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Lincoln Electric IM837-A User's Manual

1. G DIAGRAMS K 43 Je DESCH TOMAS ORY TE EE 3 enc F 6 3000 AVA9VIQ Vlog 39 0906 d39NV3 RANGER 305D CE LINCOLN E 7 Jequunu epoo 1u uudinb eu e 40 94 si eu j sjeued y Jo euo UO y pejsed si epoo sejnomed Aq 40 eq jou AjUO 10 SI SIUL 310 WOW NMOHS SLN3NOdWO9 3SVO TV NOLLHASNI AMAIA SHO 15913 H3d STOBIAS Enhanced Diagram DIAGRAMS F 7 78 1109 T1Nd
2. 2 04 WO NMOHS SINSNOdWOO 1NOH3 3SVO TV NOLLHASNI WOH4 SHO193NNOO LES13 H3d STOBIAS IWOIHIO3TH e 10 SI 4141 310 la 4 21 MOTISA M N33u9 5 31IHM M HO AVHO 3OV18 8 3900 80109 8 at 504 NE IS Kg mors B NOUWNIWW HL OL G3123NNOO es ES 92 1 D w n uogoejoid 002 H30N3S BNA va 3 kf HHOM KEEN THOM RE URS ovast ONY OVAL CBS LON ZE ONY SQV3 ON 133130SN NO MAYOS OND 801 T cawassy e FBI SSVdAB ii SI lt 104 1N09 118170 iH Ka 6 2 lt o 7I1OHINOO ZY z WNINYAL 0319907 HOLIMS uo193T3s 300 9S 3ungasaN qva O3SN LON OYN
3. ue ee geng ALIAVHO 10 YALNAO g oc O 1 F Hea 1 959 1 M S s d 59 7 1968 La 6ccl Rt Le 09 5 RANGER 3050 LINCOLN 5 5 RANGER 3050 LINCOLN 5 5 RANGER 3050 LINCOLN 5 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ELE EE LATE e J T p gt 7 E NTWSHRELTFSU e E BASURA TERRE RR ER 9 amp C EUREN T PETER ecran 2488 RE EE nisle e Su AXE HSA olla Aral slay ay icy A et w l lala AA Jai P dua ule Vile e Keep flammable mat
4. eee B 1 Breakin DEE B 1 Add Fue tie EIE B 1 gi ee B 1 Weller Controlsisi cT B 2 Engine Controls sisi 3 Starting and Stopping the Engine B 3 B4 SLOP PING EE Welding Operation Duty ee EE Constant Current Stick Welding ss B 5 Downhill Pipe Stick Welding B 5 JI pm B 5 Typical Current Ranges for Tungsten Electrodes B 5 Wire Welding GV cies ss ner ide pe tr e epe o E EE a ne B 6 le Su Ed B 6 Auxiliary Ge TEE B 6 LcrrIgQrpme T Section C Field Installed Options Accessories sse C 1 XI TABLE OF CONTENTS 2 Section 0 Safety Precautions iii D 1 Houtine Maint nance acierto one D 1 Engine Maintenance Components eee D 1 Kubota Diesel Ee ahi D 1 Engine Oil Change ie D 2 Engine Oil Refill D 2 Engine Oil Filter Change D 2 Alr Cleaner Servio avi a Ee ee D 2 Service Instructions And Installation Tips for Engine Air Filter D 3 Gooling SYST ME D 4 pcs D 4 PUGH A
5. 3HL 803 ALIO VdV9 s3dOsd dO 38 LSAN 3 18 V9 9NIQT3M 51972 3404191 MHOMOL m OL qvaldro AYOM 4305953 ALOWSY 0 1584 Nid 9 jueuudinbo sjy 8911498 10 sued 100 esn ejsui jouuosiod e 210 8 q sued eme e pee Meyeg JAILVDAN 109 0 02510 e 9989 ui deay e uedo sjaued jou ONINHVM V TOYLNOD 3 1038 2987 IVNOILdO NOILO3NNOO JHL 5504 S N T S33Q0 13M 3NI9N3 RANGER 305D CE LINCOLN E DIAGRAMS 2 2 DNK 0002 1201 0341510 SV NOILISOd 3101 HOI HO OLAV NI HOLIMS 39 Id NOLLISOd S IVNIIWS3L OM JHL NI HOLIMS S IVNIIWS2 L 9NIQT2M SOV ON NOILISOd SHL NI HOLIMS 30914 318V2 300319313 AHL 30 ALIHV 10d AHL HOLVIN OL HOLIMS YALSWLIOA 830334 AHL NOILISOd 0341530 50015 LNdLNO OL S318V9 LO3NNOO ON TWANVW 9NILV33dO 33 380 1613 ANY ALVICANWI dO 31949 ALNG CNV 1 JHL ALIOVaVO H3dOsld 10 38 LSNW 58 318v9 30041931 MYOM OL MOM V31dl O 430933 38IM SON TOYLNOO SLOWS TYNOILdO
6. Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end W which is the sealing area NEVER install a damaged filter When the filter in is place put the service cover back on making sure the Vacuator Valve points down Inspect the Vacuator Valve for cracks or dust hang ups to insure that it is functioning properly Re fasten the latches Check Connections for Tight Fit Make sure that all clamps bolts and connections in the entire air intake system are tight Check for holes in piping and repair if needed Insert the New RadialSeal Filter by Hand Insert carefully Seat the new filter by hand making certain it is completely into the air cleaner housing before latching the cover in place If the cover hits the filter before it is fully in place remove the cover and push by hand the filter further into the air cleaner and try again The cover should go on with no extra force Never use the latches on the cover to force the filter into the air cleaner It is tempting to assume the cover will do the job of seating the filter but it will not Using the latches to push the filter in could cause damage to the housing and will void the warranty RANGER 305D CE LINCOLN 5 D 4 COOLING SYSTEM A WARNING t 2 HOT COOLANT can burn skin Do not remove cap if radiator 15 hot Check the coolant level by o
7. ee D 4 Bleeding the Fuel System D 4 en D 5 Engine 5 ss D 5 Battery Maintenance mua Bee E D 5 Servicing Optional Spark Arrestor sse D 5 Welder Generator Maintenance enne D 6 eir ze TS D 6 erem D 6 Brush Removal and Replacement D 6 Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 Diagrams and Dimension Print ss Section F Parts ELEME a lun u P494 xi A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS RANGER 305D CE INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities cu in cu cm System 43 88 789 12VDC Battery amp Fuel starter 45L 12 US gal 12 KW High Idle 3100 Bore x Stroke inch mm Oil Net intermittent 3 2L 3 4 US Qts 3000 RPM Full Load 3000 2 64 x 2 68 Group 58 550 Radiator Coolant naturally aspirated 67 68 cold crank amps 3 61 3 85 U Qts 3 cylinder 4 stroke 15 9 HP water cooled Low Idle 2200 Battery Charger Diesel engine 3 6L RATED OUTPUT 40 C 104 F WELDER Current Voltage Duty Cycle Rated Load RPM DC Constant Current 250A 30V 100 20 TO 305 AMPS DC Pipe Current 250A 30V 100 40 TO 300 AMPS Touch Start TIG 250A 20V 10096 20 TO 250 AMPS 60 Volts DC Consta
8. ONILLAS 3NION3 4101 HOIH SHL dO 3SV3SHONI Q333 OL 11890 300819313 MYOM OL 318 0 01 6181 318v9 1 lt TONSHdNV INdNI 27Z N1 OL jueuudinbe siy ea ues 10 syed Aj eouioe e uonoj jou oqe esn j ejsui pinous jeuuosied eJojeq sued Aeme FAILVOAN 12euuoosig e ui uedo sjeued ag eco jou oq e sinful ue S1HVd ONIAOW UE9 HOOHS 9141911 ONINHVM WV CtZ N 1 SH3Q0713M ANISNA RANGER 3050 CE LINCOLN E DIAGRAMS F 4 F 4 6 282725 0341530 Sv NOILISOd J101 HOH OLAV NI HOLIMS 414101 JOVId NOILISOd IONLNOO SLOWSY NI HOLIMS TOHINOO LNdLNO 39V 1d NOILISOd 911 SHL NI HOLIMS AHL 3914 10d 934 534 403 sanas LAdLNO OL 511490 LO3NNOO INVI ONT 335 ANY ALVIGSNA dO 319A9 ANY 2 3H1 803 ALIOD Va vo Y3dO Hd dO 38 LSNW S318V9 9NIQT3A ONILVH340 3NION3 3157 SNOILVOISIOSdS 3AO8V 151 LON 00 AHO10Vd JHL LV 138 SI ONILL3S 9 1041400 JHL NYO HOIHM AOVLIOA 830333 OV 3H L NI 3SV3SONI NV 3envo JOVMNIT3
9. 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 you have 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 Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page INStAN ATION E Section A Technical 5 EE A 1 E TEE A 2
10. Nid 9 jueuudinbe siy 89IMSS 10 esn jejsui pinous peyijenb e syed wo deey e ui ONINHVM V 1 310138 IWNOILdO sued uonoj jou Buraas 91094 pee eg JALLVON e uedo sjaued jou NOLL23NNOO 3H1 5504 S N T SH3Q 13M 3NION3 RANGER 305D CE LINCOLN E DIAGRAMS F 3 F 3 18 9705 9 5 SV NOILISOd 7101 HO OLAV HOLIMS 3 IGI 39V NOILISOd GATIOUNLNOSD OL HOLIMS STVNINYAL 0 OM 39 1 NOILISOd JHL HOLIMS SGOW 39V Id d18v5 30041933 dO JHL OL HOLIMS YALAWLIOA 830333 NOILISOd Q38IS3G 58715 LAdLNO OL 318v9 L93NNOO N NV 9 33 CNOU VT Vd 39113 ANY 3 dO 319A9 ANY JHL 8043 ALIO VaVO dO 38 LSNW S318V9 SNIQT3M ON VN V NV ONILVYSdO 830 13M JHL NI Q31STT SNOILV2I3IO3dS 5 LON OG AYOL Y4 LV 138 SI ONILLAS HONS3AO9 3NION3 JHL HOIHM 830334 38IM OV NI 3SV3SONI NV ASNVO TIM 39 VXNET 31LLOSHL JHL ONIGINYSAO
11. Please see Engine Owners Manual for Warranty Statement in detail RANGER 305D CE LINCOLN 5 D 2 ENGINE OIL CHANGE gt Drain the engine oil while the engine is warm to assure rapid and complete draining It is recommend ed that each time the oil is changed the oil filter be changed 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 base and pull through the hole in the battery access panel on the welder Remove the cap from the drain valve Push valve in and twist counterclockwise Pull to open and drain the oil into a suitable container for disposal Close the drain valve by pushing in and twisting clockwise Replace the cap Re fill the crankcase to the upper limit mark on the dipstick with the recommended oil see engine oper ation manual OR engine service items decal OR below 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 and engine top cover before restarting unit Wash your hands with soap and water after handling used motor oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclama tion DO NOT throw it in the trash pour it on the ground or down drain ENGINE OIL REFILL CAPA
