Lincoln Electric IM10053 User Manual

Download

Page 1

Operator’s Manual

RETURN TO MAIN MENU

RANGER®305D (AU)

For use with machines having Code Numbers:

11692, 12193

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10053-A | Issue D ate Aug- 13

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Need Help? Call 1.888.935.3877

to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

Use “Ask the Experts” at lincolnelectric.com A Lincoln Service Representative will contact you no later than the following business day.

For Service outside the USA:

Email: globalservice@lincolnelectric.com

Page 2

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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.

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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

Page 3

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY 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 & 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.

SAFETY

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.

1.e. In some cases it may be necessary to remove safety 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.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. 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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

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

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.

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 vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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.

2.d.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.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Page 4

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) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical (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

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.

between the

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. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening 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 circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. 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 specific 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.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. 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.

5.f. Also see item 1.b.

cause

Page 5

SAFETY

WELDING AND CUTTING SPARKS CAN 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.

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 circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums 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).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. 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.

6.g. 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 circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. 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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” 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.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. 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.

6.j. Do not use a welding power source for pipe thawing.

8.c. 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.

Welding Safety Interactive Web Guide for mobile devices

Page 6

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Location and Ventilation................................................................................................A-2

Stacking ........................................................................................................................A-2

Angle of Operation ........................................................................................................A-2

Lifting.............................................................................................................................A-2

High Altitude Operation .................................................................................................A-2

High Temperature Operation ........................................................................................A-2

Cold Weather Operation ...............................................................................................A-2

Towing...........................................................................................................................A-3

Vehicle Mounting...........................................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-3

Oil..................................................................................................................................A-3

Fuel ...............................................................................................................................A-3

Engine Coolant..............................................................................................................A-4

Battery Connections......................................................................................................A-4

Muffler Outlet Pipe ........................................................................................................A-4

Spark Arrester ...............................................................................................................A-4

Remote Control .............................................................................................................A-4

Electrical Connections..........................................................................................................A-4

Machine Grounding.......................................................................................................A-4

Welding Terminals ........................................................................................................A-5

Welding Output Cables .................................................................................................A-5

Cable Installation...........................................................................................................A-5

Electrical Device Used with the Ranger 305D (AU) .............................................................A-6

Auxiliary Power Receptacles and Plugs...............................................................................A-7

Standby Power Connections ................................................................................................A-7

Premises Wiring ...................................................................................................................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 ..............................................................................................................B-4,B-5

Constant Current (Stick) Welding..................................................................................B-5

Downhill Pipe (Stick) Welding .......................................................................................B-5

Tig Welding ...................................................................................................................B-5

Typical Current Ranges for Tungsten Electrodes .........................................................B-5

Wire Welding-CV...........................................................................................................B-6

Arc Gouging ..................................................................................................................B-6

Auxiliary Power Operation.............................................................................................B-7

Simultaneous Welding and Auxiliary Power Loads.......................................................B-7

Extension Cord Recommendations...............................................................................B-7

________________________________________________________________________________

Accessories .....................................................................................................Section C

Field Installed

________________________________________________________________________________

Options / Accessories ...............................................................................C-1

Page 7

vii

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

GFCI Testing and Resetting Procedure..........................................................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.................................................................................................................P-646

________________________________________________________________________

vii

Page 8

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger® 305D (AU) (K2922-1)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

A-1

3 cylinder 43.88(789) 4 stroke starter (45 Liters)

18.8 HP High Idle 3650

Kubota** (14 KW)

D722 Net intermittent Full Load 3500

3600 RPM

naturally aspirated Low Idle 2450 Battery Charger

water cooled (3.6L)

Diesel Engine

Bore x Stroke inch (mm)

2.64 x 2.68

(67 x 68 mm) cold crank amps) 3.85Qts. (3.6L)

12VDC Battery &

(Group 58; 550 Radiator Coolant:

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Process

DC Constant Current

DC Pipe Current

Touch-Start™TIG

DC Constant Voltage

Welding Output

Current/Voltage/Duty Cycle

305A / 29V / 100% 300A / 29V / 100% 250A / 30V / 100% 300A / 29V / 100%

Output Range

20 TO 305 AMPS 40 TO 300 AMPS 20 TO 250 AMPS 14 TO 29 VOLTS

RATED OUTPUT @ 104° F (40° C).- GENERATOR

Auxiliary Power

7200 Watts Continuous, 60 Hz 240 Volts

Sound Levels

Sound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m )

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.00* in. 21.50 in 52.25 in.

762.0 mm 546.0 mm 1327.0 mm

698 lbs. (317kg.)

Fuel: 12 gal.

Oil: 3.4Qts. (3.2L)

Max. Weld OCV

@Rated Load RPM

60 Volts

ENGINE

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

Full Pressure with Full Flow Filter

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Single Element Automatic Idler Top outlet can be rotated. pressure & engine

ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)

Certified to EPA Tier 4

Compliant

Mechanical Fuel Pump, Auto air bleed

system Electric shutoff solenoid Indirect fuel injector

Low noise Muffler: Shutdown on low oil

Made from long life, aluminized steel. temperature

Mechanical

Governor

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

(2) 240VAC Receptacles Two 15AMP for Two Receptacles 15AMP for Battery Charging Circuit

15AMP for 42V Wire Feeder Power

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.

* Top of enclosure add 6in. (152mm) for exhaust pipe. ** Engine warranty may vary outside of the USA. (See Engine warranty for details)

RANGER® 305D (AU)

Page 9

A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

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.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• 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.

•

Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operatorʼs manual.

Only qualified personnel should install, use, or service this equipment.

