Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Soudage A L...
Page 8 - vii
Page 9 - viii
Page 10 - Thank You; Please Examine Carton and Equipment For Damage Immediately
ix ix Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 manua...
Page 11 - TABLE OF CONTENTS
x x TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1...
Page 13 - INSTALLATION; INPUT - DIESEL ENGINE; PHYSICAL DIMENSIONS
RANGER 305D (CE) (1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. (2) To top of enclosure, add 152mm (6 “) to top of exhaust elbow.(3) Engine warr...
Page 14 - SAFETY PRECAUTIONS; LOCATION AND VENTILATION; electrode with skin or wet clothing.; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t
LIFTINGThe machine weighs approximately 374 kg. (824 lbs)with a full tank of fuel. A lift bail is mounted to themachine and should always be used when lifting themachine. HIGH ALTITUDE OPERATIONAt higher altitudes, output derating may be necessary. For max-imum rating, derate the machine 2.5% to 3.5...
Page 15 - TOWING; PRE-OPERATION ENGINE SERVICE; VEHICLE MOUNTING
A-3 INSTALLATION RANGER 305D (CE) A-3 TOWING Check with distributor for the recommended trailer for use withthis equipment for road, in-plant and yard towing by a vehicle. Ifthe user adapts a non-Lincoln trailer, he must assume responsi-bility that the method of attachment and usage does not resulti...
Page 16 - ELECTRICAL CONNECTIONS; • Be grounded to the frame of the welder using a
A-4 INSTALLATION RANGER 305D (CE) A-4 ENGINE COOLING SYSTEM Air to cool the engine is drawn in the base sidesand exhaust through radiator & case back. It isimportant that the intake and exhaust air is notrestricted. Allow a minimum clearance of 0.6m (2feet) from the case back and 40cm (16”) from...
Page 17 - Cable Length; CAUTION
CABLE INSTALLATIONInstall the welding cables to your machine as follows: 1. The diesel engine must be OFF to install welding cables. 2. Remove the flanged nuts from the output termi- nals. 3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identi-fied on ...
Page 18 - • T h e i n s t a l l a t i o n c o m p l i e s w i t h t h e N a t i o n a l; • Control Cable Model:
A-6 INSTALLATION RANGER 305D A-6 Connection of the LN-25 to the RANGER 305D(CE)Shut off welder before making any electrical con-nections.------------------------------------------------------------------------The LN-25 with or without an internal contactor maybe used with the RANGER 305D (CE). See t...
Page 20 - OPERATION; GENERAL DESCRIPTION; ENGINE OPERATION; • Do not leave unattended while; DIESEL FUEL ONLY; DIESEL FUEL
B-1 OPERATION RANGER 305D (CE) B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesi m p o r t a n t s a f e t y p r e c a u t i o n s , d e t a i l e d e n g i n estarting, operating and main...
Page 21 - WELDING CONTROLS; DIGITAL OUTPUT METERS
B-2 OPERATION 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 weldingmodes. When in the CC-STICK, DOWNHILL PIPEor CV-WIRE modes and when a remote control isconnected to the 6-Pin or ...
Page 22 - : The ARC CONTROL dial is active in; WELD OUTPUT TERMINALS WITH FLANGE; • AUTO BLEED FUNCTION – Air will automatically; START PUSH BUTTON
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 isnot active in the TIG mode. CC-STICK mode: In this mode, the ARC CONTROL dialsets the short circuit current (arc-force) during...
Page 23 - ENGINE HOUR METER; • Do not allow the starter motor to run continuously; STOPPING THE ENGINE; TYPICAL RANGER 305D (CE) FUEL CONSUMPTION
B-4 OPERATION B-4 15. ELECTRIC FUEL GAUGE- Provides accu- rate, reliable indication of how much fuel is in thetank . 16. ENGINE HOUR METER – Displays the total time that the engine has been running. This meteris useful for scheduling prescribed maintenance. 17. ENGINE PROTECTION LIGHT- A warning ind...
Page 24 - WELDER OPERATION; DUTY CYCLE
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH 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-...
