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Lincoln Electric RANGER 305 D CE, Operator'S Manual

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Lincoln Electric RANGER 305 D CE Operator'S Manual Download Page 38

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

(SYMPTOMS)

POSSIbLE 

CAUSE

RECOMMENDED

COURSE OF ACTION

The  welding  arc  is  “cold.”  The  weld-
ing  arc  is  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 connections.

4. 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.

Summary of Contents for RANGER 305 D CE

Page 1: ...OT 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 For use with machines having Code Numbers 11457 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 ...

Page 2: ...AKER 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 ava...

Page 3: ...or 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 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s 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 Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...riés 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 Elo...

Page 6: ...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 linc...

Page 7: ...ing A 8 Connection of Lincoln Electric Wire Feeders A 9 A 10 ________________________________________________________________________________ Operation Section b Safety Precautions B 1 General Description B 1 For Auxiliary Power B 1 Engine Operation B 1 Add Fuel B 1 Break in Period B 1 Welder Controls B 2 B 3 Engine Controls B 3 Starting and Stopping the Engine B 4 Welding Operation B 4 Duty Cycle...

Page 8: ...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 GFCI Testing and Resetting Procedure D 6 ________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 __________________________________...

Page 9: ...nical Fuel Pump Auto air bleed Mechanical with Full Flow Filter Compliant system Electric shutoff solenoid Indirect fuel injector Governor 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 and labor 3r...

Page 10: ... 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 performa...

Page 11: ... time A 3 INSTALLATION RANGER 305D 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...

Page 12: ...hat carries explosive or combustible material WARNING ENGINE COOLING SYSTEM Air to cool the engine is drawn in the base sides and exhaust through radiator 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 Use caution as the elect...

Page 13: ...nding 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...

Page 14: ...WITHOUT ADDI TIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders small current inrush for starting refrigerators weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV...

Page 15: ...ceptacle 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 Connecti...

Page 16: ... 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE No 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS 240 VOLT GROUNDED CONDUCTOR 50AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 1...

Page 17: ...gger is closed the wire will begin to feed and the welding process is started Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Across The Arc Model Attach the single lead from the fron...

Page 18: ...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 s...

Page 19: ...e 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 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...

Page 20: ...ted to the 6 Pin Connector the OUTPUT dial is used to set the maximum current 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 DOWN HILL PIPE and TIG modes to be set prior to welding using the OUT PUT control dial During welding the meter dis play the actual output voltage VOLTS and cur rent AMPS A memo...

Page 21: ...actor 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 Includes 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 pos...

Page 22: ... 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 motor IF the Engine Protection or battery Charging Light...

Page 23: ...mmended that the ARC CON TROL be set to the minimum number without electrode sticking Start with the dial set at 0 DOWNHILL 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 ...

Page 24: ...nely 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 NR 203 Ni 1 NR 212...

Page 25: ...ed 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 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 auxiliar...

Page 26: ... 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 ...

Page 27: ... 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 Every 50 hours Every 75 hours Every 100 hours Ev...

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

Page 29: ...self 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 ...

Page 30: ...HE FAN bELT If the fan belt is loose the engine can overheat and the battery lose its charge Check tightness by press ing on the belt midway between the pulleys It should deflect about 25 in under a load of 20 lbs 9 Kg 6 mm 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 exp...

Page 31: ...lt 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 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 e...

Page 32: ...st 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 GFCI receptacle and turn the product ON Push the Test button located on the GFCI recepta cle The nig...

Page 33: ...LE 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 Authori...

Page 34: ...rtical 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 a...

Page 35: ...enings on both sides of base and 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 m...

Page 36: ... 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 spee...

Page 37: ...en welding without control cable 3 Faulty PC board or welder alterna tor 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 and 120V beakers and reset if tripped 2 Faulty control cable...

Page 38: ...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 con...

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

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

Page 41: ...F 3 DIAGRAMS F 3 RANGER 305D ...

Page 42: ...F 4 DIAGRAMS F 4 RANGER 305D ...

Page 43: ... INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING 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 ...

Page 44: ...F 6 DIAGRAMS F 6 RANGER 305D ...

Page 45: ...F 7 DIAGRAMS F 7 RANGER 305D ...

Page 46: ...F 8 DIAGRAMS F 8 RANGER 305D 2 9 03 ...

Page 47: ...F 9 DIAGRAMS F 9 RANGER 305D ...

Page 48: ...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 ...

Page 49: ... 6 1 C E N T E R O F G R A V I T Y N O T E C A S E F R O N T G R A P H I C S M A Y N O T M A T C H A L L C O D E S 2 9 5 7 7 5 1 0 2 6 6 4 6 7 6 7 1 1 0 3 2 8 0 2 6 3 3 1 6 0 9 M20334 B 21 06 534 9 51 2 0 1300 5 17 50 444 5 19 50 495 3 35 77 908 4 29 83 757 6 34 24 869 8 CI R CU IT BREAKE RS 1326 4 52 0 0 1320 8 29 0 0 736 6 11 3 0 287 0 21 5 0 546 1 CENTER OF GRAVITY NOTE CASE FRONT GRAPHICS MAY ...

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

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

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 Elektrod...

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 öffnen 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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