LOCATION AND VENTILATION

A-2

LIFTING

The Ranger® 305D (AU) 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.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

--------------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 2.5% to 3.5% 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 performance 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.

The welder should be located to provide an unrestricted 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 (AU) 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.).

RANGER® 305D (AU)

HIGH TEMPERATURE OPERATION

At temperatures above 104°F(40°C), Welder output derating is necessary. For maximum output ratings, derate the welder output 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. 2D at temperatures 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.

WARNING

Under no conditions should ether or other starting fluids be used with this engine!

--------------------------------------------------------------------------------

Page 10

A-3

INSTALLATION

A-3

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincolnʼs K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility 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 framework.

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions 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 overfill.

• Wipe up spilled fuel and allow fumes to clear before starting engine.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------

OIL

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 serviced.

4. Typical conditions of use, i.e., travel speed; roughness of sur-

face on which the trailer will be operated; environmental conditions; 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.

(1)

VEHICLE MOUNTING

The Ranger® 305D (AU) 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. Refer to the engine Operatorʼs Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operatorʼs Manual for more details on the proper service and

maintenance intervals.

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 components such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufacturerʼs instructions.

--------------------------------------------------------------------------------

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® 305D (AU)

Page 11

A-4

INSTALLATION

A-4

ENGINE COOLING SYSTEM

WARNING

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

CAUTION

Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.

--------------------------------------------------------------------------------

The Ranger® 305D (AU) 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 battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench.

NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polarity.

REMOTE CONTROL

The Ranger® 305D (AU) 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 K936-3 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remote control 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 Amptrol 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 connector, the auto-sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active

WARNING

NOTE: When a wire feeder with a built in welding voltage control is connected to the 14-pin connector, do not connect anything to the 6-pin connector.

--------------------------------------------------------------------------------

ELECTRICAL CONNECTIONS

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 maintained.

WARNING

An incorrect spark arrestor may lead to damage to the engine or adversely affect performance.

--------------------------------------------------------------------------------

RANGER® 305D (AU)

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

• Be grounded to the frame of the welder using a grounded type plug.

• Be double insulated.

• Do not ground the machine to a pipe that carries explosive or combustible material.

--------------------------------------------------------------------------------

Page 12

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 connected to premises wiring such as that in a home or shop, its frame must be connected to the system 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.

INSTALLATION

A-5

TABLE A.1

CABLE INSTALLATION

Install the welding cables to your Ranger® 305D (AU) 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.

The National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

WELDING TERMINALS

The Ranger® 305D (AU) 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 dictates the polarity of the electrode cable. These connections 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 long cable lengths to reduce voltage drops.

6. Check and tighten the connections periodically.

CAUTION

• 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.

--------------------------------------------------------------------------------

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30 meters)

100-150 Ft. (30-46 meters)

150-200 Ft. (46-61 meters)

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

3 / 0 AWG

RANGER® 305D (AU)

Page 13

A-6

ELECTRICAL DEVICE USE WITH THE RANGER® 305D (AU).

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capaci-

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

INSTALLATION

TABLE lll

tative elements to fail. Surge protection, transient protection, and additional loading is recommended for 100% fail-safe oper-

ation. DO NOT RUN THESE

DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS.

maximum output torque, but they SHOULD BE SAFE from any frequency induced failures.

A-6

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required, and

liabilities still exist. DO NOT

USE THESE DEVICES WITH A RANGER® 305D (AU)

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER® 305D (AU).

RANGER® 305D (AU)

Page 14

A-7

INSTALLATION

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Ranger® 305D (AU) is 7.2KW of 60Hz single phase power protected by an RCD (Residual Current Device) and 2 single phase 15 amp circuit breakers. The auxiliary power capacity in watts equivalent to volt-amperes at unity power factor.

This model has:

1 Residual Current Device (RCD) protection (30mA). 2 x 1 phase 15 amp Circuit Breakers. 2 x 1 phase 240 volt 15 amp per outlet.

Note: The single-phase outlets are from different

phases and cannot be paralleled.

The auxiliary power receptacles should only be used with three grounded type plugs or approved double insulated tools. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

A-7

STANDBY POWER CONNECTIONS

The Ranger® 305D (AU) is suitable for temporary, standby or emergency power using the engine manufacturerʼs recommended maintenance schedule.

The Ranger® 305D (AU) can be permanently installed as a standby power unit for 240 volt (60Hz). Connections must be made by a licensed electrician who can determine how the 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications.

1 Install an isolation switch between the power com-

pany meter and the premises disconnect. (The Ranger® 305D (AU) and the power company supplies must not be connected together).

Switch rating must be the same or greater than the customerʼs premises disconnect and service over current protection.

2. Take necessary steps to assure load is limited to the capacity of the Ranger® 305D (AU). Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the Ranger® 305D (AU) engine.

RANGER® 305D (AU)

Page 15

A-8

INSTALLATION

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

Connection of LN-15 to the Ranger® 305D (AU)

These connections instructions apply to both the LN15 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.

• Shut the welder off.

A-8

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 electrode 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.

• 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 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 TERMINALS ON"

• Control Cable Model:

Connect Control Cable between Engine Welder and Feeder.

Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED".

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 "0" initially and adjust to suit.

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger® 305D (AU) 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. When the gun trigger is closed, the current sensing circuit will cause the Ranger® 305D (AU) engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

CAUTION

• Set the MODE switch to the "CV-WIRE " position.

• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the "IDLE" switch to the "AUTO" position.

Connection of the LN-25 to the Ranger® 305D (AU)

WARNING

Shut off welder before making any electrical connections.

--------------------------------------------------------------------------------

The LN-25 with or without an internal contactor may be used with the Ranger® 305D (AU). See the appropriate connection diagram in Section F.

