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Lincoln Electric 305D Welder User Manual

1. D 1 Kubota Diesel Engine saine x mena xu a ca D 1 Engine Oil baya tert ated kk Waaa ka D 2 Engine Oil Refill Capacities esses D 2 Engine Oil Filter Charige ence eth ab ka wa Va Adnan D 2 Air Cleaner Service tiet rnt aaa bA am aX ER Ra wa naa D 2 Service Instructions And Installation Tips for Engine Air Filter D 3 Cooling SYSTEM en ar W k Ei D 4 r gg D 4 FUG ace EET D 4 Bleeding the Fuel System D 4 Fuel nhe ae aaah eed D 5 D 5 Battery D 5 Servicing Optional Spark D 5 Welder Generator D 6 STOLA EEA D 6 urere EE D 6 Brush Removal and D 6 Testing and Resetting Procedure D 6 Troubleshooting sine Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 Diagrams and Dimension Print sn Section F LAS CAD PRE DE A A P 492 vii A 1 INSTALLATION A 1 TECHNICAL SP
2. AREY cus Vil jall Ida Jad y e Ale Count gl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese tm BIR LEIA E COMPREENDA AS INSTRU OES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR gt RM PBHOA A NHERBCE lt BA 38 CT SL LTRHOR MEI ED TF SU RA ET ER HE AR QU XES RR JE WE BA JLI FA BA AO SR 2 R78 SEE SALSA HAR RAS EFEM BEHE Jali a lal gl a al gly oig gil giall ciae 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
3. NYO HOIHM 39 VL 10A 830334 3SIM JHL NI 3SV38ONI ASNVS TIM 3TLLOSH L SHL ONIGIHS3AO ONILLAS HONS3AO9 JHL ANIONS HOIH SHL 30 3SV389NI ANV NOILNVO OL HOLIMS LYVLS F18 80 E TOULdINY QNVH 2 2967 10041971 N n 10HLdNY 1003 028 9264 ONILLIA LNdNI YSGNITAD SV9 OL 579 NO9 V JONJHANY HALINMOT4 uolvn93s jueuudinbo si eo es 10 syed Ajeoujoeje jou oqe esn fejsur pinoys jeuuosiod peyijenb e e10Jeq sued pee 3ALLVO3N 129000281 e eoejd ul uedo sjaued ejejedo jou ode ONINHVM NOLLO3NNOO 0664 SHAQTAIM RANGER 3050 LINCOLN E 01 28278 F 9 0002 22 01 JAMA OL HOLIMS AOW NOILISOd 21872 300819313 SHL 40 ALIS V 10d AHL HOLVW OL LAS SI HOLIMS SIHL SSTINN 31V33d0 LON TIM 3801V33 LYVLS VSOd JHL NOILISOd IHL OL HALINLIOA Y30334 38IM 195 8 N WANVW 9 33 5 39173 ANY SLVIGSWWI 40 37949 ANY LNSYYND JHL ALIOVdVO 38 LSNW S4118V09 ONIGTAM ONILLVeI3dO YSCTAM ANIONS JHL NI 031511 SNOILVOISIDAdS Wd 3AO8V LON OG LV 13S 34d SI ONILLAS YONYSAOD ANIONS JHL LINDYIO TO
4. A 2 Location ard VentlldtlOni sooo ie eri ceken RE E e A 2 SLACKING DD rr E A 2 Angle Of Operation a A 2 EH s TAND US A 2 High Altitude Operation ss A 2 High Temperature Operation sisi A 2 Cold Weather seen A 2 aepo EE A 3 Vehicle A 3 Pre Operation Engine Service ss A 3 A 3 gi Me RUN A 3 COOMA cir epe Oran Dti m MEL vd A 4 Battery Connections ss A 4 tied cT A 4 Spark All S S xa ry A 4 REMOTE a ab yener lah lena ee K aan A 4 Electrical Connections si A 4 Machine Grounding 4 Welding 5 Welding Output Cables iii A 5 Cable Installation ss A 5 Electrical Device Used with the Ranger 3050 A 6 Auxiliary Power Receptacles and A 7 Standby Power Connections ss A 7 N rrr ah dee erdt A 8 Connection of Lincoln Electric Wire 5 A 9 A 10 R xen ana a Rez Na Ka wa ke S Sube Section B Safety Precautions Ea POEET EAA AAA B 1 Gerneral
5. pd Ve C0 udioviNoo 9 T ouiNon dv ANNOYS FON E T 1NOH 3SVO 3dISNI NO M3H2S OND SLOWSY HOM viz N ON9 OND AVE apros 7 10035 F 9 u N002 he 9002 A eneg pales ESISWEDOH 6 ns PIN NS na assv le Hat id ANO 35 2 13313QISNI NO GND 01 pow 3005 indio 44 T 9 1 108 NOD 178170 8 2 6 2 j ue 4 102 0 1 2 ZH Q31v901 za vl 2 009 z A 9991 J Qni H2LIMS 4019385 IAOW 95 OTE H QN9 SSVdAB AA AAA 3 HOLYLS 2 ANOH43S O1437 AGISNI INO WOL108 _ ULATION 902 ME 0802 DNKINIM H3MOd 0334 SHIM 95 Cue 58 99 300 0 4 0902 c 8902 4 8802 L vaoz
6. LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES E DISCONNECT AND SERVICE 50AMP GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 N N 50 AMP 120 240 VOLT NOTE 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Only a licensed certified trained electrician should install the machine to premises or residential electrical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter RANGER 305D LINCOLN 8 A 9 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN 7 or LN 8 to the RANGER 305D Shut the welder off Connect the LN 7 or LN 8 per instructions on the appropriate connection diagram in Section F Set the WIRE FEEDER VOLTMETER switch to either or a
7. 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 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 LINCOLN 8 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 Welde
8. xS SONIONIM TM HOLVLS BERR dv 006 018 9 8902 g 00 ANOS NMOHS NOLL93HIQ ANnHS NI SOWAT 9 9 88 so SNENLL OML dv ji 5708 5902 e ella 2 XNISIV3H 31411934 390 48 3SVHd LA Q3ISIML ZSt LL 2803 NVH9VIQ VLOEN QS0 H39NVH RANGER 3050 LINCOLN E v 0cIN F 11 a 63 02 TIV HOLVIN LON AVIN SOIHdVHO LNOH4 3SVO ALON 0061 0219 80261 00724 DIMENSION PRINT F 11 RANGER 3050 LINCOLN E NOTES RANGER 305D LINCOLN 5 NOTES RANGER 305D LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese BIR Korean Do not touch el
9. 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 TABLE B 1 TYPICAL RANGER 305D FUEL CONSUMPTION Kubota D722 Gal Hr Liters Hr Low Idle No Load 2450 R P M High Idle No Load 3650 R P M DC Weld Output 250 Amps 28 Volts DC Weld Output Running time for 12 gallons hours 29 1 09 41 77 54 2 06 22 02 96 3 63 12 50 70 2 67 17 03 RANGER 305D LINCOLN 1 03 3 91 11 62 9 500 Watts 7 000 Watts 3 000 Watts B 5 The Ranger 305D 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 number 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 CON TROL be set to the minimum number without electrode Sticking Start with the dial set at 0 DOWNHILL
10. TWNOILdO NOLL23NNOO AHL SSOUIVY SC N T SH3Q13M ANISNA RANGER 3050 LINCOLN E 7 282708 F 3 0002 22 01 DIAGRAMS F 3 NOILISOd H9IH NI HOLIMS 44101 32 14 NOILISOd SHL NI HOLIMS 39 Vd d18V9 300819313 JHL 30 ALI V 10d JHL OL HOLIMS YSLAWLIOA 430333 38IM JHL NOILISOd ALIYV10d 0341540 803 50715 LAdLNO 01 318V9 9NIQT3M L93NNOO WANVW 9NILVS3dO 335 SNOILVOMddV 34N1N14 ANY 31VIG3IAINI 40 41949 ANY LN3880 SHL ALIOVdVO 40 38 LSNW 318V9 ONILVYAdO 830713M SHL NI GALSIT SNOILVOISIOAdS Wd 3AO8V 15 LON OG AHOLOVJ SHL LV 13S 34d SI ONILL3S HONSH3AO9 ANIONS JHL LINDYIO TOH LNOO JHL NYO HOIHM 39 V L10A Y30334 38IM OV SHL NI 3SV3SONI NV ASNVO TIM 39 VMNIT3TLLOSHL SHL ONILLAS HONSH3AO9 JHL 9NISNVHO 3NION3 3 IIl H9IH JHL AO 3SV38HONI LINN 9995 OL NOI 3149 30019714 OL IJONZHdINV Nid 9 ESSA MAO 318 2 10HLNOO 7899 LAdNI Z N1 OL jueuudinbe si 2 5 JO sued Ajeouioeje jou AIUO e e ojeq sued deeye pes AM e eg 3ALLVO3N 12euuoosiq e eoejd ui e s eu
11. 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 NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty If the service cover hits the filter before it is fully in place remove the cover and push the filter by hand further into the air cleaner and try again The cover should go on with no extra force Once the filter is in place secure the service cover A Caution NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty 6 Check Connectors for Tight Fit Make sure that all mounting bands clamps bolts and connections in the entire air cleaner system are tight Check for holes in piping and repair if needed Any leaks in your intake piping will send dust directly to the engine RANGER 305D LINCOLN amp D 4 MAINTENANCE COOLING SYSTEM A WARNING COOLANT can burn skin Do not remove cap if radiator is hot Check the coolant level by observing the level in the radiator and recovery bottle Ad
12. dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo H EROS SICORHEREUCF Ue ORNE ez 119 go HSE dis die ily cl soi 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 ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases 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 Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Ent
13. erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device RANGER 3050 LINCOLN E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual 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 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 un
14. requirements for API service classification CC CD CE CF CF 4 CG 4 or CH 4 ACEA 1 2 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 5F to 104F 15C to 40C See engine owner s manual for more specific informa tion on oil viscosity recommendations MAINTENANCE Cil 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 and check the oil level If neces sary add oil to the upper limit mark on the dipstick WARNING Never use gasoline or low flash point solvents for cleaning the air cleane
15. 2D at tempera tures below 23 F 5 C Allow the engine to warm up before applying a load or switching to high idle Note Extreme cold weather starting may require longer glow plug operation A WARNING Under no conditions should ether or other starting fluids be used with this engine RANGER 305D LINCOLN 5 A 3 TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 is Lincoln s K957 1 If the user adapts a non Lincoln trailer he must assume responsi bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors 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 federal state and local laws 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING
16. DescriptiOri cocco correcte ce Paper ecrire eet Re rre tintin B 1 For Auxiliary nir ret tercie te ib nett E eec Ee Ex be cH te Re reke B 1 Engine issues B 1 elel 1 Z B 1 rm B 1 Welder Controls treten rer J RR B 2 B 3 Engine Controls usines B 3 Starting and Stopping the B 4 Weldine OperaliOl s Hi B 4 gg reer 4 5 Constant Current Stick 5 Downhill Pipe Stick Welding seu ke tete deb y gr l ke B 5 epa B 5 Typical Current Ranges for Tungsten Electrodes B 5 Wire Welding CV AVC GOUGING DURAM EA Simultaneous Welding and Auxiliary Power LoadS B 7 Extension Cord B 7 eese Section C Field Installed Options Accessories C 1 vil TABLE OF CONTENTS cu syn aya k naya Ay dinanan a RAN ka SAR KAS kan A KRN Section D Safety Pr cautions E D 1 ROUTING erc xal ten an s rek e kra d k D 1 Engine Maintenance
17. JON3HdMAV 3050 LINCOLN E 21 18195 0002 22 01 F 6 LNIYYNO TVNVIN NOILONELSNI 19HNOS HAMOd OL 83438 AN X30334 9134 336 79 2 50 31 35010 OL JHM NOILYTOSI ISN 11110 ONIGTAM TYNOIS V NYNLIY LWHL S830334 SHIM TN ATIVNGIAIONI SQv31G3SnNn HOW 31VTInSNI L NOLLISOd 3HIM A9 IHL NI HOLIMS IQON JHL ON PS J18VO 300810313 JHL 40 ALII V TOd JHL HOLVIN OL HOLIMS Y3LIWLIOA 830333 NOLLISOd ALIHY10d GAUISAG HOI 0015 1141010 015318 0 ONIGTAM 193NNOO EN NOILYOITddY 30 1949 LNIYYN9 013215 38 LSNW 5318 0 ONIGTAM 0 83Q13M 3NISN3 NI 031611 SNOLLV2I3I93dS 3A08V LSNPAV LON OG 7 A HO LOV4 SHL 13S 3Md SI 9NILL3S ANIDNA JHL LINDYID TOH1NOO JHL HOIHM 830334 SHIM JHL NI 3SV38ONI NV ASNVO TIM ADVANI 31LLOSH L 3HL ONILLAS HONS3AO9 JHL 9NIDNVHO ANION HOIH SHL 40 3SV3HONI ANV M en JINN G34 HIM OL 3199 300319373 LL gt 0l 11 304005 HAMOd 40 IVNINHAL OL SLO3NNOO OL NOLLO3NNOO YALINLIOA 420134 38IM Le NOLLO3NNOO 2240105 HMOd 0 QN9 CE P OWA SLI 19 TN 9NIGTaM ON T 4H3H13901 193NNOO ee
18. Module WIRE WELDING CV Connect a wire feeder to the RANGER 305 D according to the instructions in INSTALLATION INSTRUCTIONS Section The RANGER 305 D in the CV WIRE mode permits 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 prefer ence Start with the dial set at 0 Listed below are some wires suitable for use on this machine Innershield NR 311 NS 3M NR 207 203 Ni 196 NR 212 Outershield 05 70 0S 71M 05 71 ELITE Solid wires for MIG welding 035 0 9 mm and 045 1 1 mm Super Arc L 50 and L 56 035 0 9 mm and 045 1 1 mm Blue Max MIG 308 LS Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain appli cations with this machine OPERATION ARC GOUGING The RANGER 305D 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 Tabl
19. PIPE Welding This slope controlled setting is intended for out of posi tion and down hill pipe welding where the operator would like to control the current level by changing the arc length The output CONTROL dial adjusts the full output range for pipe welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or more forceful digging arc crisp Increasing the number from 10 soft to 10 crisp increases the short circuit current which results in a more forceful 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 This can also increase spatter OPERATION TABLE B 2 B 5 It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the dial set at 0 TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the CONTROL dial is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the work there is very little volt age or current and in general no tungsten contamina tion Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc When in the TOUCH START TIG mode and when a Amptrol is conne
20. The auxiliary power of the RANGER 305D consists of two 20 Amp 120 VAC 5 20R duplex receptacles with GFCI protection and one 50 Amp 120 240 VAC 14 50R receptacle The 240 VAC receptacle can be split for single phase 120 VAC operation Also refer to the AUXILIARY POWER OPERATION section later in this chapter ENGINE OPERATION Before Starting the Engine Be sure the machine is on a level surface Open top amp side engine doors and remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dip Stick Add oil if necessary to bring the level up to the 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 WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fuel ing DIESEL FUEL Wipe up spilled fuel and allow can cause fire fumes to clear before starting engine Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada Remove the fuel tank cap Fill the tank approximately 4 inches 100mm from the top of the filler neck to allow for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW Replace the fuel cap a
21. eg JALLVO3N 199uuoosi d e eoejd ui e uedo sjeued ejejedo jou oq e INV 9VIQ NOILOANNOD cF2 NI SH3Q 13M 3NION3 RANGER 3050 LINCOLN E DIAGRAMS F 5 F 5 9 282 5 0002 L NOILISOd H9IH NI HOLIMS 414141 40V ld 300810313 SHL 40 SHL OL HOLIMS YALAWLIOA 830333 NOILISOd ALII V TOd Q441 3Q 804 58715 LAdLNO OL SATEVD ONIGTAM 124 09 TIV NVIN 9NILV 4dO 33 SNOILY NddY 39113 ANY 31vIq3AWI 30 41949 ANY LN3YYN9 AHL ALIOVdVO 40 38 LSNW 318V9 9NIQTJM TIVNVIN 9NILV 4dO 83Q13M ANIONS JHL NI 031611 SNOLLV2I3IO3dS Wd 3AO8V 15 LON OG AYOLOVS SHL 13S 3Hd SI ONILLAS HONS3AO9 3NISN3 1 TOHLNOO JHL 39 VIVO NVO HOIHM 39V L10A 830334 38IM OV JHL NI 3SV3SONI NV ASNVO TIM 39 VXNIT 31LLOSH L 9NIGIHS3AO 9NILL3S HONS3AO9 JHL Ad 3NION3 4101 H9IH 40 3SV38ONI ANV 0334 OL 31872 300412413 MYOM OL 18 2 9697 9n ld 41879 8 NTOL juewudinbs siy JO syed Ajeoujoeje jou esn jejsur pinoys jeuuosied AIUO e eJoJeq syed Aeme e peg Aisyeg JALLVO3N 99uuoos d e ul sp en6 e sjaued ejeJedo jou og e ONINHVM 77 NOLLO3NNOO 8 N 1 SH3Q 13M ANISNA NOLLOVO
