Lincoln Electric IM836-B manual

Ranger 305D OPERA TOR’S MANUAL IM836-B May, 2007 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL A[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... .... Section A Technical Specifications ....................................................................................................... A-1 Safety Precautions ........................[...]

vii vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................[...]

RANGER 305D 1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up t o rated capacity. When welding, available auxiliary power will be reduced. * Top of enclosure add 6in. (152mm) for exhaust pipe. ** Engine warranty may vary outside of the USA. (See Engine warranty for details[...]

LIFTING The RANGER 305D weighs approximately 775lbs.(352kg.) with a full tank of fuel (698 lbs. less fuel). A lift bail is mounted to the machine and should always be used when lifting the machine. HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For max- imum rating, derate the machine 2.5% to 3.5% for every 1000 ft. [...]

PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Stop engine and allow to cool before fueling • Do not smoke when fueling. • Fill fuel tank at a moderate rate and do not over- fill. • Wipe up spilled fuel and allow fumes to clear before starting engine. • Keep sparks and [...]

A-4 INST ALLA TION RANGER 305D 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 control is connecte[...]

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. [...]

AUXILIAR Y POWER RECEPT ACLES 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- ta[...]

A-7 INST ALLA TION RANGER 305D A-7 CONNECTION OF RANGER 305D T O PREMISES WIRING W ARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that: • The installation complies with the National Electrical Code and all other applicable electrical codes. • The p[...]

A-8 INST ALLA TION RANGER 305D A-8 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 "-" as requi[...]

A-9 INST ALLA TION RANGER 305D A-9 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 Modu[...]

B-1 OPERA TION RANGER 305D B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ----------------------------------------------[...]

B-2 OPERA TION B-2 WELDING CONTROLS (Figure B.1) 1 . OUTPUT CONTROL- The OUTPUT dial is used to preset the output voltage or current as dis- played on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit a[...]

B-3 OPERA TION 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 a[...]

B-4 OPERA TION 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 L[...]

TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORC H Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5) 1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel Tungsten Tungsten .010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6 0.020 (.50) 5-20 (3) 5-10[...]

RANGER 305D B-6 OPERA TION 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. Th[...]

Permissible Auxiliary Current in -Amps @ 240 VAC 44 31 24 19 12 3 B-7 OPERA TION B-7 AUXILIAR Y 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 regardle[...]

C-1 ACCESSORIES C-1 FIELD INST ALLED OPTIONS / ACCESSORIES K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS For road, off-road and in-plant and yard 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 Hit[...]

D-1 MAINTENANCE D-1 RANGER 305D SAFETY PRECAUTIONS • 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 gua[...]

D-2 MAINTENANCE D-2 Engine Oil Change Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommend- ed that each time the oil is changed the oil filter be changed as well. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Locate oil drain hose and valve in bottom of ba[...]

D-3 MAINTENANCE D-3 RANGER 305D Service Instructions & Installation T ips For Engine Air Filter F Release the 1 Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they don t hinder filter removal/installation. Most latches are spring loaded to fold back when[...]

D-4 MAINTENANCE D-4 COOLING SYSTEM HOT 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. Add 50/50 antifreeze / water solution if the level is close to or below the "LOW&quo[...]

D-5 MAINTENANCE D-5 FUEL FIL TER 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. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Servic[...]

D-6 MAINTENANCE D-6 RANGER 305D WELDER / GENERA T OR 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: Itʼs nor- mal for the brushes and slip rings to w[...]

E-1 TROUBLESHOOTING E-1 RANGER 305D 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair poss[...]

E-2 TROUBLESHOOTING E-2 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S[...]

E-3 TROUBLESHOOTING E-3 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S[...]

E-4 TROUBLESHOOTING E-4 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S[...]

E-5 TROUBLESHOOTING E-5 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S[...]

E-6 TROUBLESHOOTING E-6 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S[...]

F-1 DIAGRAMS F-1 RANGER 305D[...]

F-2 DIAGRAMS F-2 RANGER 305D[...]

F-3 DIAGRAMS F-3 RANGER 305D[...]

F-4 DIAGRAMS F-4 RANGER 305D[...]

F-5 DIAGRAMS F-5 RANGER 305D[...]

F-6 DIAGRAMS F-6 RANGER 305D or service this equ ipm ent. On l y qualified personne l should install,use Keep away from m oving parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch e lectrically live parts. before servicing. Disconnect NEGATIVE (-) Battery lead Do not operate with panels open. ELECTRIC SH OCK can kill 14 [...]

F-7 DIAGRAMS F-7 RANGER 305D[...]

F-8 DIAGRAMS F-8 RANGER 305D[...]

F-9 DIAGRAMS F-9 RANGER 305D 2 9/03[...]

F-10 DIAGRAMS F-10 RANGER 305D[...]

F-11 DIAGRAMS F-11 RANGER 305D NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code numbe[...]

F-12 DIAGRAMS F-12 RANGER 305D NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code numbe[...]

F-13 DIMENSION PRINT F-13 RANGER 305D M20334 B 21 .0 6 53 4. 9 51. 2 0 1300 .5 17 .5 0 44 4. 5 19 .50 49 5.3 35. 77 908 .4 29 .8 3 75 7. 6 34. 24 869 .8 CI RCU IT B R E AKE RS 13 26 .4 52. 0 0 1320 .8 29 .0 0 73 6. 6 11 .3 0 28 7. 0 21. 5 0 546. 1 CE N TE R OF GR AV IT Y NO T E : C ASE F RO N T GRAPHI CS MAY NOT MA T C H A L L C O DES. 29 .5 7 75 1[...]

NOTES RANGER 305D[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA [...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]