RANGER® 305D (AU)

If you are using an LN-25 without an internal contactor, the electrode will be energized when the Ranger® 305D (AU) is started.

--------------------------------------------------------------------------------

Connection of LN-742, Spool Gun (K487-25) and Cobramatic to Ranger® 305D (AU)

• Shut the welder off.

• Connect per instructions on the appropriate connection diagram in Section F.

Page 16

B-1

OPERATION

SAFETY PRECAUTIONS

WARNING

--------------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• 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 (AU) is a diesel engine powered DC multi-process welding power source and 240 volt AC power generator. The engine drives a generator that supplies three phase power for the DC welding 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 welding 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.

The auxiliary power of the Ranger® 305D (AU) consists of two 15 Amp-240 VAC receptacles. 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 dipstick.

B-1

• 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 necessary).

• See Engine Ownerʼs 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 fueling.

DIESEL FUEL

can cause fire.

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 and tighten securely.

• See Engine Ownerʼs Manual for specific fuel recommendations.

BREAK-IN PERIOD

Any engine will use a small amount of oil during its “break-in” period. For the diesel engine on the Ranger® 305D (AU), 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.

• Wipe up spilled fuel and allow fumes to clear before starting engine.

• Do not overfill tank, fuel expansion may cause overflow.

CAUTION

During break-in, subject the Ranger® 305D (AU) 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 (AU)

Page 17

B-2

OPERATION

B-2

FIGURE B.1

WELDING CONTROLS (Figure B.1)

1. OUTPUT CONTROL-

used to preset the output voltage or current as displayed 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 automatically switches the OUTPUT CONTROL from control at the welder to the remote control.

In the CV-WIRE mode, when the wire feeder control cable is connected to the 14-Pin Connector, the auto-sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active.

When in the TOUCH START TIG mode and when a Amptrol 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 OUTPUT dial is

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 OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on for seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior to when welding was ceased.

While the display is being held the left-most decimal point in each display will be flashing. The accuracy of the meters is +/- 3%.

3. WELD MODE SELECTOR SWITCH-

(Provides four selectable welding modes)

CV-WIRE DOWNHILL PIPE CC-STICK TOUCH START TIG

RANGER® 305D (AU)

Page 18

B-3

OPERATION

B-3

4. ARC CONTROL

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.

- The ARC CONTROL dial is active in

10. WIRE FEEDER VOLTMETER SWITCH:

ENGINE CONTROLS:

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 sticking. 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 preferred 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 recommended 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-

connecting the machine case to earth ground.

7. 14-PIN CONNECTOR-

trol cables to the Ranger® 305D (AU). Includes contactor closure 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-

control equipment. Includes auto-sensing remote control circuit.

Provides a connection point for

For attaching wire feeder con-

For attaching optional remote

11. RUN/STOP SWITCH

12. GLOW PLUG PUSH BUTTON

13. START PUSH BUTTON

14. IDLER SWITCH

Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.

(Figure B.2)

- 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.

• When pushed activates the glow plugs. Glow plug should not be activated for more than 20 seconds continuously.

Energizes the starter motor to crank the engine.

- 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 full 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.

9. WELD TERMINALS CONTROL SWITCH-

WELD TERMINALS 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 electrically off until a remote switch is

depressed.

In the

RANGER® 305D (AU)

Page 19

B-4

OPERATION

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 systems are functioning properly. The light turns on when the RUN-STOP switch is in the “ON” position 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.

AUXILIARY POWER CONTROLS

(Items 18-21)

18. CIRCUIT BREAKERS

These circuit breakers provide separate overload current protection for each 240V receptacles, the 42VAC in the 14-Pin connector and battery circuit overload protection.

B-4

19. 240 VAC RECEPTACLES

These two 240VAC receptacles provide up to 15 amp total rating each and are IP66 rated. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

20. RCD:

“Residual Current Device” provides protection

from active to ground contact.

RCD will not protect against electrical shock resulting from contact with active and neutral wires.

21. VRD INDICATOR LIGHTS:

(Part of Optional VRD Kit)

Indicates OCV voltage across the output terminals. Also indicates operation of VRD in CC mode. A Green light indicates OCV below 30V and a red light indicates OCV above 30V.

During welding both lights will flash, depending on the type of Consumable being used.

RANGER® 305D (AU)

Page 20

B-5

OPERATION

B-5

STARTING THE ENGINE

1. Remove all plugs connected to the AC power receptacles.

2. Set IDLER switch to AUTO.

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 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

CAUTION

NOTE: When starting a Ranger® 305D (AU) for the

first time, or after and extended period of time of not operating, 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 prefilter.

WELDER OPERATION

DUTY CYCLE

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.

• 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.

--------------------------------------------------------------------------------

TABLE B.1

TYPICAL Ranger® 305D (AU) FUEL CONSUMPTION

Kubota D722 Running time for

Gal./Hr (Liters/Hr) 12 gallons-hours Low Idle - No Load 2450 R.P.M. .29 (1.09) 41.77 High Idle - No Load 3650 R.P.M. .54 (2.06) 22.02 DC Weld Output 250 Amps @ 28 Volts 1.03 (3.91) 11.62 DC Weld Output 300 Amps @ 29 Volts 1.18 (4.47) 10.16

7,000 Watts .96 (3.63) 12.50

3,000 Watts .70 (2.67) 17.03

RANGER® 305D (AU)

Page 21

B-6

OPERATION

The Ranger® 305D (AU) can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows:

B-6

It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

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 electrodes, especially low hydrogen. The output CONTROL dial adjusts the full output range for stick welding.

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-

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

age or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

+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 sticking. Start with the dial set at 0.

DOWNHILL PIPE Welding

This slope controlled setting is intended for "out-of-position" 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).