22. long cable lengths to reduce voltage drops TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 305 Amps 10026 Duty Cycle 1 0AWG Cable Length 0 100Ft 0 30 meters 100 150 Ft 30 46 meters 2 0 AWG 150 200 Ft 46 61 meters 3 0 AWG TABLE A 1 INSTALLATION A 5 CABLE INSTALLATION Install the welding cables to your RANGER 305D as follows 1 The engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are identified 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 CAUTION 6 Check and tighten the connections periodically Loose connections will cause the output termi nals to overheat The terminals may eventually melt Do not cross the welding cables at the output ter minal connection Keep the cables isolated and separate from one another RANGER 305D LINCOLN 5 Type INSTALLATION TABLE Ill ELECTRICAL DEVICE USE WITH THE RANGER 305D Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE Capacitive TV sets radios microwaves appliances with electrical control Voltage spikes
23. or high voltage regulation can cause the capaci tative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe oper ation DO NOT RUN THESE DEVICES WITHOUT ADDI TIONAL RESISTIVE TYPE LOADS Inductive Capacitive Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers Computers high resolution TV sets complicated electrical equipment These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A RANGER 305D The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER 305D RANGER 305D LINCOLN 8 A 7 INSTALLATION A 7 AUXILIARY POWER RECEPTACLES Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI receptacle can be reset prop erly See the MAINTENANCE section for detailed information on testing and resetting the GFCI recep tacle The auxiliary power of the RANGER 3050 consists of two 2
24. 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 V V for selecting a QUALITY product by Lincoln Electric We want you l hank to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including a
25. 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 A 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 for the first time or after and extended period of time of not oper ating 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 engine by placing the RUN STOP switch in the STOP position NOTE A fuel shut off valve is located on the fuel pre filter WELDER OPERATION DUTY CYCLE
26. 0 Amp 120 VAC 5 20R duplex receptacles with GFCI protection and one 50 Amp 120 240 VAC 14 50R receptacle The 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 10 000 watts Peak 9 500 Watts Continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The max permissible current of the 240 VAC output is 40 amps The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissi ble current of 40 Amps per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 1096 at all loads up to rated capacity All auxiliary power is protected by circuit breakers The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two 120 V circuits but are of opposite polarities and cannot be paral leled STANDBY POWER CONNECTIONS The RANGER 305D is suitable for temporary standby or emergency power using the engine manu facturer s recommended maintenance schedule The RANGER 305D can be permanently installed as a standby power unit for 240 VAC 3 wire single phase 40 amp service Connect
27. 244409 TOHLNOI OL ONILdWALLV 340338 NOILISOd 3408019 LOVLNOD 102 11 IHL NI SI HOLIMS IAOW TINGON 1081NOO LVHL 3405 38 NOILNVO 3100 OHLNOO OL 318V9 300819313 OL 318 02 1 189039 01 1699 ALOWSY Nid 9 NNO 10095 GC L87 JINGOW 10HLNO9 3719143934 OS 88 Y30334 3HIM Nid 7 SEHEN jueuudinbe siy JO sued Ajeoujooje jou esn jeisui pjnous jauuosied peyrjenb AIUO e e10Jeq sued Aeme peaj Ajegeg 3ALLVON 199uuoosid e ul uedo sjaued jou e ONINHVM WV IVO VIO NOLLO3NNOO NN9 100dS 2877 8877 01 1699 SH3TT3M RANGER 3050 LINCOLN E DIAGRAMS F 8 F 8 6 8 705 8341530 SV NOILISOd 3101 HOIH NI HOLIMS H3 dI 2 14 TN NOILISOd IONLNOOD 310IN3H NI HOLIMS 1041 02 LAdLNO NOLLISOd 911 SHL NI HO LIMS SGOW 39 1 A Ll V 10d 6341530 58715 LNdLNO OL 318V9 ONIGTAM LOANNOO aN IVNNVN 33 SNOILVOrTaav 3snin3 ANY 3L1VIQHININI dO 319A9 ANY LN H n 0O JHL ALIOVdVO 30 38 LSNW SATEVO ONIGTAM 0 YS0TSM 3NION3 3H NI 031611 SNOILVOISIOAdS Wd 3AO8V LSNPAV LON 00 7 AUOLIVA SHL LV 13S 3Hd SI ONLLL3S 3NION3 SHL LINDYID TOHLINOO 3H1
28. 3lavav S39HNOS 3NION3 NO LON 1 9 28 2987 1 19 jueuudinbe s u 2 5 10 sued Ajeoujos e uonoj jou oe esn jejsui pjnous jauuosied juo e sued dosye peg A e eg J3ALLVO3N 199uuoos d e eoejd ui deey e uedo sjeued jou ONINHVM WV INV 9VIQ NOLLO3NNOO 1 414V9 2987 OL SS3Q 13M 3NION3 DIAGRAMS RANGER 3050 LINCOLN E DIAGRAMS F 7 F 7 8 8 65 0002 22 01 NOILISOd 4101 HOIH NI HOLIMS 414101 39 1 NOILISOd GATIOULNOD OL HOLIMS STVNINYSL ONIQT3M 39V ld NOILISOd 2 IHL NI HOLIMS SHL 39V Id ALI V 10d Q38IS3G 804 SGALS LAdLAO 015318 2 L93NNOO NOILVOMddV 40 31949 ANY LN3SSCIO 9215 38 1SnIN S3 18V9 ONIQ TIM WANVW S9NILVe3dO ANIONS JHL NI Q L1SI1SNO0ILV9l4l944S Wd 3AO8V 15 LON OG 1 SHL LV 13S 3Md SI ONILL3S HONH3AO9 ANIONS IHL TOHLNOO JHL 39 VIAVO NVO HOIHM 39VL10A 83033 JHL NI 3SV3HONI NV ASNVO 39 VMNTET3TLLOSHL JHL ONIGIHS3AO ONILLAS JHL 3NION3 31d H9IH SHL 30 3SV389NI ANV 194N0S YAMOd SO ONV FINGOW IOHLNOO JHL OL 39 VIAVG NI L10S38 1002 NOILISOd HOLIMS 1
29. 89119 DIAGRAMS F 10 80d Ebr Evd v soy gl 8 EN 8711744 INNOHO ANIONS MS rot dna Saud 10 502 5 602 3012 8012 QNVOS Id TOHLNOD 2824 52 192 a WMd API lo penal A Bg0c E jousuduv 1 14 woz ob sae 44 Nong 1526 Ho y oz role 22 ool sodnn 5 WE HOLIMS 57212 sols NAIS NOILISOd 017 NINMOHS 182 JOHLNOD EFI 2467 ionpeyoag 3012 NOLINS 5 NOLLYNINYT 3HL OL 163 415 OL Q3193NNOO 3ALLISOd 1304 oez e esr i 3envo ana 002 002 HS 106 dir NO M3HOS QNO NO NITEM NINWOHS 5 1081309 HOLOVINOO 1 er en SHOHO 1 21 dIHLS N3349 9 3LIHM M 395 XOV 8 8 3002 40109 av31 210 lt 2
30. 9 syed YOno jou Bu o Jes e oJeq pee Me eg 3ALLVO3N 9euuoosiq e uedo sjeued um ejejedo jou ode NINHVM WV 10 1 09 3 038 7689 TWNOILdO HLIM NOLL23NNOO AHL SSOUIVY SC N TI SH3Q13M ANISNA JON3HdlAV RANGER 3050 LINCOLN E DIAGRAMS F 2 F 2 CL8LvCS 0002 22 01 Qd llS4Q SV NOILISOd 3 0l YO OLAV NI HOLIMS 44101 22 1 3N NOILISOd NO STVNINYSL TM SHL NI HOLIMS S IVNIINS3 L SHL SOV NOILISOd AHL NI HOLIMS SGOW 39Vld 1899 300819313 AHL 40 ALINY 10d JHL HOLVW OL HOLIMS S313IALL 10A 430334 38IM JHL NOILISOd TOd 4 1530 803 50015 1NdINO OL 318V9 9NIQT3M LOANNOO AN WANVA 9NILV J4dO 33 SNOILLVOlr1aav SYNLNS ANY ALVIGAWWI 40 41949 ANY LN38S09 JHL ALIOVdVO 43d0 d 40 38 LSNW 5418 2 ONIGTAM 418v9 300819313 OL OL 0 1 412 4202331 38IM SCNI 31054 L vvv TYNOILdO TONZHdINV Nid 9 TONZdHdINV ueu d nbe siu eorues Jo sued uonoi jou esn jejsui jauuosied AIUO e sued Aeme deeye pee JALLVO3N 12euuoosiq e eoe d ui sjeued jou ode ONINHVM WV 10 1 09 3 L0IN38