Page 25 - Simultaneous Welding and Auxiliary Power Loads; ARC GOUGING; AMPS
AUXILIARY POWER: Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn. Simultaneous Welding and Auxiliary Power Loads While welding, the amount of 3-phase Auxiliary...
Page 26 - ACCESSORIES
C-1 ACCESSORIES C-1 FIELD INSTALLED OPTIONS /ACCESSORIES K1898-1 SPARK ARRESTOR - Mounts between muf-fler & elbow to eliminate any risk of spark from exhaust. K704 ACCESSORY SET - Includes (10m) 35 ft. ofelectrode cable and (9.m) 30 ft. of work cable, head-shield, work clamp electrode holder. Ca...
Page 27 - MAINTENANCE
D-1 MAINTENANCE D-1 RANGER 305D (CE) SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • R e m o v e g u a r d s o n l y w h e n n e c e s s a r y t o perform maintenance and rep...
Page 28 - • Never use gasoline or low flash point solvents; AIR CLEANER
D-2 MAINTENANCE D-2 ENGINE OIL CHANGED r a i n t h e e n g i n e o i l w h i l e t h e e n g i n e i s w a r m t oassure rapid and complete draining. It is recommend-ed that each time the oil is changed the oil filter bechanged as well. • Be sure the unit is off. Disconnect the negative bat- tery ca...
Page 29 - Service Instructions & Installation Tips; For Engine Air Filter
D-3 MAINTENANCE D-3 RANGER 305D (CE) Service Instructions & Installation Tips For Engine Air Filter Release the 1 Seal Carefully Unlatch and remove the servicecover of the air cleaner. Makecertain the latches are foldedback against the cover so thatthey donít hinder filterremoval/installation. M...
Page 30 - COOLING SYSTEM; • Do not remove cap if radiator is; TIGHTENING THE FAN BELT; Bleed the fuel system as follows:
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 theradiator and recovery bottle. Add 50/50 antifreeze /water solution if th...
Page 31 - ENGINE ADJUSTMENT; GASES FROM BATTERY can explode.; • ALLOW ENGINE TO COOL BEFORE INSTALLING
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. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by aLincol...
Page 32 - • Do not attempt to polish slip rings while the; • Service and Repair should only be performed by
D-6 MAINTENANCE D-6 RANGER 305D (CE) WELDER / GENERATORMAINTENANCE STORAGE: Store the RANGER 305D (CE) in clean,dry protected areas. CLEANING: Blow out the generator and controls peri-odically with low pressure air. Do this at least once aweek in particularly dirty areas. BRUSH REMOVAL AND REPLACEME...
Page 33 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 RANGER 305D (CE) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshootin...
Page 34 - PROBLEMS; C o n t a c t y o u r l o c a l L i n c o l n
E-2 TROUBLESHOOTING E-2 RANGER 305D (CE) 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshoot...
Page 39 - DIAGRAMS
Page 41 - MOVING PARTS can injure; RNI; ELE; ENGI
F-3 DIAGRAMS F-3 RANGER 305D (CE) or ser v ice this equip m ent. Only qual ified pe rsonnel should instal l,u se Keep a w ay f rom m o v ing pa rts. Keep guards in place. MOVING PARTS can injure W A RNI NG Do not touch elect ri ca lly liv e part s. before se rv ic ing. D is connect NEG AT IVE (- ) B...
Page 44 - Enhanced Diagram
F-6 DIAGRAMS F-6 RANGER 305D (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Depar...
Page 45 - ANGE
F-7 DIAGRAMS F-7 RANGER 305D (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Depar...
Page 48 - DIMENSION PRINT; MM
F-10 DIMENSION PRINT F-10 RANGER 305D (CE) MM 20 33 5 A. A . 0 2 60.2 1 15 29.3 29.6 7 75 3.6 26.5 2 67 3.6 60.0 0 15 24.0 59.2 0 15 03.7 17.5 0 44 4.5 19.5 0 49 5.3 21.0 6 53 4.9 21.5 0 54 6.1 29.8 3 75 7.6 34.2 4 86 9.8 35.7 7 90 8.4 6.33 16 0.9 11.0 3 28 0.2 29.6 3 75 2.6 17.0 0 43 1.8 CE NTER OF...
Page 49 - NOTES