When in the TOUCH START TIG mode and when a Amptrol 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 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.

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 preferred 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. This can also increase spatter.

TABLE B.2

TYPICAL CURRENT RANGES

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 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6

3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8 1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10 3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10) 1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

The Ranger® 305D (AU) can be used in a wide variety of DC TIG welding applications. In general the ʻTouch Startʼ 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® 305D (AU). The settings are for reference.

(1)

FOR TUNGSTEN ELECTRODES

(2)

(1) When used with argon gas. The 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:

(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

# 4 = 1/4 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = _ in. (12.5 mm) #10 = 5/8 in. (16 mm)

and high duty cycles.

RANGER® 305D (AU)

Page 22

B-7

OPERATION

B-7

Ranger® 305D (AU) 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" contactor 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® 305D (AU) is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.

WIRE WELDING-CV

Connect a wire feeder to the Ranger® 305D (AU) according to the instructions in INSTALLATION INSTRUCTIONS Section.

The Ranger® 305D (AU) 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 preference. Start with the dial set at 0.

ARC GOUGING

The Ranger® 305D (AU) 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 Table.

Carbon Diameter

1/8" 60-90 Amps

5/32" 90-150 Amps

3/16" 200-250 Amps

Current Range (DC, electrode positive)

Listed below are some wires suitable for use on this machine:

• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-212.

• Outershield - 0S-70, 0S-71M, 0S-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 applications with this machine.

RANGER® 305D (AU)

Page 23

B-8

OPERATION

AUXILIARY POWER OPERATION:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn.

The auxiliary power of the Ranger® 305D (AU) consists of two 15Amp 240VAC single phase receptacles.

The 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 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:

B-8

Current (Amps)

Voltage

Volts

240

Ranger® 305D (AU) Simultaneous Welding and Power Loads

Welding

Output-Amps

0 100 150

200 250 300

* Each receptacle is limited to 15 amps.

Ranger® 305D (AU) Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Load

(Watts)

3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

Conductor size is based on maximum 2.0% voltage drop.

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Permissible Power-Watts

(Unity Power Factor)

7200 7200 5600 4200 2300

RANGER® 305D (AU)

Page 24

C-1

FIELD INSTALLED OPTIONS / ACCESSORIES

ACCESSORIES

C-1

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 Hitch K959-2 Fender & 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, headshield, 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 output control on the welder. Has a convenient 6 pin plug for easy connection to the welder.

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)

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.

K32043-2 VRD VOLTAGE REDUCTION DEVICE KIT

Provides reduced Open Circuit Voltage (OCV) in the CC Stick Weld Mode.

RANGER® 305D (AU)

Page 25

D-1

MAINTENANCE

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 Ownerʼs Manual before working on this machine.

D-1

KUBOTA D722 DIESEL ENGINE

FREQUENCY

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 recommended in the table below depending on the operating condition.

MAINTENANCE REQUIRED

• FILL FUEL TANK.

• CHECK OIL LEVEL.

• CHECK COOLANT LEVEL.

• CHECK AIR CLEANER ELEMENT AND HOUSING FOR DIRTY, LOOSE OR DAMAGED PARTS.

• CHECK AIR INTAKE HOSE FOR CRACKS OR LOOSE CONNECTIONS.

• CHECK AIR INTAKE/EXHAUST AREAS & RADIATOR FOR DIRT. CLEAN AS NECESSARY.

• CHECK ALTERNATOR BELT TENSION AND WEAR.

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 dayʼs 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 DIESEL ENGINE

ITEM

OIL FILTER KUBOTA 70000-15241

AIR FILTER ELEMENT DONALDSON P822686

FUEL FILTER ELEMENT KUBOTA 15231-43560

BATTERY KUBOTA GROUP 58, 550 CCA

BELT KUBOTA 15881-97011

GLOW PLUGS KUBOTA 16851-65512

INLINE FUEL FILTER KUBOTA 12581-43012

MAKE AND PART NUMBER

Intervals

Every 50 hours Every 75 hours

Every 100 hours

Every 150 hours

Every 200 hours Every 400 hours Every 500 hours

Every 1 or 2 months Every 800 hours Every 1500 hours

Every 3000 hours

Every 2 years

IMPORTANT

Check of fuel pipes and clamp bands. Change of engine oil

Inspect/Clean air cleaner element and Vacuator™ valve. Cleaning of fuel filter. Check the battery electrolyte level. Check the fan belt tightness. Check the radiator and hose clamps. Replacement of oil filter cartridge Check the intake air lines. Replacement of Air Filter element. Replacement of fuel filter element. Cleaning of water jacket (radiator interior).

Replacement of fan belt.

Recharging of Battery. Check of valve clearance. Check the fuel injection nozzle injection pressure. Check of injection pump. Check of fuel injector timer. Replacement of battery Replacement of radiator hoses and clamp band. Replacement of fuel pipes and clamps. Change the radiator coolant.(L.L.C.) Replacement of intake air line.

Items

•

*1,*2

*3 *3

@ @ @

@ @

• These jobs should be done after the first 50 hours of operation.

*1 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.

RANGER® 305D (AU)

Page 26

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 recommended that each time the oil is changed the oil filter be changed as well.

• Be sure the unit is off. Disconnect the negative battery 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 operation manual OR engine service items decal OR below). Replace and tighten the oil filler cap securely.

• Push oil drain hose and valve back into unit, re-connect 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 reclamation. 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 requirements for API service classification 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 classifications.) SAE 10W30 is recommended for general, all temperature use, 5F to 104F (-15C to 40C). See engine ownerʼs manual for more specific information on oil viscosity recommendations.

Oil 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 cleaner element. A fire or explosion could result.