31. A 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 WARNING Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not over fill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL TA The RANGER 305D 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 run ning time during the first 50 running hours Refer to the engine Operator s Manual for specific oil recom mendations and break in information The oil change interval is dependent on the quality of the oil and the oper
32. ECIFICATIONS Ranger 305D K1727 3 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities cu in cu cm System 3 cylinder 43 88 789 12VDC Battery amp Fuel 12 gal 4 stroke starter 45 Liters 18 8 HP High Idle 3650 Bore x Stroke inch mm Oil 3 4Qts 3 2L Kubota 14 KW D722 Net intermittent Full Load 3500 2 64 x 2 68 Group 58 550 Radiator Coolant 3600 RPM 67x68mm cold crank amps 3 85Qts 3 6L naturally aspirated Low Idle 2450 Battery Charger water cooled 3 6L Diesel Engine RATED OUTPUT 104 F 40 C WELDER Current Voltage Duty Cycle Rated Load RPM DC Constant Current 305A 29V 100 20 TO 305 AMPS DC Pipe Current 300A 29V 100 40 TO 300 AMPS Touch Start TIG 250A 30V 100 20 TO 250 AMPS 60 Volts DC Constant Voltage 300A 29V 100 14 TO 29 VOLTS RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 10 000 Watts Peak 9 500 Watts Continuous 60 Hz 120 240 Volts Sound Levels Sound Power 104 2 dB Lwa Sound Level 80 6 dBA 23 ft 7m PHYSICAL DIMENSIONS 30 00 in 21 50 in 52 25 in 762 0 mm 546 0 mm 1327 0 mm LUBRICATION EMISSIONS ______FUEL SYSTEM ______ Full Pressure Certified to EPA Tier 4 Mechanical Fuel Pump Auto air bleed Mechanical with Full Flow Filter Compliant system Electric shutoff solenoid Indirect fuel injector Governor Low noise Muffler Shutdown on low oil Single Element Au
33. HLNOO SHL NVO HOIHM SOVLIOA 830333 SYIM OV JHL NI SSVSYONI NV ASNVS 39 VMNET 31LLOSH L ONILLAS AHL ONIONVHO Ad 3NION3 40 3SV38ONI NOILOVO 1 0333 38IM OL 318 2 300419313 OL TONZHdINV A 318V9 LNdNI 0333 38IM 9ILVNV4409 OL jueuudinbe s u eorues 10 sued Ajeouioeje U9n0 jou esn jje sul pjnous jeuuosied AIUO e Bu o J9s sued desye peaj AM e eg 3ALLVO3N 199uuoosi d e ui deey e sjeued ejejedo jou oq e gt Ti INV 9VIQ NOILOANNOD 2891 SSH3Q TSM 3NION3 RANGER 3050 LINCOLN E F 10 Jequunu epoo jueuudinbe jueujeae dai 10 juawpedaq eo J9S o 9 ejq Bejji s eui sjaued einsojoue y JO euo uo eu 9pISUI paysed s epoo Jejnoed o jloeds siy Aq seuruoeui 10 eq jou Ajuo 10 SI 541 ALON c L26 9 982 982 SV 031314301 HVH IMIA NMOHS SLN3NOdOO 359 NS NOLHASNI WOH GAMBIA 58012388029 45913 Had STOBWAS TVOIH193T3 2 QIONSTOS TANS H3IHVIS TInd SIN3NOdWOD
34. RY 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 Z49 1 from the American Welding Society P O 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 744 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 o 4 24 1 h To avoid scalding do not remove the AN Wi A radiator pressure cap when the engine is AWA hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool 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
35. SEL 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 KUBOTA D722 DIESEL ENGINE 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 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 Intervals Items Every 50 hours Check of fuel pipes and clamp bands Every 75 hours Change of engine oil Every 100 hours Inspect Clean air cleaner element 1 and Vacuator valve Cleaning of fuel filter Check the battery electrolyte level Check the fan belt tightness E EH Every 150 hours Check the radiator and hose c
36. able 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 LINCOLN E 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 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 checked 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
37. all 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 Refer to http www lincolnelectric com safety for additional safety information iv SAFETY iv PR CAUTIONS 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 contre 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 da
38. ating environment Refer to the Engine Operator s Manual for more details on the proper service and maintenance intervals m FUEL DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada WARNING Fill the fuel tank with clean fresh fuel The capacity of the tank is 12 gals 45 4ltrs When the fuel gauge reads empty the tank contains approximately 2 gals 7 6ltrs of reserve fuel 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 ran for extended periods of time RANGER 3050 LINCOLN 5 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 2 feet 0 6m from the case back and 16in 406mm from either side of the base to a vertical surface BATTERY CONNECTION A CAUTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes RANGER 305D is shipped with the negative battery cable disconnected Make certain that the RUN STOP switch is in the STOP position Remove the two screws from the rear battery tray using a screwdriver or a 3 8 socket Attach the negative bat tery cable to the negative battery terminal and tighten using a 1 2 socket or wrench NOTE This machine is furn
39. attery be sure the polarity is correct Improper polarity can damage the charging circuit The RANGER 305D positive battery ter minal 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 WARNING MUFFLER MAY BE HOT ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER RANGER 3050 LINCOLN D 6 MAINTENANCE D 6 WELDER GENERATOR MAINTENANCE STORAGE Store the RANGER 305D in clean dry 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 A CAUTION Do not attempt to polish slip rings while the engine is running WARNING Service and Repair should only be performed by Lincoln Electr
40. ble insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two circuits each of which measure 120 V to neutral but are of opposite polarities and cannot be paralleled Simultaneous Welding and Auxiliary Power Loads The above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in the following table The permissible cur rents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time RANGER 305D Simultaneous Welding and Power Loads Welding Output Amps Each duplex receptacle is limited to 20 amps Permissible Power Watts Unity Power Factor Permissible Auxiliary Current in Amps Not to exceed 44A per 120 VAC branch circuit when splitting the 240 VAC output RANGER 305D Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Amps Volts Watts 1 44 240 9500 n 40 9 23 150 46 225 69 350 107 600 18 15 90 69 Conductor size is based on maximum 2 0 voltage drop RANGER 3050 LINCOLN 1 ACCESSORIES 1 FIELD INSTALLED OPTIONS ACCESSORIES K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard
41. cable is connected to 14 pin open Check 42V and 120V checked and the problem persists connector beakers and 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 GFCI Receptacle may have tripped Follow GFCI Receptacle Testing and Resetting Procedure in the MAINTENANCE section of this manual 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 3050 LINCOLN E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual The welding arc is cold The weld 1 Make sure the MODE selector ing arc is not stable or is not satis switch is in the correct position for factory the engine runs normally the process being used For exam The auxiliary power is normal ple CV WIRE 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 ter