12. GION310S GIONSHOS TANS EI OVNI TV soma SIN3NOdWOO HOT MS E 31428 77 84 15 MOTISA M N33H9 O SLIHM M HO Aug HO MOV 18 8 3900 40109 ava1 NO OND uopoung isz TOULNOD OLD NENMOHS XE 3HLOL OL G3123NNOO HSB 3ALISOd 8 302 u3qN3S una aioWad RE RIBERY KI d op nre ad RH CH 1 9 0 KETTER OH ovner ovast 5 SONS vos LON ONY I LON s x ap BVO 1431301SNI NO dOL 3onvo ER ane kee SEET 32 7 96 8455 6 2 i lt IOH1INOO 24 wNINHSL 0319001
13. Faulty PC board Low idle speed set to low CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305D CE LINCOLN 5 Engine will not go to high idle under weld or auxiliary loading Engine does not develop full power Engine runs rough Engine will not go to high idle when attempting to weld or using auxil iary power Switching to manual high idle does not work Engine will not shut off Engine does not develop full power Low weld and auxiliary output Engine runs rough TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Engine will not go to high idle when using auxiliary power 1 Auxiliary power load is less than 100 watts Idler may not respond with less than a 100 watt load Set idler to High 2 Faulty PC board 1 Faulty idler solenoid Check for bent 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 filter and empty of water bleed fuel system Replace fuel in tank if needed 1 Broken spring on Idle
14. UNIES QN WN INL LON HOLYLS LON qawassv FBI NOILISOd 3ALLISOd NI NMOHS r p HOLIMS ol uuviOd H313WLTOA 95 0 0902 HOLIMS 9S 43411934390149 39 Hd LO bag o q 8902 00 AWOS 1NnHS ES 1 590 DI aed 2 GALSIML 68111 3009 404 AVHOVIQ 9NISIM YLONA 32 0606 YAONVY RANGER 3050 LINCOLN E 8 Diagram DIAGRAMS F 8 epoo 1u uudinb SAID e 104 eui 0 e qiDej s sjeued y JO euo UO euiuoeu pejsed si epoo e siy Aq 40 eq jou Aew 10 S SIUL 310 08 1102 11d AVT NOR OMT A NAD ATAOdINOS NOH L7SVC TV MANEN Rief OND OS ASIA ITA ZA S
15. of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Scloctive screening and shiclding of other cables and cquipment in the surrounding arca may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN50199 Electromagnetic Compatibility EMC product standard for arc welding equipment 3 1 96H L10093 RANGER 305D CE LINCOLN 5 ix ix for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product 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 is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number
16. 8500 watts Peak 8 000 Watts Continuous of 50 Hz three phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The max permissible current of the 400 VAC output is 20 amps Output voltage is within 10 at all loads up to the rated capacity STANDBY POWER CONNECTIONS The machine is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The machine can be permanently installed as a standby power unit for 400 VAC three phase 20 amp service Connections must be made by a licensed electrician who can determine how the power can be adapted to the particular installation and comply with all applica ble electrical codes Take necessary steps to assure load is limited to the capacity of the RANGER 305D CE A WARNING Only a licensed certified trained electrician should install the machine to a premises or resi dential electrical system Be certain that RANGER 305D CE LINCOLN 5 6 The installation complies with the National Electrical Code and all other applicable electri cal codes The premises is isolated and no feedback into the utility system can occur Certain laws require the premises to be isolated before the generator is linked to the premises Check your local requirements CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN 15 to the Ranger 305D These connecti
17. API classification with a low sulfur fuel in use If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter intervals than recommend ed in the table below depending on the operating condition Items Every 50 hours Check of fuel lines and clamp bands Every 75 hours Change of engine oil very 100 hours Inspect Clean air cleaner element and Vacuator valve Cleaning of fuel filter Every 150 hours Replacement of Air Filter element 15 Replacement of fuel filter element Every 500 hours Removal of of sediment in fuel tank Cleaning of water jacket radiator interior Replacement of fan belt Recharging of Battery Check of valve clearance Check the fuel injection nozzle injec tion pressure Every 3000 hours Check of injection pump Check of fuel injector timer very 2 years Replacement of battery Replacement of radiator hoses and clamp band Replacement of fuel pipes and clamps Change the radiator coolant L L C IMPORTANT These jobs should be done after the first 50 hours of operation 71 Air cleaner should be inspected cleaned more often in dusty conditions than the normal conditions 2 Follow Service Instructions and Installation Tips for air cleaner in Section D 3 Consult your local KUBOTA Dealer for this service 4 Replace only if necessary Every 1 or 2 months Every 800 hours 3 Every 1500 hours al a
18. NOLVIS LON NOILISOd 3ALLISOd NI NMOHS p v80z HOLIMS 2IALIHVIOd H3I3WLTOA 95 vam rj ose D 0902 9 o Do 11 uoivis L v90c 9902 saw o ANNHS n Svoz 5902 35311038 390188 338HL LO 06 3002 3103 3d0303 WVYOVIC 9NIMHIM 39 050 HIONVA Jd 2 O3LSIML RANGER 305D CE LINCOLN E DIMENSION PRINT F 10 F 10 RANGER 305D CE LINCOLN E i lo S 0ZW a i 20 V 1 96 9016 0961 091 It p Lk o La 1509 0c 69 Le V9vs Og Lc 9251 0009 9 6 ICH o TT E I j S EE E i gr i J NE j E E fi
19. Solenoid solenoid linkage binding Faulty PC board low idle speed set too low on idle solenoid 1 Fuel Shutdown solenoid not functioning properly linkage binding Stop engine by shutting off valve located on main fuel fil ter Contact authorized local Engine 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 Inline Fuel filters for water Clean and replace as needed Replace fuel in tank 5 Cracked or loose fuel hose Replace hose and tighten clamps 6 Valves out of adjustment Contact authorized local Engine Service Shop CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305D CE LINCOLN 5 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual No welding power output Poor work lead connection to Auxiliary Power OK work Make sure work clamp is tightly connected to clean base metal Terminals switch in wrong positi
20. 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 machine is shipped with the engine crankcase filled with high quality SAE 10W 30 Oil that meets classification CG 4 or CH 4 for diesel engines Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 50 running hours Refer to the engine Operators Manual for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the Engine Operator s Manual for more details on the proper service and mainte FUEL nance intervals USE DIESEL FUEL ONLY WARNING Fill the fuel tank with clean fresh fuel The capacity of the tank is about 45 ltr s 12 Gal s A WARNING NOTE A fuel shut off valve is located on the pre filter sediment filter Which should be in the closed position when the welder is not operated for extended periods of time RANGER 305D CE LINCOLN 5 A 4 INSTALLATION A 4 ENGINE COOLING SYSTEM A WARNING Air to cool the engine is drawn in the base sides and exhaust through radiator amp case back It is important that the intake and exhaust air is not restricted Allow a minimum clearance of 0 6m 2 feet fr
21. conditions A WARNING To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust 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 Press and hold the glow plug button for 10 to 20 seconds For Codes 11122 11123 3a Crank the engine by pressing the start button for 45 seconds For Codes 11189 11190 4 Check to see that fuel is flowing through both fuel filters 5 Follow the normal STARTING procedures RANGER 305D CE LINCOLN D 5 MAINTENANCE FUEL FILTER 1 Check the fuel filter and fuel pre filter for water accumulation or sediment 2 Replace the fuel filter if it is found with excessive water accumulation or sediment Empty fuel pre fil ter OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3150 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop BATTERY MAINTENANCE To access the battery Disconnect the Negative and then Positive battery cables Remove the 4 screws from the battery door