• Never run the engine without the air cleaner.

CAUTION

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 (AU)

Page 27

D-3

Remove the Filter

Clean Both Surfaces of the Outlet Tube and Check the Vacuator™ Valve

Inspect the Old Filter for Leak Clues

Inspect the New Filter for Damage

Insert the New Radial Seal Filter Properly

Check Connectors for Tight Fit

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.

Caution

Service Instructions

Single- and Two-Stage Engine Air Cleaners

MAINTENANCE

Service Instructions

Single- and Two-Stage Engine Air Cleaners

D-3

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

Rotate the filter while pulling straight out.

If 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 seal 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.

be some initial resistance, similar to breaking the seal on a jar. Gently move the end of the filter back and forth to break the seal then rotate while pulling straight out. Avoid knocking the filter against the housing.

Wipe both sides of the outlet tube clean.

Inspect the New Filter for Damage

Inspect the new filter carefully, paying attention to the inside of the open end, which is the sealing area. NEVER install a damaged filter. A new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation.

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.

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.

Outer 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 of leaks. A streak of dust on the clean side of the filter is a telltale sign. Remove any cause of leaks before installing new filter.

Inner edge of the outlet tube

RANGER® 305D (AU)

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.

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!

Page 28

D-4

COOLING SYSTEM

MAINTENANCE

FUEL

D-4

WARNING

HOT COOLANT

• 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" 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 complete 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.

can burn skin.

At the end of each dayʼs use, refill the fuel tank to minimize 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 storage. 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 starting after extended periods of non-use or out of fuel conditions.

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 during 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 pressing on the belt midway between the pulleys. It should deflect about .25 in. under a load of 20 lbs. (9 Kg) (6 mm).

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. Fill the fuel tank with fuel.

2. Open the fuel shut off valve (vertical position of handle) on the Fuel Filter.

3. Crank the engine by pressing the start button for 45 seconds.

4. Check to see that fuel is flowing through both fuel filters

5. Follow the normal STARTING procedures.

RANGER® 305D (AU)

Page 29

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

GASES FROM BATTERY can explode.

Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

INSTALLING A NEW BATTERY — disconnect negative cable from old battery first and connect to new battery last.

CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect 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 battery 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 accumulation 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 connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Ranger® 305D (AU) positive (+) battery terminal 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 manufacturer for proper charger settings and charging time.

SERVICING OPTIONAL SPARK ARRESTOR

WARNING

Clean every 100 hours.

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.

Wear gloves and eye protection and be careful when working near battery.

Follow instructions printed on battery.

RANGER® 305D (AU)

• MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER!

------------------------------------------------------------------------

Page 30

D-6

MAINTENANCE

WELDER / GENERATOR MAINTENANCE

STORAGE: Store the Ranger® 305D (AU) in clean,

dry protected areas.

CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: Itʼs normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary.

CAUTION

• Do not attempt to polish slip rings while the engine is running.

D-6

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.

RANGER® 305D (AU)

Page 31

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

E-1

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 (SYMPTOMS)”. 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 unable 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 (AU)

Page 32

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Major Physical or Electrical Damage is Evident.

Engine will not "crank".

Engine will "crank" but not start.

1. Contact your local Lincoln Authorized Field Service Facility.

1. Battery is low,

2. Loose battery cable connections. Inspect, clean and tighten terminals.

3. Faulty engine starter motor. Contact authorized local Engine Service Shop.

1. Fuel shut off valve on Main Fuel Filter in the OFF position. Open valve (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 broken fan belt.

5. Faulty fuel shutdown solenoid. Check that shutdown solenoid is functioning properly and not binding/ contact authorized engine service shop.

6. Faulty fuel pump. Check for fuel flow through filters. Contact authorized local Engine Service Shop.

Charge Battery.

f all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Engine shuts down shortly after starting.

1. High coolant temperature or low 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.

2. Faulty oil pressure switch or other engine component. Contact authorized local Engine Service Shop.

3. 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 (AU)

Page 33

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Engine shuts down while under a load.

Engine runs rough.

Battery does not stay charged. Engine alternator trouble light is on while machine is running.

Engine will not idle down to low speed.

1. High radiator coolant temperature. Reduce load if it is exceeding 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).

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 connections.

3. Faulty engine alternator or charger module. Consult authorized Engine Service Shop.

1. Idler switch in High idle position. Set switch to Auto.

2. External load on welder or auxiliary power. loads.

3. Faulty PC board or idler solenoid.

Remove all external

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

Engine will not go to high idle when attempting to weld.

1. Poor work lead connection to work. Make sure work clamp is tightly metal.

2. "Contactor" switch is in wrong position. welding without a control cable. Refer to Operations chapter for proper use of this switch.

3. Faulty PC board. Low idle speed set to low.

connected to clean base

Set to "Welding On" when

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 (AU)

Page 34

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

Engine will not go to high idle when using auxiliary power.

Engine will not go to high 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 auxiliary power. Switching to manual high idle does not work.

Engine will not shut off.

1. Auxiliary power load is less than 100 watts. 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,

2. Air filter clogged,

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 filter. Contact authorized local Engine Service Shop.

Idler may not respond

Replace.

clean or replace.

f all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Engine does not develop full power. Low weld and auxiliary output. Engine runs rough.

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 water. 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.

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 (AU)

Page 35

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

No welding power output.

Welder has output but no control.

Wire feeder does not work when control cable is connected to 14 pin connector.

1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal.

2. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On" position when welding without control cable.

3. Faulty PC board or welder alternator.

1. Poor remote/control cable connection 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 beakers and reset if tripped.

2. Faulty control cable. Repair or replace cable.

3. Faulty wire feeder. Replace wire feeder.

f all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

No auxiliary power.