42. 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 2 596 to 3 596 for every 1000 ft 305m Due to new EPA and other local emissions regulations modifications to the engine for high altitude are restricted within the United States and some other European Countries Use above 6000 ft 1828 m 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 104 F 40 C Welder output derating is necessary For maximum output ratings derate the welder out put 2 volts for every 50 F 10 C above 104 F 40 C Cold weather starting With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 5 F 15 C If the engine must be frequently started at or below 23 F 5 C it may be desirable to install cold starting aides The use of No 1D diesel fuel is recommended in place of No
43. cludes auto sensing remote control circuit 9 WELD TERMINALS CONTROL SWITCH In the WELD TERMINALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED posi tion the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch 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 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 Glow plug should not be activated for more than 20 seconds continuously 13 START PUSH BUTTON Energizes the starter motor to crank the engine 14 IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the 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 approximately 12 seconds and then go to 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 fu
44. cted 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 To STOP a weld simply pull the TIG torch away from the work When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the current to the Touch Start level To reinitiate the arc retouch the tungsten to the work and lift Alternatively the weld can be stopped by releasing the Amptrol or arc start switch The RANGER 305 D 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 305 D The settings are for reference TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES 2 Tungsten Electrode Diameter in mm DCEN DCEP Approximate Argon Gas Flow Flow Rate C F H 1 min TIG TORCH Nozzle Size 4 5 1 2 Thoriated 1 2 Thoriated Aluminum Stainless Steel Tungsten Tungsten 2 15 5 20 2 4 3 5 3 5 3 3 15 80 3 70 150 10 20 5 10 3 5 150 250 250 400 15 30 25 40 13 17 6 8 15 23 7 11 21 25 23 27 28 32 400 500 500 750 750 1000 40 55 55 80 80 125 10 12 11 13 13 15 3 8 2 4 5 10 4 5 6 5 6 6 7 8 8 10 1 When used with argon gas The
45. current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4in 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 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 LINCOLN amp B 6 RANGER 305 D 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 con tactor 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 305 D is used to set the maximum range of the CUR RENT CONTROL on the TIG Module or an Amptrol if connected to the TIG
46. d 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 petcock at the bottom of the radiator Open the radiator cap to allow com plete drainage Tighten the petcock and refill with a 50 50 antifreeze water solution Use an automotive grade low silicate ethylene glycol antifreeze The cooling system capacity is 3 85 quarts 3 6L 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 34 F 37 C 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 battery lose its charge Check tightness by p
47. do not start engine until fumes have been eliminated 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 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 In some cases it may be necessary to remove safety b minimize exposure to 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 or idler by pushing on the throttle control rods while the engine is running
48. e Current Range DC electrode positive Carbon Diameter 1 8 60 90 Amps 5 32 90 150 Amps 3 16 200 250 Amps RANGER 305D LINCOLN B 7 OPERATION B 7 AUXILIARY POWER If a GFCI receptacle is tripped See the MAINTE NANCE section for detailed information on testing and resetting the GFCI receptacle 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 The auxiliary power of the RANGER 305D consists of two 20 Amp 120 VAC GFCI 5 20R duplex recep tacles and one 50 Amp 120 240 VAC 14 50R recep tacle The 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capac ity is 10 000 watts Peak 9500 Watts continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The max permissible current of the 240 VAC output is 44 Amps The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 44 Amps per output to two separate 120 VAC branch circuits these circuits can not be paralleled Output voltage is within 10 at all loads up to rated capacity All auxiliary power is protected by circuit breakers The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou
49. eal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers say that it takes only a few grams of dirt to dust an engine Be careful not to damage the sealing area on the tube Wipe both sides of the outlet tube clean Outer edge of the outlet tube Inner edge of the outlet tube If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted damaged or plugged Inspect the Old Filter for Leak Clues Visually inspect the old filter for any signs 22 of leaks A streak of dust on the clean side of the filter is telltale sign Remove cause of leaks before installing new filter 4 Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end which is the RR sealing area NEVER install a damaged filter Anew Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 Insert the New Radial Seal Filter Properly If you re servicing the safety filter this should be seated into position before installing the primary filter Insert the new filter carefully Seat the filter by hand making certain it is completely into the air cleaner housing before securing the cover in place
50. ectrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung solieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e electro dos com a pele ou roupa molhada sole se da pe a e terra e KERORA Rise 7 17 UY C amp o J TV 7 X3 5 RE BA CRA CRM ML 845 eHEAU Xe uc zu 844 HIS 444 jas uil Quali emad ag ON pile ekl JA ule Y je Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e Havdv6008 CIZ e 18 tJ MR BEL FIST 48 AIX nig Aa ALU a U ala e Wear eye ear and body protection Prot jase los ojos los o
51. ed jou e ONINHVM 7 NOLLO3NNOO 1 43073 3NION3 3050 LINCOLN E 5 8 705 F 4 0002 22 01 8341530 SV NOILISOd 3101 HOIH NI HOLIMS 44101 39V1d TN NOLLISOd GATIONLNOD ATSLOWSY OL HOLIMS STVNINYSL ON NOILISOd AIM AO JHL NI HOLIMS 39V1d 300819313 SHL 40 3H L HOLVN OL HOLIMS YALAWLIOA 830333 38IM NOILISOd 10d 341530 50115 LAdLNO OL 318V9 ONIGTAM LOANNOO WANVA 9 395 SNOILVO dd 39813 ANY ALVIGASWWI 40 371949 ALNG ANY LNAYYNSD JHL ALIO Va VO ddO d 30 38 LSNW S414V9 ONIGTAM TIVNVIN 9NILV 4dO 83Q 13M 3NION3 JHL NI 931511 SNOILVOISIOAdS Wd 3AO8V LSfI QV LON OQ AHOLOV4J SHL 145 SI ONILL3S YONYSAOD 3NION3 JHL LINDYIO TOHLNOO 3HL HOIHM 39 VL 10A 8303343 38IM IHL NI 3SV3HONI NV 3575 TIM 39 VMNII ATLLOUHL SNIGIHS3AO ONILLAS HONH3AOS JHL 9NIDNVHO A 3NI9N3 HL 30 3SV389NI ANV LINN G334 OL MEAM 0 318 2 300410313 OL tc lt 114V9 1OHLNOO 2697 318vO TONZHdINV lf dNI CYZ NTOL Nid Fl jueuudinbe s u 2 5 Jo syed Ajeouioeje jou oq esn jje sul pjnous jauuosied AIUO e sued Aeme peaj M e