22. memory feature holds the display of both meters on for seven seconds after welding is stopped This allows the operator to read the actu al current and voltage just prior to when welding was ceased While the display is being held the left most deci mal point in each display will be flashing The accuracy of the meters is 3 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE DOWNHILL PIPE CC STICK TOUCH START TIG RANGER 305D CE LINCOLN 5 B 3 OPERATION B 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 is not active in the TIG mode 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 Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick welding 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 more forcefu
23. pressure 1995 LNE Trappes Elancourt ZA de Trappes lancourt 29 avenue Roger Hennequin 78197 TRAPPES Cedex LWA 98 dB net power Pel 7 5kW LWA 96 dB net power Pel 7 5k Gatti European Engineering Manager 26 April 2005 European Community Representative RANGER 305D CE LINCOLN 5 vii SAFETY vii ELECTROMAGNETIC COMPATIBILITY EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 50 199 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional usc Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers ctc Bo aware that interference may result and cxtra precautions may be required when a
24. remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria etai ADP55U tRE 9 fsPBHEILTAESUCFE U ZE EUR Ea fE FEES B sk 24758 e g37 E MAS AS FAAA H4 ARBSHIAIS Q3 ge Vaya duly ai EU ha jga A e Mall oe us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e 47TTLA9 UAXCNEUPD PRE DF MTF EUS e IE BIO BE fl NM il jui ae Do not operate with panel open or guards off No operar con panel abierto o guarda
25. screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating pro ducts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used includin
26. to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely 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 insure stability side to side and front to back when being moved and 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 laws in nation region to be used VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is 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 of vehicle Follow vehicle manufacturer s instructions INSTALLATION A 3 PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank
27. using a screwdriver or a 10mm socket Remove the 2 nuts from the battery bracket using a 11mm wrench or socket Slide the battery out and remove from welder A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when e INSTALLING A NEW BATTERY disconnect negative cable from old battery first and con nect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated e USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at engine foot and be careful when working near battery BATTERY ACID can burn eyes and skin e Follow instructions printed on battery n e Wear gloves and eye protection D 5 CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 113g 1 4 pound of baking soda and 0 9461L 1 quart of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery termina
28. 1LLOSHL 9NIGIHH3AO 40 ONILLIS HONS3AO9 JHL ONIONVHI INdH 3NISN3 J101 HOIH HO 3SV3389NI NOLLTIVO OL HOLIMS LAVLS YLM e 2 2967 44041941 A 318V2 10HLNOO 1003 0287 Le L 9 6 SNILII4 LNdNI 5 9 OL 599 NO93V e H313AMO T3 HOLVIN934 Jueuudinbe 2029 10 sued Aje9u199 9 jou pinous e 910120 sued Bulaow dose Aisyeg 3ALLVO3N 1290 009 e ui uedo sjeued ejejedo jou ONINHVM WV WVMOVIO NOLLO3NNOO 1 OIL DEEN SY3CTAM ANIONS RANGER 305D CE LINCOLN E 01 28 28 5 0002 22 01 OL HOLIMS NOILISOd 318VO 300819313 JHL dO ALISV 10d SHL 01 13S SI HOLIMS SIHL S83 INN 31V8H3dO LON TIM LYVLS VSOd SHI NOILISOd OL d313ALTOA 830332 38IM LAS WANVW 33 FYNLN ANY 31VIG3NWNI dO 71949 ALNG ANY 403 ALIOVdVO dO 38 LSNW 531979 ONITIAM 9NILVH3dO H3Q T3M 3NION3 NI 3151 SNOILVOISIOAdS LSNPaV LON OG AHOLOVA JHL 17 146 SI 94135 YONYSAOS JHL LINDYID JHL SOV
29. 305D CE to moderate loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes RANGER 305D CE LINCOLN 5 B 2 1 WELDING CONTROLS Figure B 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 welding modes When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control In the CV WIRE mode if the wire feeder has volt age control capability when the control cable is connected to the 14 Pin Connector the auto sens ing circuit automatically makes OUTPUT CON TROL inactive and the wire feeder voltage control active When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUTPUT control is used to set the maximum cur rent range of the CURRENT CONTROL of the Amptrol T N OPERATION ELLA 20 E AG EC 7 ___ Vi p c 9 E SH 2 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK PIPE and TIG modes to be set prior to welding using the OUT PUT control dial During welding the meter display the actual output voltage VOLTS and current AMPS A
30. ATOIRE CONFORMITY CERTIFICATE OW Manufact LINCOLN ELECTRIC COMPANY Number 2000 14 C110450 1 Fabricant 22801 St Clair Ave Num ro Nummer Hersteller USA Notified body Organisme notifi Ausstellende Pr fstelle CLEVELAND Ohio 44177 1199 N 0071 Laboratoire National d Essais Applicant LINCOLN ELECTRIC France Demandeur avenue Franklin Roosevelt EC Directive applicable Antragsteller B P 214 Directive CE applicable 2000 1 4 F 76121 LE GRAND QUEVILLY Cedex Anwendbare EG Richtline lev lt Conformity assessment procedure Annex VI Niveau de puissance acoustiq x Proc dure d valua E formit Garantierter schalleistun To be affix i Konformit tsb ahren bzw der Maschine Welding generator Directive definition item 57 me LINCOLN RANGER 3050 2279 1 2 Energy Diesel Other req H temen characteristics Pel 7 5 k Reference rn Laboratory repoi LN Units R305D gt powerlevel 96 dB A Rapport de laboratoire 4 2 0 Nov 2002 Niveau de puisse mesur Definition Art 3 e Pr fbericht Gemessener schall This certificate is issued under the following conditions Ce certificat est d livr dans les conditions suivantes Diese Bescheinigung wird unter folgenden Bedingungen applies only to the recorded type without any 1 ne s appliq
31. 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 for up to 10 seconds 6 Release the engine START button immediately when the engine starts 7 Release the glow plug button after the Engine Protection Light turns off or after an additional 5 seconds 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 several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather NOTE If the unit fails to start repeat step 4 through step 7 after waiting 30 seconds CAUTION Do not allow the starter motor to run continuously for more than 20 seconds Do not push the START button while the engine is running because this can damage the ring gear and or the starter motor IF the Engine Protection or Battery Charging Lights do not turn off shortly after starting the engine shut off the engine immediately and deter mine the cause NOTE When starting a RANGER 305D CE for the first time or after and extended period of time of not operating it will take longer than normal because the fuel pump has to fill the fuel system STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine STOP the e
32. CITIES Without oil filter replacement 3 2 liter 3 3 U S Quart With oil filter replacement 3 2 liter 3 4 U S Quart Use motor oil designed for diesel engines that meets requirements for API service classification CC CD CE CF CF 4 CG 4 or CH 4 ACEA E1 E2 E3 Always check the API service label on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classifi cations SAE 10W30 is recommended for general all tempera ture use 15C to 40C 5F to 104F See engine owner s manual for more specific informa tion on oil viscosity recommendations MAINTENANCE OIL FILTER CHANGE Drain the oil Remove the oil filter with an oil filter wrench and drain the oil into a suitable container Discard the used filter Note Care should be taken during filter removal to not disrupt or damage in any way the fuel lines Clean the filter mounting base and coat the gasket of 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 the recommended engine oil Reinstall the oil filler cap and tighten securely Start the engine and check for oil filter leaks Stop the engine