1. Open circuit breakers. Reset breakers. If breakers keep tripping, reduce power draw.

2. Faulty connections to auxiliary receptacles. Check connections.

3. Faulty PC board or welder alternator.

4. Check RCD for proper operation.

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 (AU)

Page 36

E-6

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-6

The welding arc is “cold.” The welding arc is not stable or is not satisfactory. 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 example, 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.

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 (AU)

Page 37

F-1

DIAGRAMS

F-1

RANGER® 305D (AU)

Page 38

F-2

DIAGRAMS

F-2

RANGER® 305D (AU)

Page 39

F-3

DIAGRAMS

F-3

RANGER® 305D (AU)

Page 40

F-4

DIAGRAMS

F-4

RANGER® 305D (AU)

Page 41

F-5

Keep guards in place.

MOVING PARTS can injure

DIAGRAMS

F-5

4-14-2000

S24787-6

TO WORK

or service this equipment.

Only qualified personnel should install,use

Keep away from moving parts.

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

WARNING

ELECTRIC SHOCK can kill

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

CABLE PLUG

TO LN-8 INPUT

K595 CONTROL CABLE

ELECTRODE CABLE

TO WIRE FEED UNIT

before servicing.

Do not touch electrically live parts.

CAUTION:

ANY 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 DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO

MATCH THE POLARITY OF THE ELECTRODE CABLE.

14 PIN

AMPHENOL

N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.

RANGER® 305D (AU)

Page 42

F-6

DIAGRAMS

F-6

RANGER® 305D (AU)

Page 43

F-7

DIAGRAMS

F-7

RANGER® 305D (AU)

Page 44

F-8

DIAGRAMS

F-8

9/03

RANGER® 305D (AU)

Page 45

F-9

DIAGRAMS

F-9

RANGER® 305D (AU)

Page 46

F-10

Enhanced Diagram

DIAGRAMS

F-10

RANGER® 305D (AU)

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 number.

Page 47

F-11

DIMENSION PRINT

35.77908 .4

F-11

M20334

34. 24

869 .8

29.83757.

6. 33

160. 9

11.0 3

280. 2

21.50

546.

CIRCUIT

BREAKERS

21.06534.

19.50

11.30287.

29.00736.

52.00

1320

51.20

1300

26.64

676.7

29.5 7

751.

1326 .4

495.3

NOTE: CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES.

17.5 0

444. 5

CENTER OF GRAVIT

RANGER® 305D (AU)

Page 48

NOTES

RANGER® 305D (AU)

Page 49

PARTS LIST FOR

RANGER

P-646P-646

305D (AU)

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

RANGER®305D (AU)

Page 50

ILLUSTRATION OF SUB-ASSEMBLIES

P-646-AP-646-A

RANGER®305D (AU)

08-17-2012

Page 51

P-646-A.1P-646-A.1

RANGER®305D (AU)

For Codes: 11692 & 12193

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

PAGE NO.

CODE NO.

11692 1 1 111111

12193 1 2 111111

Case Front Asbly (Upper)

P-646-C

Case Front Asbly (Lower)

P-646-D

Stator Rotor Assembly

P-646-E

Blower Baffle Assembly

P-646-F

Base, Fuel Tank, Battery

P-646-G

Assembly

Engine Assembly

P-646-H

Radiator & Case Back

P-646-J

Covers

P-646-K

RANGER®305D (AU)

Oct-13

Page 52

Case Front Assembly (Upper)

46A

38A

52C

52E

51D

51E

52B

28A

31A

51C

51A

51B

51A

51B

29A

52A

35A

P-646-CP-646-C

52C

52E

52B

51E

51D

46A

51E

38A

29A

52A

51C

51B

51A

28A

51B

51A

31A

28A

RANGER®305D (AU)

35A

08-17-2012

Page 53

P-646-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Case Front Assembly (G3666-53), Includes: NSS 1X 1A Case Front G3860-13 1 X 3A Top Bezel G3593 1 X 3B Self Tapping Screw (Not Shown) S24738-1 7 X 4A Right Bezel G3594-1 1 X 4B Self Tapping Screw (Not Shown) S24738-1 2 X 5A Left Bezel G3594-2 1 X 5B Self Tapping Screw (Not Shown) S24738-1 2 X 8 Switch, Pushbutton S13146-4 1 X 9 Start Button S13146-1 1 X 10 Hour Meter - Miniature S17475-3 1 X 23

Nameplate (Ranger 305 Diesel) G6434-1

1X 28A Toggle Switch (SPST) T10800-38 2 X 28B Sealing Boot (Not Shown) S22061-4 2 X 29A Toggle Switch (DPDT) T10800-36 1 X 29B Sealing Boot (Not Shown) S22061-4 1 X 31A Toggle Switch T10800-39 1 X 31B Sealing Boot (Not Shown) S22061-4 1 X 34 Front Door Nameplate L15010 1 X 35A Door Welded Assembly L11185 1 X 35B Rivet (Not Shown) T12584-6 2 X 37 Latch S21033 1 X 38A Catch Bracket S24659 1 X 38B Self Tapping Screw (Not Shown) S8025-98 2 X 43 Pilot Light T13534-11 1 X 46A Fuel Gauge S17585-1 1 X 46B Plug & Lead Assembly (Not Shown) S18250-889 1 X 51 Connector & Lead Assembly, Includes: M19685-4 1 X 51A Potentiometer (10K) (R1 & R2) T10812-119 2 X 51B Potentiometer Spacer S18280 2 X 51C Rotary Switch S16670-10 1 X 51D Knob T10491-1 1 X 51E Knob T10491 2 X 51F “O” Ring (Not Shown) T13483-7 2 X 52A Meter Housing Assembly (Includes Meter) L11160 2 X 52B Meter Housing Seal S24630 2 X 52C Meter Bezel M19368 2 X 52D Lens (Not Shown) T14807-9 2 X 52E #4-40 x .375 SS-PPNHS CF000389 4 X 52F #6-32 HN (Not Shown) CF000005 4 X 52G Plain Washer (Not Shown) S9262-3 4 X 55 Thread Forming Screw (Not Shown) S9225-68 4 X 60 Instruction Tag (Not Shown) M17238 1 X 61 Operation Decal (Inside Front Door) (Not Shown) M19452-4 1 X

