1. High coolant temperature or lowoil pressure. (indictor light lit)Change oil and oil filters and fill toproper level. Check and fill coolantlevel. Check for loose or brokenfan belt. Start engine and look forleaks.
2. Faulty oil pressure switch or otherengine component. Contactauthorized local Engine ServiceShop.
3. Faulty engine protection relay.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
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E-3TROUbLESHOOTINGE-3
RANGER® 305D (AU)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Engine shuts down while under aload.
Engine runs rough.
Battery does not stay charged.Engine alternator trouble light is onwhile machine is running.
Engine will not idle down to lowspeed.
Engine will not go to high idle whenattempting to weld.
1. High radiator coolant tempera-ture. Reduce load if it is exceed-ing machine rating. Add coolantto system if low. Clean fins onradiator if dirty. Tighten fan belt ifloose. Remove objects blockingor close to intake openings onboth sides of base and exhaustend (case back).
1. Dirty fuel or air filters. Inspect andclean/replace filters as needed.Inspect and clean/replace filtersas needed.
2. Water in fuel. If water found intank. Empty fuel tank and refillthen purge fuel lines.
1. Faulty battery. Replace.2. Loose connections at battery or
alternator. Clean and tighten con-nections.
3. Faulty engine alternator or charg-er module. Consult authorizedEngine Service Shop.
1. Idler switch in High idle position.Set switch to Auto.
2. External load on welder or auxil-iary power. Remove all externalloads.
3. Faulty PC board or idler sole-noid.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Contactor" switch is in wrongposition. Set to "Welding On" whenwelding without a control cable.Refer to Operations chapter for prop-er use of this switch.
3. Faulty PC board. Low idle speedset to low.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
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E-4TROUbLESHOOTINGE-4
RANGER® 305D (AU)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Engine will not go to high idle whenusing auxiliary power.
Engine wil l not go to high idleunder weld or auxiliary loading.
Engine does not develop fullpower. Engine runs rough.
Engine will not go to high idle whenattempting to weld or using auxil-iary power. Switching to manualhigh idle does not work.
Engine will not shut off.
Engine does not develop full power.Low weld and auxil iary output.Engine runs rough.
1. Auxiliary power load is less than100 watts. Idler may not respondwith less than a 100 watt load. Setidler to "High".
2. Faulty PC board.
1. Faulty idler solenoid. Check forbent linkage or broken spring
1. Fuel filter clogged, Replace.2. Air filter clogged, clean or replace.3. High idle setting incorrect, check
and adjust if required.4. Valves out of adjustment.5. Fuel contaminated with water or
sediment. Check fuel pre-filterand empty of water, bleed fuelsystem. Replace fuel in tank ifneeded.
1. Broken spring on Idle Solenoid,solenoid linkage binding, FaultyPC board, low idle speed set toolow on idle solenoid.
1. Fuel Shutdown solenoid notfunctioning properly / linkagebinding. Stop engine by shuttingoff valve located on main fuel fil-ter. Contact authorized localEngine Service Shop.
1. Fuel filter dirty/clogged. Replace.2. Air filter dirty/clogged. Replace
Air Filter Element.3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.4. Fuel contaminated with water.
Check Main Filter Bowl and InlineFuel filters for water. Clean andreplace as needed. Replace fuelin tank.
5. Cracked or loose fuel hose.Replace hose and tightenclamps.
6. Valves out of adjustment. Contactauthorized local Engine ServiceShop.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
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E-5TROUbLESHOOTINGE-5
RANGER® 305D (AU)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAUSE
RECOMMENDEDCOURSE OF ACTION
No welding power output.
Welder has output but no control.
Wire feeder does not work whencontrol cable is connected to 14 pinconnector.
No auxiliary power.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Weld Terminals" switch in wrongposition. Place switch in "WeldTerminals On" posit ion whenwelding 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.
2. Faulty remote cable or faulty wirefeeder or wire feeder cable.Replace if necessary.
3. Faulty control potentiometer or PCboard.
1. Wire Feeder Power circuit breakeropen. Check 42V beakers andreset if tripped.
2. Faulty control cable. Repair orreplace cable.
3. Faulty wire feeder. Replace wirefeeder.
1. Open circuit breakers. Resetbreakers. If breakers keep trip-ping, reduce power draw.
2. Faulty connections to auxiliaryreceptacles. Check connections.
3. Faulty PC board or welder alterna-tor.
4. Check RCD for proper operation.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
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E-6TROUbLESHOOTINGE-6
RANGER® 305D (AU)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PRObLEMS(SYMPTOMS)
POSSIbLE CAUSE
RECOMMENDEDCOURSE OF ACTION
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.
1. Make sure the MODE selectorswitch is in the correct position forthe process being used. (For exam-ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,voltage, current etc.) is correct forthe process being used.
3. Check for loose or faulty connec-tions at the weld output terminalsand welding cable connections.
4. The welding cables may be too longor coiled, causing an excessivevoltage drop. If all recommended possible areas of
misadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
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F-1DIAGRAMSF-1
RANGER® 305D (AU)
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F-2DIAGRAMSF-2
RANGER® 305D (AU)
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F-3DIAGRAMSF-3
RANGER® 305D (AU)
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F-4DIAGRAMSF-4
RANGER® 305D (AU)
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F-5DIAGRAMSF-5
RANGER® 305D (AU)
or service this equipment.
