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IM730
August, 2004
Ranger 305 D
For use with machines having Code Numbers: 10926
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Location and Ventilation................................................
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vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Maintenance Components ........................................................................D-1 Kubota Diesel
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (cu. cm.) System 3 cylinder 43.88(789) 12VDC Battery & Fuel: 12 gal. 4 stroke starter 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
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A-2 A-2 INSTALLATION LIFTING SAFETY PRECAUTIONS The RANGER 305D weighs approximately 775lbs.(352kg.) with a full tank of fuel. A lift bail is WARNING mounted to the machine and should always be used Do not attempt to use this equipment until you when lifting the machine. have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes WARNING important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. � Lift only
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A-3 A-3 INSTALLATION The oil change interval is dependent on the quality of TOWING the oil and the operating environment. Refer to the The recommended trailer for use with this equipment for road, Engine Operator’s Manual for more details on the in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. If the user adapts a non-Lincoln trailer, he must assume responsi- proper service and maintenance intervals. bility that the method of attachment and usage does not result in a safety hazar
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A-4 A-4 INSTALLATION To prevent dangerous electric shock, other equipment SPARK ARRESTER to which this engine driven welder supplies power Some federal, state or local laws may require that must be grounded to the frame of the welder using a gasoline or diesel engines be equipped with exhaust grounded type plug or be double insulated. spark arresters when they are operated in certain locations where unarrested sparks may present a fire When this welder is mounted on a truck or trailer, its ha
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A-5 A-5 INSTALLATION TABLE A-1 The 240 VAC output can be split to provide two sepa- rate 120 VAC outputs with a max permissible current TOTAL COMBINED LENGTH OF of 44 Amps per output to two separate 120 VAC ELECTRODE AND WORK CABLES branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated Cable Size for capacity. Cable Length 305 Amps 100% Duty Cycle The 120 V auxiliary power receptacles should only be 1 / 0 AWG 0-100Ft. (0-30meters)
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A-6 A-6 INSTALLATION CONNECTION OF RANGER 305D TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 50AMP PROTECTION 240 VOLT DOUBLE POLE 50 AMP, 120/240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14-50 GND N 50 AMP, 120/240 VOLT NOTE: No. 6 COPPE
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A-7 A-7 INSTALLATION � Control Cable Model: CONNECTION OF LINCOLN ELECTRIC Connect Control Cable between Engine Welder and WIRE FEEDERS Feeder. � Set the MODE switch to the "CV-WIRE " position. Connection of LN-7 or LN-8 to the RANGER 305D � Across-The-Arc Model: � Shut the welder off. Set the "WELD TERMINALS" switch to "WELD TER- MINALS ON" � Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. Control Cable Model: Set the "WELD TERMINALS" switch to "
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A-8 A-8 INSTALLATION Connection of PRINCE XL SPOOL GUN to the WARNING Ranger 305D Connection of the LN-25 to the RANGER 305D Connection of the Prince XL Spool Gun requires the Shut off welder before making any electrical con- use of the K1849-1 Adapter Module. nections. ------------------------------------------------------------------------ � Shut the Welder off. The LN-25 with or without an internal contactor may be used with the RANGER 305D. See the appropriate � For electrode Positive, co
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B-1 B-1 OPERATION ADD FUEL SAFETY PRECAUTIONS � Remove the fuel tank cap. � Fill the tank approximately 4 inches (100mm) from the top WARNING of the filler neck to allow for fuel expansion (observe the fuel gauge while filling). DO NOT FILL THE TANK TO THE POINT OF OVERFLOW. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual sup- � Replace the fuel cap and tighten securely. plied with your welder. It includes important safety pre- � See Engine Ow
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B-2 B-2 OPERATION 16 1 15 14 2 17 3 13 12 11 4 10 9 8 7 5 FIGURE B.1 6 WELDING CONTROLS (Figure B.1) 2. DIGITAL OUTPUT METERS The digital meters allow the output voltage (CV-WIRE mode) or current (CC-STICK, PIPE and TIG modes) 1. OUTPUT CONTROL: The OUTPUT dial is to be set prior to welding using the OUTPUT control used to preset the output voltage or current as dis- dial. During welding, the meter display the actual out- played on the digital meters for the four welding put voltage (VOLTS) and
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B-3 B-3 OPERATION 10. WIRE FEEDER VOLTMETER SWITCH: 4. ARC CONTROL: The ARC CONTROL dial is Matches the polarity of the wire feeder voltmeter to active in the CV-WIRE, CC-STICK and DOWNHILL PIPE the polarity of the electrode. modes, and has different functions in these modes. This control is not active in the TIG mode. ENGINE CONTROLS: (Figure B.2) CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc.
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B-4 B-4 OPERATION 8. The engine will run at high idle speed for approxi- 15. ENGINE ALTERNATOR TROUBLE mately 12 seconds and then drop to low idle speed. LIGHT-The engine alternator light is off when battery Allow the engine to warm up at low idle for several charging system is functioning normally. If light turns minutes before applying a load and/or switching to on, the alternator or the voltage regulator may not be high idle. Allow a longer warm up time in cold operating correctly. The light