RANGER

305D (AU)

08-17-2012

Page 54

Case Front Assembly (Lower)

17B

15A

50B

50C

13A

14A

18A

17A

55A

55B

50D

50E

17D

16A

47A

49A

P-646-DP-646-D

47A

17B

15A

13A

50C

14A

17A

50B

18A

17D

16A

49A

50D

50E

55B

55A

RANGER®305D (AU)

08-17-2012

Page 55

P-646-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

6A Output Terminal Kit, Includes: T14166-9 2 X X 6B Output Stud Nut T3960 2 X X 6C Self Tapping Screw S8025-91 4 X X 6D 1/2-13 x .875 HHCS CF000344 2 X X 6E Plain Washer S9262-1 2 X X 6F Lock Washer E106A-15 2 X X 13A Circuit Breaker T12287-34 2 X X 13B Sealing Boot (Not Shown) S22061 2 X X 14A Circuit Breaker (15 Amp) 250VAC, 50VDC T12287-37 1 X X 14B Sealing Boot (Not Shown) S22061-2 1 X X 15A Circuit Breaker (15 Amp) 250VAC, 50VDC T12287-38 1 X X 15B Sealing Boot (Not Shown) S22061-2 1 X X 16A Receptacle M22425 2 X X 16B #6-32 x 1.25 RHS (Not Shown) CF000050 8 X X 16C Lock Washer (Not Shown) E106A-13 8 X X 16D #6-32 HN (Not Shown) CF000005 8 X X 17A RCD (NHP) S28343 1 X X 17B Receptacle Cover S28344-2 1 X • 17B Boot (Not Shown) G7594 1 • X 17C #10-24 HN (Not Shown) CF000010 2 X X 17D Terminal Strip S15389-1 1 X X 17E Plain Washer (Not Shown) S9262-27 2 X X 17F #10-24 HLN (Not Shown) T9187-9 2 X X 18A RCD Strap S28425 1 X • 18A RCD Strap Assembly (Not Shown) S28425-3 1 • X 18B Thread Forming Screw (Not Shown) S922-63 2 X X 21 1/4-20 HJLN T9187-1 1 X X 22 1/4-20 HN CF000017 1 X X 24 Rating Plate L12790-10 1 X X 47A Shunt & Lead Assembly S24097-4 1 X X 47B 1/2-13 x .875 HHCS (Not Shown) CF000344 1 X X 47C Plain Washer (Not Shown) S9262-1 1 X X 47D Lock Washer (Not Shown) E106A-15 1 X X 49A RF-Bypass Filter Assembly S24982 1 X X 49B Plain Washer (Not Shown) S9262-27 1 X X 49C Lock Washer (Not Shown) E106A-1 1 X X 49D #10-24 HN (Not Shown) CF000010 1 X X 50A Connector & Lead Asbly, Includes: M19685-3 1 X X 50B Connector Receptacle S12021-70 1 X X 50C Connector Receptacle S12021-68 1 X X 50D Connector Cap S17062-11 1 X X 50E Connector Cap S17062-10 1 X X 50F Self Tapping Screw (Not Shown) S8025-96 4 X X 51 Decal S28435 1 X X 55A Output Stud Cover Plate S25669 2 X X 55B Thread Forming Screw S9225-66 4 X X 56 Output Stud Cover M20007 2 X X

RANGER

305D (AU)

Oct-13

Page 56

Stator Rotor Assembly

11C

11B

11F

11D

11A

P-646-EP-646-E

11C

11B

11A

11D

11F

RANGER®305D (AU)

08-17-2012

Page 57

P-646-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Stator Frame Assembly G3930-2 1 X 1B 3/8-16 x 1.25 HHCS CF000105 8 X 1C Lock Washer E106A-16 8 X 2A Plain Washer S9262-120 2 X 2B Lock Washer E106A-16 2 X 2C 3/8-16 HN CF000067 2 X 4A Disc Clamping Bar S17895 6 X 4B 5/16-18 x .875 HHCS T8833-47 6 X 4C Lock Washer E106A-14 6 X 4D Coupling Disc M15012 1 X 4E Rotor Clamping Ring S17896 1 X 4F 5/16-24 x .875 HHCS T8833-38 4 X 4G Lock Washer E106A-14 4 X 5 Rotor & Shaft Assembly L11571-2 1 X 6 Tolerance Ring S18044-5 1 X 7 Blower L9033 1 X 8 Plain Washer S9262-149 1 X 9 Bearing M9300-85 1 X 10 Brush & Brush Holder Assembly, Includes: M16158 1 X

Brush Holder Cartridge G2114 1 X Brush Assembly S19480 2 X

Brush Assembly Retainer M16157 1 X 11A Brush Holder Bracket M18336 1 X 11B Self Tapping Screw S8025-91 2 X 11C 1/4-20 x 1.00 HHCS CF000015 2 X 11D Lock Washer E106A-2 2 X 11E Flat Washer (Not Shown) S9262-98 2 X 11F 1/4-20 HN CF000017 2 X 16 Firewall G3404 1 X 17 Bushing T12380-1 1 X 18 Door Bumper T14882-1 2 X