33. Filters dirty clogged Check and replace main filter element and or Inline Fuel Filter Out of fuel Fill tank and bleed fuel system High coolant temperature or low oil pressure indictor lights lit If all recommended possible areas Check oil and coolant levels Fill misadjustment have been required Check for loose or bro Ichecked and the problem persists ken fan belt Contact your local Lincoln Faulty fuel shutdown solenoid Authorized Field Service Facility Check that shutdown solenoid is functioning properly and not bind ing contact authorized engine service shop Faulty fuel pump Check for fuel flow through filters Contact authorized local Engine Service Shop Engine shuts down shortly after High coolant temperature or low starting oil pressure indictor light lit Change oil and oil filters and fill to proper level Check and fill coolant level Check for loose or broken fan belt Start engine and look for leaks Faulty oil pressure switch or other engine component Contact authorized local Engine Service Shop Faulty engine protection relay CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305D CE LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed thr
34. IM837 A Ranger 305 D CE Jo For use with machines having Code Numbers 11122 11123 11189 11190 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 EN 60974 1 MM OPERATOR S MANUAL ISO 9001 CA ned Wi ufactured vi lera LINCOLN Copyright 2005 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A 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 A
35. Location and Ventilation u tlk ee wee eae A 2 Ite dinis u issuu ys Sam aa a END ss A 2 Andle EE A 2 Rudel EE A 2 High Altitude Operation dite nis rec retener A 2 High Temperature Operation suisse A 2 Cold Weather Operation A A 2 TOWING e A 3 Vehicle E ee A 3 Pre Operation Engine Service seen A 3 Qilla S EE A 3 gil A 3 Engine 4 Battery Connections a aG maa 4 Te UH le 4 leit 4 Remote tcr 4 Electrical aeann R Sa abf Ue duke eene A 4 Machine Grounding DEE 4 Welding Terminals A 5 Welding Output Cables cities delist aayqa ci ieee A 5 Gable IMS tall AO MA eC P ege A 5 Auxiliary Ge TEE A 5 Standby Power Connections cuties aaa maqasqa etna ture nint Bola sca A ge edhe concn A 5 Connection of Lincoln Electric Wire Feeders A 6 A 7 len M Section B Safety le TEE B 1 Ee le le EE B 1 For A xillary sterii au petas cea ee Eph nean ete co tete pe ate tuse eer en B 1 Engine
36. ND 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 you purchase a copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 1 To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND ES MAGNETIC FIELDS may 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 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
37. NVG NYO HOIHM SOVLIOA 330333 OV JHL NI NV FASNVO 39VOINIT3TLLOSH E ONIGIHH3AO ONILLAS 3NION3 HOI dO 3SV3389NI NOLL 0 334 OL 41890 300410313 OL DIAGRAMS TIYO UN 1 0333 OLLV AVS8OO OL jueuudinbo siy 10 jou esn rejsui pinous jeuuosiod parenb e sued desye pee Aiegeg SALLWOAN Weuuoosiqe ui uedo sjeued um e1ejedo jou oqe ONINHVM WV F 5 INVHSOVIO NOILOANNOD 2I1VINVH80OO 1 286813 SH3Q713M 3NISN3 RANGER 305D CE LINCOLN E 6 08102 179 Jequunu epoo 1u uudinb e 104 94 e qiDej s Ji sjeued y Jo euo uo eui pejsed si epoo e oul enueui siy Aq seuluoeui JO eq jou Aew 10 SI 4141 310 WOR EMT A MORE SA eve lt 92 Enhanced Diagram
38. S F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding
39. TON AAS LOT 9 1533325858 0 i DE AUS SN SATA AMC A Ca 2 QIMS 919 FE E 99108 3009 SNIHIM 32 0606 HIONVA RANGER 305D CE LINCOLN E 9 Enhanced Diagram DIAGRAMS F 9 Jequunu epoo 1u uudinb y e 94 s eui j sjeued y Jo euo UO y pejsed si epoo siy Aq 10 eq jou Aew y 1979 d8 1109 TINd 2808 GIONSHOS 310 DIE DEn S1N3NOdWOO 59778 MOD NO OND 3
40. al ing arc is not stable or is not satis switch is in the correct position for factory the engine runs normally the process being used For exam The auxiliary power is normal ple CV WIRE PIPE CC STICK Make sure the electrode wire gas voltage current etc is correct for the process being used Check for loose or faulty connec tions at the weld output terminals and welding cable connections The welding cables may be too long or coiled causing an excessive voltage drop If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305D CE LINCOLN 5 DIAGRAMS F 1 F 1 18 4765 0002 22 01 Qq38 3G SV NOILISOd 410 HO YO OLAY NI HOLIMS 42314 dOV d NOILISOd NO STVNINYSAL 13M NI HOLIMS S IVNIIWS3 L dH1 39V Td NOILISOd AHL NI HOLIMS SHL SOV 1d 318 0 300819313 AHL dO V 10d AHL OL HOLIMS H313 ALL 10A 430334 3H1 NOILISOd ALIMV10d 4530 4014 SANLS LAdLNO OL S418V9 LOANNOO IVANY 9NILV4340 3595 SNOLLVOI TadV ANY ALVIGSWW 40 319A9
41. and check the oil level If neces sary add oil to the upper limit mark on the dipstick A WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result A CAUTION run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine 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 of operation and sooner under dusty conditions RANGER 305D CE LINCOLN 5 D 3 MAINTENANCE Service Instructions amp Installation Tips Release the Seal Carefully Unlatch and remove the service cover of the air cleaner Make certain the latches are folded back against the cover so that they donit hinder filter removal installation Most latches are spring loaded to fold back when open The filter fits tightly over the outlet tube creating the critical seal on the inside diameter of the filter endcap The filter should be removed gently to reduce the amount of dust dislodged There will be some initial resistance similar to breaking the seal on a jar Gently move the end of the filter back and forth to break the seal Avoid Dislodging Dust from the Filter Gently pull the filter off the outlet tube and out of the housing Avoid knocking the
42. at O DOWNHILL PIPE STICK Welding The DOWNHILL PIPE position of the MODE switch is a slope controlled setting intended for out of position and down hill pipe welding where the operator would like to control the current level by changing the arc length OPERATION B 5 The OUTPUT CONTROL 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 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 more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at O TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL dial is first set to the desired cur rent and the tungsten is touched to the work During the time the tungsten is touching the work there is very little voltage or current and in general no tungsten contamina tion Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc To stop the arc simply lift the TIG torch away from the work piece When the arc voltage rea
43. before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from the gears fans and all other moving parts when starting operating or repairing the equipment Routine Maintenance At the end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated ENGINE MAINTENANCE COMPONENTS KUBOTA D722 DIESEL ENGINE ITEM MAKE AND PART NUMBER KUBOTA 70000 15241 OIL FILTER AIR FILTER ELEMENT DONALDSON P822686 FUEL FILTER ELEMENT KUBOTA 15231 43560 BATTERY KUBOTA GROUP 58 550 CCA KUBOTA 15881 97011 GLOW PLUGS KUBOTA 16851 65512 INLINE FUEL FILTER KUBOTA 12581 43012 BELT MAINTENANCE D 1 KUBOTA D722 DIESEL ENGINE FREQUENCY FILL FUEL TANK CHECK OIL LEVEL CHECK COOLANT LEVEL CHECK AIR CLEANER ELE MENT AND HOUSING FOR DIRTY LOOSE OR DAMAGED PARTS CHECK AIR INTAKE HOSE FOR CRACKS OR LOOSE CONNECTIONS CHECK AIR INTAKE EXHAUST AREAS amp RADIATOR FOR DIRT CLEAN AS NECESSARY CHECK ALTERNATOR BELT TENSION AND WEAR DAILY OR BEFORE STARTING ENGINE Service Intervals Observe the following for service and maintenance The lubricating oil change intervals listed in the table below are for Classes CF CE and CD lubricating oils of
