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Lincoln Electric RANGER 305 D (CE) IM837-A, Operator'S Manual, Page: 12 / 54

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Lincoln Electric RANGER 305 D (CE) IM837-A Operator'S Manual Download Page 12

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TABLE OF CONTENTS

Maintenance......................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance ............................................................................................D-1

Engine Maintenance Components ........................................................................D-1
Kubota Diesel Engine ............................................................................................D-1

Engine Oil Change ..........................................................................................D-2
Engine Oil Refill Capacities.............................................................................D-2
Engine Oil Filter Change .................................................................................D-2
Air Cleaner Service .........................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter .......................D-3

Cooling System .....................................................................................................D-4

Fan Belt...........................................................................................................D-4
Fuel .................................................................................................................D-4
Bleeding the Fuel System ...............................................................................D-4
Fuel Filter ........................................................................................................D-5

Engine Adjustment ..........................................................................................D-5
Battery Maintenance .......................................................................................D-5

Servicing Optional Spark Arrestor ...................................................................D-5

Welder / Generator Maintenance ........................................................................D-6

Storage ...........................................................................................................D-6
Cleaning ..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6

________________________________________________________________________

Troubleshooting ..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-6

________________________________________________________________________

Diagrams and Dimension Print ......................................................................Section F

________________________________________________________________________

Parts List ..................................................................................................................P494

________________________________________________________________________

Summary of Contents for RANGER 305 D (CE) IM837-A

Page 1: ...RATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 11122 11123 11189 11190 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 ...

Page 2: ...R 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 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 availa...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h 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 3...

Page 4: ...event 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Page 6: ...v SAFETY v ...

Page 7: ...vi SAFETY vi RANGER 305D CE c o Balmes 89 80 2a 08008 Barcelona SPAIN Measured sound power level LWA 98 dB net power Pel 7 5kW LWA 96 dB net power Pel 7 5k W 26 April 2005 Dario Gatti ...

Page 8: ...vii SAFETY vii RANGER 305D CE ...

Page 9: ...viii SAFETY viii RANGER 305D CE ...

Page 10: ...ation below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number_____________________________...

Page 11: ...nection of Lincoln Electric Wire Feeders A 6 A 7 ________________________________________________________________________________ Operation Section B Safety Precautions B 1 General Description B 1 For Auxiliary Power B 1 Engine Operation B 1 Break in Period B 1 Add Fuel B 1 Fuel B 1 Welder Controls B 2 Engine Controls B 3 Starting and Stopping the Engine B 3 B4 Stopping B 4 Welding Operation B 5 D...

Page 12: ...gine Adjustment D 5 Battery Maintenance D 5 Servicing Optional Spark Arrestor D 5 Welder Generator Maintenance D 6 Storage D 6 Cleaning D 6 Brush Removal and Replacement D 6 ________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 _______________________________________________________...

Page 13: ...th Full Flow Filter EPA Tier I Fuel Pump Codes 11189 11190 Auto air bleed Mechanical Governor system Electric shutoff solenoid Indirect fuel injector AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure engine Made from long life aluminized steel temperature ENGINE WARRANTY 2 year complete parts a...

Page 14: ...n unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area STACKING RANGER 305D CE machines 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 o...

Page 15: ...ngine Keep sparks and flame away from tank OIL The machine is shipped with the engine crankcase filled with high quality SAE 10W 30 Oil that meets classification CG 4 or CH 4 for diesel engines Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 50 running hours Re...

Page 16: ...h as the K1898 1 must be installed and properly maintained An incorrect spark arrestor may lead to damage to the engine or adversely affect performance REMOTE CONTROL The machine is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K963 3 hand Amptrol When in the CC STICK DOWNHILL PIP...

Page 17: ...e to a premises or resi dential electrical system Be certain that A 5 INSTALLATION RANGER 305D CE 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 connected between the machine grounding stud and the frame of the vehicle When this engine driven welder is connect ed to premises wiring such as ...

Page 18: ...12 seconds unless welding is resumed If you are using an LN 25 without an internal con tactor the electrode will be energized when the RANGER 305D CE is started WARNING CAUTION The installation complies with the National Electrical Code and all other applicable electri cal codes The premises is isolated and no feedback into the utility system can occur Certain laws require the premises to be isola...

Page 19: ...e 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 t...

Page 20: ...gine Be sure the machine is on a level surface Open top 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 c...

Page 21: ...hen a Amptrol is connected to the 6 Pin Connector the OUTPUT control is used to set the maximum cur rent range of the CURRENT CONTROL of the Amptrol 2 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK PIPE and TIG modes to be set prior to welding using the OUT PUT control dial During welding the meter display the actual output voltage VOLTS and curr...

Page 22: ... control equipment Includes auto sensing remote control circuit 9 WELD TERMINALS SWITCH In the WELD TERMI NALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED position the output is controlled by a wire feeder or amptrol device and is electri cally off until a remote switch is depressed 10 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltm...