52. en the gun trigger is closed the current sens ing circuit will cause the RANGER 305D engine to go to the high idle speed the wire will begin to feed and the welding process started When weld ing is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed CAUTION If you are using an LN 25 without an internal con tactor the electrode will be energized when the Ranger 305D is started INSTALLATION A 10 Connection of LN 742 Spool Gun K487 25 and Cobramatic to RANGER 305D 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 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 Set the WELD TERMINALS switch to WELD TERMINALS ON Set the ARC CONTROL knob to O initially and adjust to suit Set the IDLE sw
53. engine service shop Faulty fuel pump Check for fuel flow through filters Contact autho rized 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 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout 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 batt
54. er by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated 1 USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at engine foot BATTERY ACID can burn eyes and skin dE 1 Wear gloves and eye protection and be careful when working near battery 1 Follow instructions printed on battery 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 1 4 pound 0 1113 kg of baking soda and 1 quart 0 9461 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 terminals 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 b
55. ery Replace Engine alternator trouble light is on 2 Loose connections at battery or while machine is running 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 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 3050 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Engine will not go to high idle when using auxiliary power Engine will not go to hig
56. h 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 POSSIBLE CAUSE 1 Auxiliary power load is less than 100 watts 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 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 wate
57. he start button for 45 seconds 4 Check to see that fuel is flowing through both fuel filters 5 Follow the normal STARTING procedures RANGER 3050 LINCOLN D 5 MAINTENANCE D 5 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 3650 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 2 screws from the battery door using a screwdriver or a 3 8 Socket Remove the 2 nuts from the battery bracket using a 7 16 wrench or socket Slide the battery out and remove from welder WARNING Mss FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when 1 INSTALLING A NEW BATTERY disconnect negative cable from old battery first and con nect to new battery last 1 CONNECTING A BATTERY CHARGER remove battery from weld
58. here 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 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Installation Section A Technical Specifications siens A 1 Safety oce mere scene ueteri VR Ert ee
59. ic 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 GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To properly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the receptacle and turn the product ON Push the Test button located on the GFCI recepta cle The night light or other product should go OFF Push the Reset button again The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not working prop
60. icking 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 forceful 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 deposition stacking of iron are key to fast travel speeds It is recom mended that the ARC CONTROL be set initially at 0 CV WIRE mode In this mode turning the ARC 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 D Provides a connection point for connecting the machine case to earth ground 7 14 PIN For attaching wire feeder con trol cables to the RANGER 305D Includes contactor clo sure circuit auto sensing remote control circuit and 120V and 42V power The remote control circuit operates the same as the 6 Pin Amphenol 8 6 PIN CONNECTOR For attaching optional remote control equipment In
61. ining 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 a drain Engine Oil Refill capacities Without oil filter replacement 3 3 U S Quart 2 7 Imp Quart 3 2 liter With oil filter replacement 3 4 U S Quart 3 0 Imp Quart 3 2 liter Use motor oil designed for diesel engines that meets
62. ions must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes Install the double pole double throw switch between the power company meter and the premis es disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary steps to assure load is limited to the capacity of the RANGER 305D by installing a 50 amp 240 VAC double pole circuit breaker Maximum rated load for each leg of the 240 VAC auxiliary is 40 amperes Loading above the rated output will reduce output voltage below the allow able 10 of rated voltage which may damage appliances or other motor driven equipment and may result in overheating of the RANGER 3050 engine and or alternator windings Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the double pole circuit breaker using No 6 4 conductor cable of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit or as part number T12153 9 Plug this cable into the 50 Amp 120 240 Volt recep tacle on the RANGER 305D case front RANGER 3050 LINCOLN 5 A 8 INSTALLATION A 8 CONNECTION OF RANGER 305D TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR Wer Pa 60 Hz 3 Wire COMPANY E Servi ervice METER NEUTRAL
63. ira Ranger 3050 December 2010 For use with machines having Code Numbers 11457 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ISO 9001 Designed and Manufactui Quality Program Certi y ABS Quality Evaluations Inc s BENE LI NCOLN Copyright Lincoln Global Inc World s Leader 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 gt CALIFORNIA PROPOSITION 65 WARNINGS gt Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJU
64. ished 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 in the desired direction Tighten using a 9 16 socket or wrench SPARK ARRESTER Some federal state or 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 main tained WARNING An incorrect spark arrestor may lead to damage to the engine or adversely affect performance INSTALLATION A 4 REMOTE CONTROL The RANGER 305D is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connect ing the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K936 3 hand Amptrol When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote conirol is connected to the 6 pin Connector the auto sensing circuit automatically switches the OUTPUT control from control at the welder to remote control When in TOUCH START TIG mode and when a A
