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IM836-B
May, 2007
Ranger 305D
For use with machines having Code Numbers: 11121, 11188, 11275
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.
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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 and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque dʼincendie dû aux étincelles. générales su
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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! CUSTOMER ASSISTANCE POLICY The 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 Linco
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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 vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Maintenance Components ........................................................................D-1 Kubota Die
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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 (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
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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 (698 lbs. less WARNING fuel). A lift bail is mounted to the machine and should always be used when lifting the machine. Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes WARNING important safety precautions, detailed engine • Lift only with equipment of ade- starting, operating an
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A-3 A-3 INSTALLATION PRE-OPERATION ENGINE SERVICE TOWING READ the engine operating and maintenance instruc- The recommended trailer for use with this equipment for road, tions supplied with this machine. in-plant and yard towing by a vehicle(1) is Lincolnʼs K957-1. If the user adapts a non-Lincoln trailer, he must assume responsi- WARNING bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of • Stop engine and allow to cool
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A-4 A-4 INSTALLATION REMOTE CONTROL ENGINE COOLING SYSTEM The RANGER 305D is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connect- WARNING ing the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-3 hand Air to cool the engine is drawn in the base sides Amptrol. When in the CC-STICK, DOWNHILL PIPE, and exhaust through radiator & case back. It is or CV-WIRE modes and when a remote control is important that the intake and exhaust air
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A-5 A-5 INSTALLATION When this welder is mounted on a truck or trailer, its CABLE INSTALLATION frame must be electrically bonded to the metal frame Install the welding cables to your RANGER 305D as of the vehicle. Use a #8 or larger copper wire connect- follows. ed between the machine grounding stud and the frame of the vehicle. When this engine driven welder 1. The engine must be OFF to install welding cables. is connected to premises wiring such as that in a home or shop, its frame must b
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A-6 A-6 INSTALLATION AUXILIARY POWER RECEPTACLES • Install the double-pole, double-throw switch between the power company meter and the premis- es disconnect. Switch rating must be the same or Start the engine and set the “IDLER” control switch to greater than the customerʼs premises disconnect the “High Idle” mode. Voltage is now correct at the and service over current protection. receptacles for auxiliary power. This must be done before a tripped GFCI receptacle can be reset prop- • Take ne
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A-7 A-7 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
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A-8 A-8 INSTALLATION • Across The-Arc Model: CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder Connection of LN-7 or LN-8 to the RANGER 305D motor; it does not carry welding current. • 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 d
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A-9 A-9 INSTALLATION Connection of LN-742, Spool Gun (K487-25) and Connection of the LN-25 to the RANGER 305D Cobramatic to RANGER 305D WARNING • Shut the welder off. Shut off welder before making any electrical con- • Connect per instructions on the appropriate connec- nections. tion diagram in Section F. ------------------------------------------------------------------------ The LN-25 with or without an internal contactor may Connection of PRINCE XL SPOOL GUN to the be used with the RANGER
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B-1 B-1 OPERATION • Add oil (if necessary) to bring the level up to the full SAFETY PRECAUTIONS mark. Do not overfill. Close engine door. • Check radiator for proper coolant level. (Fill if nec- WARNING essary). • See Engine Ownerʼs Manual for specific oil and Do not attempt to use this equipment until you coolant recommendations. have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes ADD FUEL important safety precautions, detailed engine starting, operat
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B-2 B-2 OPERATION 16 1 15 14 2 17 13 3 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,DOWN HILL PIPE and TIG 1. OUTPUT CONTROL- The OUTPUT dial is modes) to be set prior to welding using the OUT- used to preset the output voltage or current as dis- PUT control dial. During welding, the meter dis- played on the digital meters for the four welding play the actual output voltage
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B-3 B-3 OPERATION 10. WIRE FEEDER VOLTMETER SWITCH: 4. ARC CONTROL- The ARC CONTROL dial is active in Matches the polarity of the wire feeder voltmeter to the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, the polarity of the electrode. and has different functions in these modes. This control is not active in the TIG mode. 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.