44. bserving the level in the radiator 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 Fill up to the top of the tube in the radiator filler neck which includes a connecting hose coming from the thermostat housing To drain the coolant open the valve of the radiator Open the radiator cap to allow complete drainage Tighten the valve and refill with a 50 50 antifreeze water solution Use an automotive grade low silicate ethylene glycol antifreeze The cooling system capacity is 3 6L 3 85 quarts Squeeze upper and lower radiator hoses while filling to bleed air from system coolant Replace and tighten the radiator cap CAUTION Always premix the antifreeze and clean tap water before adding to the radiator It is very important that a precise 50 50 solution be used with this engine year round This gives proper cooling dur ing hot weather and freezing protection to 37 C 34 F Cooling solution exceeding 50 ethylene glycol can result in engine overheating and damage to the engine Coolant solution must be premixed before 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 and the batter
45. ch is depressed 10 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode ENGINE CONTROLS Figure B 2 OQeoo o 11 RUN STOP SWITCH RUN position energizes the engine prior to starting STOP position stops the engine The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating 12 GLOW PLUG PUSH BUTTON When pushed activates the glow plugs as well as the electric fuel pump for quick starting Glow plug should not be activated for more than 20 seconds continuously For Codes 11122 11123 AUTO BLEED FUNCTION Air will automatically bleed from the fuel system by simply pushing the GLOW PLUG BUTTON It is generally not required to crack open fittings in the fuel system to bleed air from the fuel system For Codes 11122 11123 When pushed activates the glow plugs Glow plug should not be activated for more than 20 seconds continuously For Codes 11189 11190 13 START PUSH BUTTON CH Energizes the starter motor to crank engine 14 IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the high idle 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 for approxi mately 12 seconds and then go to
46. ches approximately 30 volts the arc will go out and the machine will automati cally reset to the touch start current level The tungsten may then be retouched to the work piece to restrike the arc The arc may also be started and stopped with an Amptrol or Arc Start Switch See the following para graphs TABLE B 2 TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODESO Tungsten Electrode Diameter in mm 196 296 Thoriated Tungsten 2 15 5 20 15 80 70 150 150 250 250 400 400 500 500 750 750 1000 DCEN DCEP Approximate Argon Gas Flow Flow Rate C F H 1 min 1 2 Thoriated Aluminum Stainless Steel Tungsten TIG TORCH Nozzle Size 4 5 3 8 4 5 6 5 10 5 10 9 13 5 6 6 7 8 8 10 1 When used with argon gas The current ranges shown must reduced when using argon helium pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure 1 Thoriated 2 Thoriated EWTh 1 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 6 mm 5 5 16 8 mm 6 3 8 10 mm 7 7 16 in 11 mm 8 _ in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles are
47. column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305D CE LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual Authorized Field Service Facility Engine will not crank Battery is low Charge Battery 2 Loose battery cable connections Inspect clean and tighten terminals Faulty engine starter motor Contact authorized local Engine Service Shop Engine will crank but not start Fuel shut off valve on Main Fuel Filter in the OFF position Open valve vertical position of handle Fuel
48. der AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable
49. erials away Mantenga el material combustible fuera del area de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e 4 MMIC U THEN EKA eh 9E Vi S BET Ac APA OMe Am AL al gll e Wear eye ear and body protection Prot jase los ojos los oidos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und perschutz Use protec o para vista ouvido e corpo EU OMAR HRSRSORENE ez 119 Sal Soars AI die Jde cl gal ee Meu 9 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to
50. filter against the housing Clean Sealing Surface of the Outlet Tube Use a clean cloth to wipe the sealing surface Dust on the outside diameter of the outlet tube could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Clean the Inside of the Outlet Tube Carefully wipe the inside of the outlet tube with a clean cloth Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers says that it takes only a few grams of dirt to dusti an engine Be careful not to damage the sealing area on the tube Visually inspect the old filter for any signs of leaks A streak of dust on the clean side of the filter is a telltale sign Remove any cause of leaks before installing new filter For Engine Air Filter Donaldson filters with RadialSeal Sealing Technology are self aligning self centering and self sealing A new filter has a dry lubricant to aid installation The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal Again do NOT use the service cover to push the filter into place Check the Old Filter for Leak Clues
51. g the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 SAFETY WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AW
52. he United States and some European Countries Use above 1828m 6000 ft may be limited due to poor engine per formance or excessive exhaust smoke An authorized Kubota engine field service shop should be contacted to determine if any adjustments can be made for operation in higher elevations locally HIGH TEMPERATURE OPERATION At temperatures above 40 C welder output derating is neces sary For maximum output ratings derate the welder output 2 volts for every 10 C above 40 C Cold weather starting With a fully charged battery and the proper oil the engine should start satisfactorily down to about 15 5 F If the engine must be frequently started at or below 5 C 23 F it may be desirable to install cold starting aides The use of No 1D diesel fuel is recom mended in place of No 2D at temperatures below 5 C 23 F Allow the engine to warm up before applying a load or switching to high idle A WARNING Note Extreme cold weather starting may require longer glow plug operation Under no conditions should ether or other starting fluids be used RANGER 305D CE LINCOLN 5 A 3 TOWING Check with distributor for the recommended trailer for use with this equipment for road in plant and yard towing by a vehicle If the user adapts a non Lincoln trailer he must assume responsi bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors
53. in INSTALLATION INSTRUCTIONS Section The RANGER 305D CE 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 wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with the dial set at 0 OPERATION B 6 For any electrodes the procedures should be kept within the rating of the machine For additional elec trode information see WWW Lincolnelectric com or the appropriate Lincoln publication ARC GOUGING The RANGER 305D CE can be used for limited arc gouging For optimal performance set the MODE switch to CC STICK and the ARC CONTROL to 10 Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following TABLE B 3 Table Carbon Diameter Current Range DC electrode positive 1 8 60 90 Amps 5 32 90 150 Amps 3 16 200 250 Amps AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn Simulta
54. ine or adversely affect performance REMOTE CONTROL The machine is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K963 3 hand Amptrol When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 pin Connector the auto sensing circuit auto matically switches the OUTPUT control from control at the welder to remote control When in TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin connector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active A WARNING NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connec tor do not connect anything to the 6 pin connec tor ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies
55. itters and receivers computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out L10093 RANGER 305D CE LINCOLN 5 viii SAFETY viii ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding powcr source enclos
56. k 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 full mark Do not overfill Close engine door Check radiator for proper coolant level Fill if nec essary See Engine Owner s Manual for specific oil and coolant recommendations ADD FUEL m A WARNING e Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling DIESEL FUEL Wipe up spilled fuel and allow can cause fire fumes to clear before starting engine e Do not overfill tank fuel expansion may cause over flow DIESEL FUEL ONLY Remove the fuel tank cap Fill the tank approximately 4 inches 100mm from the top 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 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 the RANGER 305D CE break in is about 50 running hours Check the oil every four hours during break in Change the oil after the first 50 hours of operation every 100 hours thereafter Change the oil filter at the second oil change CAUTION During break in subject the RANGER
57. l digging arc Typically a forceful digging arc is pre ferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposi tion stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at 0 CV WIRE mode In this mode turning the ARC CONTROL clock wise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with a setting of 0 5 WELD OUTPUT TERMINALS WITH FLANGE NUT 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 CE Includes contactor closure circuit auto sensing remote control circuit and 42V power The remote control circuit operates the same as the 6 Pin connector Note The 14 pin connector does not include 120V 8 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control circuit 9 WELD TERMINALS SWITCH In the WELD TERMI NALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED position the output is controlled by a wire feeder or amptrol device and is electri cally off until a remote swit
58. les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie d
59. low idle speed When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed When welding ceases or the AC power load is turned off a fixed time delay of approximately 12 seconds starts If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle speed The engine will automatically return to high idle speed when there is welding load or AC power load reapplied RANGER 305D CE LINCOLN B 4 OPERATION B 4 15 ELECTRIC FUEL GAUGE Provides accu rate reliable indication of how much fuel is in the tank 16 ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance 17 ENGINE PROTECTION LIGHT A warning indicator light for Low Oil Pressure and or Coolant Over Temperature The light is off when the sys tems are functioning properly The light turns on when the RUN STOP switch is in the ON posi tion prior to starting the engine If the Engine Protection or Battery Charging Lights do not turn off shortly after starting the engine shut off the engine immediately and determine the cause STARTING THE ENGINE 1 Remove all plugs connected to the AC power receptacles 2 Set IDLER switch to AUTO 2 lt 3 Set the RUN STOP switch to RUN 4 Press Glow Plug
60. ls lightly with petroleum jelly 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 discharge and early battery failure CHECKING THE ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY When you charge jump replace or otherwise con nect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The RANGER 3050 CE positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR Clean every 100 hours A WARNING MUFFLER MAY BE HOT e ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER RANGER 305D CE LINCOLN 5 D 6 MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store the RANGER 305D CE in clean dr
61. n 78197 Trappes Cedex Siret 313 320 244 00012 T l 01 40 43 37 00 Fax 01 40 43 37 37 T l 01 30 69 10 00 Fax 01 30 69 12 34 NAF 743 B BARCLAYS Panis CENTRALE 30588 Guichet 60001 Compte 49726740101 70 CRCA Paris IAA DISTRIB 18206 Guichet 00426 Compte 58381956001 RIB 45 THE LINCOLN ELECTRIC COMPANY SAFETY vi LINCOLN P ELECTRIC EC DECLARATION OF CONFORMITY Manufacturer and technical documentation holder Address EC Company Address Hereby declare that machine Sales code Is in conformity with Council Directives and amendments Standards Notified body for LWA determination Address Guaranteed sound power level Measured sound power level ufacturer Frank Stupezy M Compliance Engineering Manager 6 March 2003 The Lincoln Electric Company 22801 St Clair Ave Cleveland Ohio 44117 1199 USA Lincoln Electric Europe by c o Balmes 89 80 2a 08008 Barcelona SPAIN Welding Equipment Ranger 305D K2179 with prefixes and suffixes EMC Directive 89 336 EEC Low Voltage Directive 73 23 EEC Noise emission in the environment by equipment for use outdoors 2000 14 EC Annex VI procedure 1 EN 50199 Electromagnetic compatibility EMC product standard for arc welding equipment 1995 Al EN 60974 1 Safety requirements for arc welding equipment power sources 1998 Al EN ISO 3744 Acoustic Determination of sound power levels of noise sources using sound
62. neous Welding and Auxiliary Power Loads While welding the amount of 3 phase Auxiliary power available is reduced See table A 4 TABLE A 4 UNITY POWER FACTOR 8000 6500 5000 3500 2000 0 POWER 400V 3PHASE 12 Amps 9 Amps 7 Amps 5 Amps 3 Amps 0 Amps RANGER 305D CE LINCOLN 1 ACCESSORIES FIELD INSTALLED OPTIONS ACCESSORIES K1898 1 SPARK ARRESTOR Mounts between muf fler amp elbow to eliminate any risk of spark from exhaust K704 ACCESSORY SET Includes 10m 35 ft of electrode cable and 9 m 30 ft of work cable head shield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 7 6m 25 ft or K857 1 30 4m 100 ft REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder RANGER 305D CE LINCOLN 5 C 1 D 1 SAFETY PRECAUTIONS A WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine or servicing the engine Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete If guards are missing from the machine obtain replacements from a Lincoln Distributor See Operating Manual Parts List Read the Safety Precautions in the front of this manual and in the Engine Owner s Manual
63. ngine by placing the RUN STOP switch in the STOP position NOTE A fuel shut off valve is located on the fuel pre filter Turn on Fuel shut off valve on the fuel pre filter TABLE B 1 Kubota D722 Liters Hr Gal Hr Running time for 45 Liters hours 1 62 43 28 07 3 42 90 13 30 15 59 2 19 24 C77 70 58 13 54 17 12 20 78 RANGER 3050 LINCOLN B 5 WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period The RANGER 305D CE can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CONSTANT CURRENT CC STICK Welding The CC STICK position of the MODE switch is designed for horizontal and vertical up welding with all types of elec trodes especially low hydrogen The OUTPUT CONTROL 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 or crisp arc Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the elec trode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting
64. nt Voltage 250A 27V 100 14 TO 29 VOLTS RATED OUTPUT 40 C 104 F GENERATOR Auxiliary Power 1 8 500 Watts Peak 8 000 Watts Continuous 50 Hz 230 400 Volts 3 Phase Sound Levels Sound Power 98 dB Lwa PHYSICAL DIMENSIONS 546mm 1524mm 21 50 in 60 0 in ENGINE LUBRICATION EMISSIONS FUEL SYSTEM Full Pressure Certified to Electric Fuel Pump Codes 11122 11123 Mechanical with Full Flow Filter EPA Tier I Fuel Pump Codes 11189 11190 Auto air bleed Mechanical Governor System Electric shutoff solenoid Indirect fuel injector Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure amp engine Made from long life aluminized steel temperature ENGINE WARRANTY 2 year complete parts and labor 3rd year major components parts and labor 341kg 752lbs Receptacles 400V 3 Ph x 1 400V 3 Ph x 1 230V 1 Ph x 1 230V 1 Ph x2 115V x 19 14 Pin Connector 14 Pin Connector 6 Pin Connector 6 Pin Connector 4 pole 25 Amp 30mA trip current 3 Phase 20 Amp x 1 3 Phase 20 Amp x 1 1 Phase 15 Amp x 5 1 Phase 15 Amp x 4 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 1096 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 To top of enclosure add 152mm 6 7 to top of exhaust elbow 3 Engine warranty ma