65. itch to the HIGH position RANGER 3050 LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECAUTIONS 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 TA electrode with skin or wet clothing e 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 is a diesel engine powered DC multi process welding power source and 120 240 volt AC power generator The engine drives a genera tor that supplies three phase power for the DC weld ing circuit and single phase power for the AC auxiliary outlets The DC welding control system uses state of the art Chopper Technology CT tm for superior weld ing 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
66. l ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria etai AP5AmtRB XocCUC HRAV HELTIBELTTFEL EOF OR E Ek HJ JA SR ER 18 AzzTE 247 S XACOERE pisi 2184 72H21 7 amp ASHIS s iua daly as l e gall bis jua 3 Les All olaa us power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X3TTTLAS9 UAUBRUD SEC tT8REAT 7T amp 4392CF v e HEMMER SHA HAE all J il Sl juil all e Do not operate with panel open or guards off No operar con panel abierto o guardas 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 Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas IJI 0 CRRBTES 3R RT PI BOR T RT EVE zaol Sel AE
67. lamps Md Replacement of oil filter cartridge Check the intake air lines O O Replacement of Air Filter element Replacement of fuel filter element Every 500 hours Cleaning of water jacket radiator interior Replacement of fan belt E Every 1 or 2 months Recharging of Battery Every 800 hours Check of valve clearance Check the fuel injection nozzle injec 3 tion pressure Every 3000 hours Check of injection pump Every 2 years Replacement of radiator hoses and clamp band Replacement of fuel pipes and BB clamps Replacement ofintake aire IMPORTANT These jobs should be done after the first 50 hours of operation 51 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 All these markings are registered as emission related critical parts by KUB OTA in the U S EPA nonroad emission regulation As the engine owner you are responsible for the performance of the required maintenance on the according to the above instruction Please see Engine Owners Manual for Warranty Statement in detail Every 1500 hours RANGER 305D LINCOLN D 2 Engine Oil Change Sn Drain the engine oil while the engine is warm to assure rapid and complete dra
68. ll 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 LINCOLN B 4 OPERATION B 4 15 ELECTRIC FUEL GAUGE The electric fuel gauge gives accurate and reliable indication as to how much fuel is in the fuel tank 16 ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance 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 lt 3 4 3 Set the RUN STOP switch to RUN 4 Press Glow Plug Button and hold 5 to 10 seconds 5 Press and hold both the Glow Plug Button and START button together until the engine starts or for up to 10
69. lugs For connection of Lincoln equipment with NEMA 6 50R plug TIG Welding K1783 9 TIG Torch PTA 26V 25ft K963 3 Hand Amptrol K870 Foot Amptrol KP509 Magnum Parts Kit Spool Gun K1692 2 Prince XL Spool Gun 25ft K487 25 Magnum Spool Gun K488 Magnum Control Module K691 10 Input Cable RANGER 3050 LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS 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 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 DIE
70. minals 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 3050 LINCOLN DIAGRAMS F 1 F 1 l 282F2S 0002 22 01 0341540 SV NOILISOd 4101 H9SIH HO OLAY NI HOLIMS 44101 4dOVld NOILISOd NO S IVNIINS3 L NI HOLIMS S IVNIINSI3 L ONIQT3M JHL 39V ld NOILISOd 2 3H L NI HO LIMS SGOW 39V ld 1899 300419313 30 ALIS V 10d SHL HOLVW OL HOLIMS S31L3IAL 10A 430334 38IM AHL NOILISOd ALIS V Od 4341530 SCALS LAdLNO OL 531979 L93NNOO TIV NVIN 9NILV J4dO 33 SNOILLVOlr1aav SYNLNA ANY 31VIQ3AWI 40 41949 ALNA ANY AHL ALIOVaVO 43d0 d 50 38 LSNN 318V9 ONIGTAM 18 5 300819313 OL 0 1 430334 38IM SALOWSY OF 1584 TYNOILdO ueu d nbe s u 2 5 10 esn jje sul pjnous jeuuosJed AIUO e syed Aeme desye eoejd ui e 9 OL TONZdHdINV Nid
71. mptrol 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 con nector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder volt age control active 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 power must WARNING grounded to the frame of the welder using grounded type plug Be double insulated Do not ground the machine to a pipe that carries explosive or combustible material RANGER 305D LINCOLN 5 A 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 connect ed between the machine grounding stud and the frame of the vehicle When this engine driven welder is connected to p
72. nd 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 3050 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 A CAUTION During break in subject the RANGER 305D 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 LINCOLN Km OPERATION EN lt FIGURE 1 AL TT Le 2 2 27 gt 4 OS CE 2640 9999 WELDING CONTROLS Figure B 1 2 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode OUTPUT CONTROL The OUTPUT dial is or current CC STICK DOWN HILL PIPE and TIG used to preset the output voltage or current as dis modes to be set prior to welding using the OUT played on the digital meters for the four welding PUT control dial During welding the meter dis modes When in the CC STICK DOWNHILL PIPE play the actual output voltage VOLTS and cur or CV WIRE modes and when a remote control is rent AMPS A memory feature holds the display connected to the 6 Pin or 14 Pin Connector the of b
73. ng and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can reac
74. ns l eau pour le soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d 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 refroidir 10 Ne pas souder en pr sence de vapeurs de chlore provenant 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 so
75. ny warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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 Code Number or Date Code Serial Number Date Purchased W
76. ot operate with doors open or 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 machines cannot 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 12 gallons 45ltrs INSTALLATION A 2 LIFTING The RANGER 305D weighs approximately 775lbs 352kg with a full tank of fuel 698 Ibs less fuel A lift bail is mounted to the machine and should always be used when lifting the machine WARNING HE Lift only with equipment of ade quate lifting
77. oth meters on for seven seconds after welding auto sensing circuit automatically switches the is stopped This allows the operator to read the OUTPUT CONTROL from control at the welder to actual current and voltage just prior to when weld the remote control ing was ceased trol cable is connected to the 14 Pin Connector the mal point in each display will be flashing The auto sensing circuit automatically makes OUTPUT accuracy of the meters is 3 CONTROL inactive and the wire feeder voltage control active 3 WELD MODE SELECTOR SWITCH Provides four selectable welding modes When in the TOUCH START TIG mode and when a 4 Amptrol is connected to the 6 Pin Connector the CC STICK OUTPUT dial is used to set the maximum current TOUCH START TIG range of the CURRENT CONTROL of the Amptrol RANGER 3050 LINCOLN 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 st