Only qualified personnel should install,use
Keep away from moving parts.
Keep guards in place.
MOVING PARTS can injure
WARNING
Do not touch electrically live parts.
before servicing.
Disconnect NEGATIVE (-) Battery lead
Do not operate with panels open.
ELECTRIC SHOCK can kill
14 PIN AMPHENOL
TO WORK
+_ENGINE WELDERS /LN-8 CONNECTION DIAGRAM
S24787-64-14-2000
TO LN-8 INPUT
CABLE PLUG
ELECTRODE CABLE
TO WIRE FEED UNIT
CAUTION: ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET
AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.
K595 CONTROL CABLE
or s
ervi
ce th
is e
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stal
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befo
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DES
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F-6DIAGRAMSF-6
RANGER® 305D (AU)
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F-7DIAGRAMSF-7
RANGER® 305D (AU)
AR
C WEL
DING S
UPPLIE
S - 0
7 847
7870
F-8DIAGRAMSF-8
RANGER® 305D (AU)
2
9/03
2
9/03
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F-9DIAGRAMSF-9
RANGER® 305D (AU)
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F-10DIAGRAMSF-10
RANGER® 305D (AU)
NO
TE
:T
his
dia
gra
m is for
refe
rence o
nly
. It m
ay n
ot
be a
ccura
te f
or
all
machin
es c
overe
d b
y t
his
manual.
The s
pe
cific
dia
gra
m f
or
a p
art
icu
lar
co
de
is p
aste
d in
sid
e t
he
machin
e o
n o
ne o
f th
e e
nclo
sure
panels
. If th
e d
iagra
m is ille
gib
le,
write
to t
he S
erv
ice D
epart
ment
for
a r
epla
cem
en
t.
Giv
e t
he
eq
uip
me
nt
co
de
nu
mb
er.
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F-11DIMENSION PRINTF-11
RANGER® 305D (AU)
M20334 B
21.0 6 534. 9
51.20 1300.5
17.50 444.5 19.50 495.3
35. 77 908.4
29.83 757. 634.24 869.8
CIRCUIT BREAKERS
1326.4 52.00 1320 .829.0 0 736. 6
11.3 0 287. 0
21.50 546. 1
CENTER OF GRAVIT Y
NOTE: CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES.
29.57 751. 0 26.64 676.7
11.03 280.2 6.33 160.9
M203
34 B
21.0
653
4.9
51.2
013
00.5
17.5
044
4.5
19.5
049
5.3
35. 7
790
8.4
29.8
375
7.6
34.2
486
9.8
CIRCU
ITBR
EAKE
RS
1326
.4
52.0
013
20.8
29.0
073
6.6
11.3
028
7.0
21.5
054
6.1
CENT
ER O
F GR
AVIT
Y
NOTE
: CAS
E FR
ONT
GRAP
HICS
MAY
NOT
MAT
CH A
LL C
ODES
.
29.5
775
1.0 26.6
467
6.7
11.0
328
0.2 6.
3316
0.9
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NOTES
RANGER® 305D (AU)
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NOTES
RANGER® 305D (AU)
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WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THECONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DEESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SUSUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENTET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTREEMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERSSIND EBENFALLS ZU BEACHTEN.
• Do not touch electrically live parts orelectrode with skin or wet clothing.
• Insulate yourself from work andground.
• No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
• Aislese del trabajo y de la tierra.
• Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
• Isolez-vous du travail et de la terre.
• Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
• Isolieren Sie sich von denElektroden und dem Erdboden!
• Não toque partes elétricas e electro-dos com a pele ou roupa molhada.
• Isole-se da peça e terra.
• Keep flammable materials away.
• Mantenga el material combustiblefuera del área de trabajo.
• Gardez à l’écart de tout matérielinflammable.
• Entfernen Sie brennbarres Material!
• Mantenha inflamáveis bem guarda-dos.
• Wear eye, ear and body protection.
• Protéjase los ojos, los oídos y elcuerpo.
• Protégez vos yeux, vos oreilles etvotre corps.
• Tragen Sie Augen-, Ohren- und Kör-perschutz!
• Use proteção para a vista, ouvido ecorpo.
ARC W
ELDIN
G SUPP
LIES
- 07 8
47 78
70
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
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LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTESDE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Keep your head out of fumes.• Use ventilation or exhaust toremove fumes from breathing zone.
• Los humos fuera de la zona de res-piración.
• Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
• Gardez la tête à l’écart des fumées.• Utilisez un ventilateur ou un aspira-teur pour ôter les fumées des zonesde travail.
• Vermeiden Sie das Einatmen vonSchweibrauch!
• Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
• Mantenha seu rosto da fumaça.• Use ventilação e exhaustão pararemover fumo da zona respiratória.
• Turn power off before servicing.
• Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
• Débranchez le courant avant l’entre-tien.
• Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öffnen;Maschine anhalten!)
• Não opere com as tampas removidas.• Desligue a corrente antes de fazerserviço.
• Não toque as partes elétricas nuas.
• Do not operate with panel open orguards off.
• No operar con panel abierto oguardas quitadas.
• N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
• Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
• Mantenha-se afastado das partesmoventes.
• Não opere com os paineis abertosou guardas removidas.
ARC W
ELDIN
G SUPP
LIES
- 07 8
47 78
70
• 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
• World's Leader in Welding and Cutting Products •
ARC W
ELDIN
G SUPP
LIES
- 07 8
47 78
70