65. o 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 AR Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 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 bare skin 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 full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Wel
66. om the case back and 40cm 16 from either side of the base to a vertical surface BATTERY CONNECTION CAUTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes The machine is shipped with the negative battery cable disconnected Make certain that the RUN STOP switch is in the STOP position Attach the negative battery cable to the negative battery terminal and tighten using a 13mm socket or wrench It may be helpful to remove the coolant over fill bottle Pull up on bottle to remove from bracket NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity MUFFLER OUTLET PIPE Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust to the radiator end of the machine Tighten using an adjustable wrench SPARK ARRESTER Some local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester such as the K1898 1 must be installed and properly maintained A WARNING An incorrect spark arrestor may lead to damage to the eng
67. on Place switch in Weld Terminals On position when welding without control cable Faulty PC board Welder has output but no control Poor remote control cable connec tion to 6 pin or 14 pin connector Check connections Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary Faulty control potentiometer or PC board If all recommended possible areas Wire feeder does not work 1 Wire Feeder Power circuit breakerlof misadjustment have been control cable is connected to 14 pin open Check 42V beaker and checked and the problem persists connector reset if tripped Contact your local Lincoln Faulty control cable Repair or Authorized Field Service Facility replace cable Faulty wire feeder Replace wire feeder No auxiliary power Open circuit breakers Reset breakers If breakers keep trip ping reduce power draw Faulty connections to auxiliary receptacles Check connections RCD tripped Clear any ground fault and reset RCD circuit by pressing Reset button Faulty PC board or welder alterna tor CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305D CE LINCOLN 5 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manu
68. ons instructions apply to both the LN 15 Across The Arc and Control Cable models The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Across The Arc Model 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 motor 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 and Feeder Set the MODE switch to the CV WIRE position Set the WELD TERMINALS switch to REMOTELY CONTROLLED Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity being used Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the AUTO position 0 INSTALLATION A 6 A WARNING Connection of the LN 25 to the RANGER 305D CE Shut off welder before making any electrical con nections The LN 25 with or wi
69. or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous cont
70. oroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or e electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Always operate the welder with the hinged door closed and the side panels in place Read carefully the Safety Precautions page before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The RANGER 305D CE is a diesel engine powered DC multi process welding power source and AC power generator The engine drives a generator that supplies three phase power for the DC welding circuit and three phase and single phase power for the AC auxiliary outlets The DC welding control system uses state of the art Chopper Technology CT for supe rior welding performance FOR AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn ENGINE OPERATION Before Starting the Engine pA Be sure the machine is on a level surface Open top amp side engine doors and remove the engine oil dipstic
71. oughout this manual High radiator coolant tempera ture Reduce load if it is exceed ing machine rating Add coolant to system if low Clean fins on radiator if dirty Tighten fan belt if loose Remove objects blocking or close to intake openings on both sides of base and exhaust end case back Engine runs rough Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed Water in fuel If water found in tank Empty fuel tank and refill then purge fuel lines Battery does not stay charged Faulty battery Replace 2 Loose connections at battery or alternator Clean and tighten con nections If all recommended possible areas of Faulty engine alternator or charg misadjustment have been checked er module Consult authorized and the problem persists Contact Engine Service Shop your local Lincoln Authorized Field Service Facility Engine will not idle down to low ldler switch in High idle position speed Set switch to Auto External load on welder or auxil iary power Remove all external loads Faulty PC board or idler sole noid Engine will not go to high idle when Poor work lead connection to attempting to weld work Make sure work clamp is tightly connected to clean base metal Contactor switch is in wrong position Set to Welding On when welding without a control cable Refer to Operations chapter for prop er use of this switch
72. power must A WARNING Be grounded to the frame of the welder using a grounded type plug Be double insulated Do not ground the machine to a pipe that carries explosive or combustible material RANGER 305D CE LINCOLN 5 5 When this welder is mounted on a truck or trailer its frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle When this engine driven welder is connect ed to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power Connections In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded A machine grounding stud marked with the symbol is provided on the front of the welder WELDING TERMINALS The machine is equipped with a toggle switch for selecting hot welding terminal when in the WELD TERMINALS ON position or cold welding terminal when in the REMOTE position WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tate
73. re la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou
74. s quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas RJ J ZEE U u VC F uv e SER 3R11 Bi st 2 8 Z SERB 20 Sel tele E hiyi cuts Pb ai Jai e Aale aug Al al WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ies BIR Chinese Korean LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR DMR GE p A EFTBRLTF SU ET PR Rr TE fit BB SR SP EZ 09 EJ OR AAS St it OFA 44g Aal alal dl aul J AAL oig Gail agil LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
75. s the polarity of the electrode cable These connec tions should be checked periodically and tightened with a 19mm wrench Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops TABLE A 1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 305 Amps 100 Duty Cycle 1 0 AWG Cable Length 0 30 meters 0 100Ft 30 46 meters 100 150 Ft 2 0 AWG 46 61 meters 150 200 Ft 3 0 AWG INSTALLATION A 5 CABLE INSTALLATION Install the welding cables to your machine as follows 1 The diesel engine must be OFF to install welding cables 2 Remove the flanged nuts from the output termi nals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are identi fied on 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 and cable 6 Check and tighten the connections periodically A CAUTION Loose connections will cause the output termi nals to overheat The terminals may eventually melt Do not cross the welding cables at the output terminal connection Keep the cables isolated and separate from one another AUXILIARY POWER The auxiliary power capacity is