78. r 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 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 Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 1 LINCOLN 8 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screeni
79. r 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 RECOMMENDED COURSE OF ACTION 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 3050 LINCOLN 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual No welding power output 1 Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Weld Terminals switch in wrong position Place switch in Weld Terminals On position when welding without control cable Faulty PC board or welder alterna tor 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
80. r element A fire or explosion could result A CAUTION Never 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 LINCOLN MAINTENANCE Service Instructions Single and Two Stage Engine Air Cleaners 1 Remove the Filter Unfasten or unlatch the service cover Because the filter fits tightly over the outlet tube to create the critical seal there will be some initial resistance similar to breaking Rotate the filter while the seal on a jar Gently move the end of the filter pulling back and forth to break the seal then rotate while straight out pulling straight out Avoid knocking the filter against the housing lf your air cleaner has a safety filter replace it every third primary filter change Remove the safety filter as you would the primary filter Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube Contaminant on the sealing surface could hinder an effective s
81. remises wiring such as that in a home or shop its frame must be connected to the sys tem earth ground See further connection instructions in the section entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local code 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 The National Electrical Code lists a number of alter nate means of grounding electrical equipment ACD machine grounding stud marked with the symbol is provided on the front of the welder WELDING TERMINALS The RANGER 305D 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 REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened with a 3 4 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
82. ress ing on the belt midway between the pulleys It should deflect about 25 in under a load of 20 Ibs 9 Kg 6 mm 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 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 conditions 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 Fillthe fuel tank with fuel 2 Open the fuel shut off valve vertical position of handle on the Fuel Filter 8 Crank the engine by pressing t
83. rums 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 AWS 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not u
84. s required by the electrode being used Set the MODE switch to the CV WIRE position Set the ARC CONTROL knob to O initially and INSTALLATION A 9 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 WELD TERMINALS switch to REMOTELY CONTROLLED adjust to suit Set the MODE switch to the CV WIRE position e Set the WELD TERMINALS switch to the REMOTELY CONTROLLED position Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity Set the IDLE switch to the HIGH position being used Set the ARC CONTROL knob to O initially and Connection of LN 15 to the Ranger 305D adjust to suit These connections 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 Set the IDLE switch to the AUTO position Shut the welder off For electrode Positive connect the electrode cable to the terminal of
85. se a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 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 Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding 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 P I Precautions for Safe Handling of Compressed Gases in Oylinders 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 Inst
86. t with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 including 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 SAFETY KE WELDING and CUTTING gt SPARKS 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 d
87. 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 RANGER 305D LINCOLN 8 A 10 WARNING Connection of the LN 25 to the RANGER 305D Shut off welder before making any electrical con nections The LN 25 with or without an internal contactor may be used with the RANGER 305D See the appropri ate connection diagram in Section F 1 Shut the welder off 2 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 3 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 4 Set the MODE switch to the CV WIRE position 5 Set the WELD TERMINALS switch to WELD TERMINALS ON 6 Set the ARC CONTROL knob to O initially and adjust to suit 7 Set the IDLE switch to the AUTO position When not welding the RANGER 305D 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 Wh
88. tomatic Idler Top outlet can be rotated pressure amp engine Made from long life aluminized steel temperature 698 Ibs 317kg RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS 2 120VAC GFCI Duplex 5 20R Two 20AMP for Two Duplex Receptacle 15AMP for Battery Charging Circuit 1 120 240VAC Dual Voltage One 50AMP for Dual Voltage 2 pole 15AMP for 42V Wire Feeder Power Full KVA 14 50R 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 Top of enclosure add 152mm for exhaust pipe Engine warranty may vary outside of the USA See Engine warranty for details RANGER 3050 LINCOLN 8 A 2 SAFETY PRECAUTIONS 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 TA Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure n
89. towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc Order K957 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 2 Fender amp Light Kit K965 1 Cable Storage Rack K1789 1 ROLL CAGE Gives added damage protection K1898 1 SPARK ARRESTOR K704 ACCESSORY SET Includes 35 ft 10m of electrode cable and 30 ft 9 1m of work cable head shield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 25 ft 7 6m or K857 1 100 ft 30 4m REMOTE CONTROL Portable control provides same dial range as the out put control on the welder Has a convenient 6 pin plug for easy connection to the welder K2174 1 COLD WEATHER OPERATIONS KIT Provides starting aid and enhancement in extreme cold weather Includes radiator grill cover oil pan heater coolant Lester and all hardware required for installation K802 N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps K802 R POWER PLUG KIT Provides four 120 volt plugs rated at 15 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps T12153 9 50 AMP 120 240 V POWER PLUG K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong p
90. udage 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 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 du 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

Lincoln Electric 305D Welder User Manual

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