Page 23: ... 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 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 m...

Page 24: ...OL dial adjusts the full output range for stick welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the elec trode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to...

Page 25: ...set the maximum range of the CURRENT CONTROL on the TIG module or an Amptrol if connected to the TIG Module See Table B 2 WIRE WELDING CV Connect a wire feeder to the Ranger 305D according to the instructions in INSTALLATION INSTRUCTIONS Section The RANGER 305D CE in the CV WIRE mode per mits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires...

Page 26: ...ORY SET Includes 10m 35 ft of electrode cable and 9 m 30 ft of work cable head shield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 7 6m 25 ft or K857 1 30 4m 100 ft REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder RANGER 305D CE ...

Page 27: ...22 DIESEL ENGINE KUBOTA D722 DIESEL 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 recomme...

Page 28: ...CF CF 4 CG 4 or CH 4 ACEA E1 E2 E3 Always check the API service label on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classifi cations SAE 10W30 is recommended for general all tempera ture use 15C to 40C 5F to 104F See engine owner s manual...

Page 29: ... job of seating the filter ñ but it will not Using the latches to push the filter in could cause damage to the housing and will void the warranty Donaldson filters with RadialSeal Sealing Technology are self aligning self centering and self sealing A new filter has a dry lubricant to aid installation The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure ...

Page 30: ...f 9 Kg 20 lbs 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 syst...

Page 31: ...if operated at speeds above maximum CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 113g 1 4 pound of baking soda and 0 9461L 1 quart of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters t...

Page 32: ...es and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary Do not attempt to polish slip rings while the engine is running WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equip ment may result in danger to the technician and machine operator and will invalidate yo...

Page 33: ...BLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Author...

Page 34: ...vertical position of handle 2 Fuel Filters dirty clogged Check and replace main filter element and or Inline Fuel Filter 3 Out of fuel Fill tank and bleed fuel system 4 High coolant temperature or low oil pressure indictor lights lit Check oil and coolant levels Fill if required Check for loose or bro ken fan belt 5 Faulty fuel shutdown solenoid Check that shutdown solenoid is functioning properly...

Page 35: ...nd exhaust end case back 1 Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed 2 Water in fuel If water found in tank Empty fuel tank and refill then purge fuel lines 1 Faulty battery Replace 2 Loose connections at battery or alternator Clean and tighten con nections 3 Faulty engine alternator or charg er module Consult authorized Engin...

Page 36: ...nt 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 sp...

Page 37: ...ition Place switch in Weld Terminals On position when welding without control cable 3 Faulty PC board 1 Poor remote control cable connec tion to 6 pin or 14 pin connector Check connections 2 Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary 3 Faulty control potentiometer or PC board 1 Wire Feeder Power circuit breaker open Check 42V beaker and reset if tripped 2 F...

Page 38: ...s not stable or is not satis factory the engine runs normally The auxiliary power is normal 1 Make sure the MODE selector switch is in the correct position for the process being used For exam ple CV WIRE PIPE CC STICK 2 Make sure the electrode wire gas voltage current etc is correct for the process being used 3 Check for loose or faulty connec tions at the weld output terminals and welding cable c...

Page 39: ...F 1 DIAGRAMS F 1 RANGER 305D CE ...

Page 40: ...F 2 DIAGRAMS F 2 RANGER 305D CE ...

Page 41: ... OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N...

Page 42: ...F 4 DIAGRAMS F 4 RANGER 305D CE 2 9 03 ...

Page 43: ...F 5 DIAGRAMS F 5 RANGER 305D CE ...

Page 44: ...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 number ...

Page 45: ...10 1 1 M1 M2 M3 M4 M5 M10 1 1 M1 M2 M3 M4 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 G4572 1 31 32 GND B A B C D E F 77B 21 75B GND A 41A 42A 76B 115VAC CONTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHENO...

Page 46: ...t 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 number 3 ...

Page 47: ...M10 1 1 M1 M2 M3 M4 M5 M10 1 1 M1 M2 M3 M4 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 M6 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 1 5 1 5 M1 M2 M3 M4 M9 M5 M10 G4573 1 31 32 GND B A B C D E F 77B 21 75B GND A 41A 42A 76B 115VAC CONTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND AMPHEN...

Page 48: ...05D CE M M 20335 A A 0 2 60 21 1529 3 29 67 753 6 26 52 673 6 60 00 1524 0 59 20 1503 7 17 50 444 5 19 50 495 3 21 06 534 9 21 50 546 1 29 83 757 6 34 24 869 8 35 77 908 4 6 33 160 9 11 03 280 2 29 63 752 6 17 00 431 8 CENTER OF GRAVITY ...

Page 49: ...NOTES RANGER 305D CE ...

Page 50: ...NOTES RANGER 305D CE ...

Page 51: ...NOTES RANGER 305D CE ...

Page 52: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 53: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 54: ...s 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 ...

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