76. t be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved The maximum angle of continuous operation is 20 degrees in all directions 35 degrees Intermittent less than 10 minutes continuous in all directions If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 45 liters 12 gallons INSTALLATION A 2 LIFTING The machine weighs approximately 374 kg 824 lbs with a full tank of fuel A lift bail is mounted to the machine and should always be used when lifting the machine A WARNING e Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lift ing Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For max imum rating derate the machine 2 5 to 3 5 for every 305m 1000ft Due to new EPA and other local emissions regula tions modifications to the engine for high altitude are restricted within t
77. the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed CAUTION If you are using LN 25 without an internal con tactor the electrode will be energized when the RANGER 305D CE is started RANGER 305D LINCOLN 5 A 7 INSTALLATION Connection of LN 742 and Cobramatic to RANGER 305D CE Shut the welder off Connect per instructions on the appropriate connec tion diagram in Section F Connection of PRINCE XL SPOOL GUN to the RANGER 305D CE Connection of the Prince XL Spool Gun requires the use of the K1849 1 Adapter Module Shut the Welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder Connect the Gas Hose Set the MODE switch to the CV WIRE position Get the WELD TERMINALS switch to WELD TERMINALS ON Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the HIGH position RANGER 305D CE LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have th
78. thout an internal contactor may be used with the RANGER 305D CE See the appro priate connection diagram in Section F NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the RANGER 305D CE 1 Shut the welder off D For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the elec trode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder e Attach the single lead from the front of the LN 25 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current A Set the MODE switch to the CV WIRE position Set the WELD TERMINALS switch to WELD TERMINALS ON Set ARC CONTROL knob to 0 initially and adjust to suit N Set the IDLE switch to the AUTO position When not welding the RANGER 305D CE engine will be at the low idle speed If you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed 8 When the gun trigger is closed the current sensing circuit will cause the RANGER 305D CE engine to go to the high idle speed the wire will begin to feed and the welding process started When weld ing is stopped
79. to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety MS aM minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 D
80. typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles RANGER 305D CE LINCOLN B 6 When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 pin Connector the OUT PUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol The ARC CONTROL is not active in the TIG mode The RANGER 305D CE can be used in a wide variety of DC TIG welding applications In general the Touch Start feature allows contamination free starting without the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the RANGER 305D CE The settings are for reference RANGER 305D CE settings when using the K930 2 TIG 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 keep the Solid State contactor open and provide a cold electrode until the Amptrol or Arc Start Switch is pressed When using the TIG Module the OUTPUT control on the RANGER 305D CE is used to set the maximum range of the CURRENT CONTROL on the TIG module or an Amptrol if connected to the TIG Module See Table B 2 WIRE WELDING CV Connect a wire feeder to the Ranger 305D according to the instructions
81. u corps LES MACHINES SOUDER 3 Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place SAFETY NATIONAL SR ores sats ESSAIS Certificat de conformit Konformit tsbescheinigung Ke LABOR
82. ue qu au type mentionn sans ausgestellt change in the above referenced technical file changement dans le dossier technique soumis au 1 Sie gilt f r das gepr fle Baumuster ohne Anderung der subjected to the LNE examination LNE et r f renc ci dessus technischen Dokumentation die dem LNE bermittelt wurde implies that a follow up of the manufacturing is 2 implique qu une surveillance de production est mise 2 Ein berwachungsverfahren der Herstellung wurde performed with a LNE control carried out at least once en place avec un contr le par le LNE au moins tous durchgef hrt mit einer berpr fung von LNE mindestens alle every three years Without this control or in case of les 3 ans Sans ce contr le ou en cas de non 3 Jahre Ohne diese berpr fung oder im Falle einer nonconformity the LNE is bound to inform the French conformit le LNE est engag en informer le Unkonformit t hat sich LNE verpflichtet diesen Zustand dem Ministry in charge of environment Minist re Francais charg de l Environnement franz sischen Ministerium f r Umwelt zu melden Trappes 14 January 2003 The Head of Image Acoustic environment The technical Responsible Officer and sound Division Form Certif2014A6 Rev06 Dec02 ETABLISSEMENT PUBLIC CARACTERE INDUSTRIEL ET COMMERCIAL SIEGE SOCIAL LABORATOIRES DE PARIS LABORATOIRES DE TRAPPES E mail info ine fr 1 rue Gaston Boissier 75724 Paris Cedex 15 29 avenue Roger Hennequi
83. ure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position o g ships hull or building stcolwork a connection bonding the workpicce to carth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk
84. welding power soutce is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as carthing grounding the welding circuit scc Noto In other casos it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage tho carth circuits of other equipmont Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment radio and television transm
85. y lose its charge Check tightness by press ing on the belt midway between the pulleys It should deflect about 6mm 25 in under a load of 9 Kg 20 Ibs MAINTENANCE D 4 FUEL At the end of each day s use refill the fuel tank to min imize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Use only fresh No 2 grade DIESEL fuel Do not use kerosene See the Engine Operator s Manual for instructions on replacing the fuel filter BLEEDING THE FUEL SYSTEM You may need to bleed air from the fuel system if the fuel filter or fuel lines have been detached the fuel tank has been ran empty or after periods of long stor age It is recommended that the fuel shutoff valve be closed during periods of non use For Codes 11122 11123 The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that functions when the electric fuel pump is actuated It is generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system For Codes 11189 11190 The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that helps purge the air from the mechanical fuel pump system It is generally not necessary to open a vent screw 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 fuel
86. y protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It s nor mal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary CAUTION e Do not attempt to polish slip rings while the engine is running A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equip ment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and pre cautions RANGER 305D CE LINCOLN 5 D 6 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the
87. y vary outside of the USA See Engine warranty for details 4 Center Tapped to ground RANGER 305D CE LINCOLN 5 Residual Current Device RCD 4 pole 25 Amp 30mA trip current Circuit Breakers Thermal Magnetic A 2 SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting 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 23 MOVING PARTS can injure Do not operate with doors open guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual 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 to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area STACKING RANGER 305D CE machines canno

Lincoln Electric IM837-A User's Manual

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