RANGER

305D (AU)

08-17-2012

Page 58

Blower Baffle Assembly

13A

14A

15A

3F 3G 3H

15A

P-646-FP-646-F

13A

15A

14A

15A

3F 3G 3H

RANGER®305D (AU)

08-17-2012

Page 59

P-646-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Blower Baffle Assembly, Includes: G4097-13 1 X 1 Baffle G3862-2 1 X 2 Warning Decal T13086-163 1 X 3A Chopper Board Assembly L11845-[ ] 1 X 3B Baffle S24624 1 X 3C Heat Sink Holder S22168 3 X 3D Thread Forming Screw S9225-17 3 X 3E Thread Forming Screw (Not Shown) S9225-17 3 X 3F Plain Washer S9262-98 3 X 3G Lock Washer E106A-2 3 X 3H 1/4-20 HN CF000017 3 X 4A Weld Control PC Board Assembly G5507-[ ] 1 X 4B Self Tapping Screw (Not Shown) S8025-100 4 X 5A Capacitor S13490-114 1 X 5B Capacitor Bracket L9250 1 X 7 Bushing T14614-1 1 X 8A Resistor S10404-132 1 X 8B #10-24 x 3.00 RHS (Not Shown) CF000009 1 X 8C Insulating Washer T4479-A 2 X 8D Plain Washer (Not Shown) S9262-27 1 X 8E Lock Washer (Not Shown) E106A-1 1 X 8F #10-24 HN (Not Shown) CF000010 1 X 9A Resistor S10404-138 1 X 9B Heat Sink Holder S22168 2 X 9C Thread Forming Screw (Not Shown) S9225-17 2 X 9D Plain Washer S9262-98 2 X 9E Lock Washer E106A-2 2 X 9F 1/4-20 HN CF000017 2 X 9G #10-24 x 7.50 RHS CF000191 1 X 9H Plain Washer S9262-27 2 X 9J Lock Washer E106A-1 1 X 9K #10-24 HN CF000010 1 X 13A Pull Coil PC Board Assembly L11768-[ ] 1 X 13B Self Tapping Screw (Not Shown) S8025-100 4 X 14A Relay, SPDT 12-VDC S14293-20 1 X 14B Self Tapping Screw (Not Shown) S8025-91 2 X 15A Diode Bridge, 35A, 400V, FW 1PH T13637-6 2 X 15B #10-24 x .75 RHS (Not Shown) CF000072 2 X 15C #10-24 HN (Not Shown) CF000010 2 X 15D Lock Washer (Not Shown) E106A-1 2 X 15E Plain Washer (Not Shown) S9262-27 2 X 17 Thread Forming Screw (Not Shown) S9225-68 1 X 20 Grommet S18543-5 1 X 21 Socket, Relay (Part of G4244-4 Wiring Harness) S14531-5 1 X

RANGER

305D (AU)

08-17-2012

Page 60

Base, Fuel Tank, Battery Assembly

10A

11B

11A

10B

14A

15A

P-646-GP-646-G

15A

10A

14A

RANGER®305D (AU)

10B

11B

11A

Oct-13

Page 61

P-646-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Base G3925 1 X 2 Fuel Tank Assembly, Includes: L12164-2 1 X 2A Fuel Tank NSS 1X 2B Fuel Sender M20302 1 X 2D Fuel Pick-Up Tube Assembly S19565-4 1 X 2E Rubber Plug S19563 2 X 2F Fuel Cap S20541 1 X 2G Fuel Fitting, Return S19564 1 X 3 Rectifier, Choke, Stator Support Asbly, Includes: L11135-3 1 X 3A Stator Support Bracket L11010 1 X 3B Choke Assembly M19416 1 X 3C 5/16-18 x 2.75 HHCS CF000187 3 X 3D Plain Washer S9262-121 1 X 3E Lock Washer E106A-14 3 X 3F 5/16-18 HN (Not Shown) CF000029 3 X 3G Three Phase Bridge Rectifier L11132-3 1 X 3H Lock Washer E106A-14 2 X 3J Rubber Mounting S24344 2 X 3K 3/8-16 x 2.50 HHB CF000196 2 X 3L Plain Washer S9262-113 2 X 3M 3/8-16 HN CF000067 2 X 3N Plain Washer S9262-47 4 X 4A Fuel Tank Brace G4003-1 1 X 4B Thread Forming Screw S9225-68 2 X 5A 12 Volt Storage Battery (M9399-14) NSS 1X 5B Battery Cable (Negative) S8070-28 1 X 5C Battery Cable (Positive) S8070-11 1 X 5D Plastic Cap (Not Shown) T14654 1 X 5E Battery Bracket S22018 1 X 5F Carriage Bolt T11827-45 2 X 5G Lock Washer E106A-2 2 X 5H 1/4-20 HN CF000017 2 X 6 Battery Terminal Cover S20191-1 1 X 8A Fuel Hose (Return) T10642-257 1 X 8B Hose Clamp S10888-35 2 X 9A Fuel Hose T10642-65 2 X 9B Hose Clamp S10888-35 1 X 9C Hose Clamp T13777-5 2 X 10A Engine Cross Support L11643 1 X 10B Thread Forming Screw S9225-68 1 X 1 1A Battery Access Door M19770 1 X 11B Thread Forming Screw S9225-68 4 X 12 Thread Forming Screw S9225-68 4 X 13 Battery Caution Decal S17851 1 X 14A Hinge Assembly S24295-1 2 X 14B Rivet (Not Shown) T12584-9 4 X 15A Hinge Assembly S24295-2 2 X 15B Rivet (Not Shown) T12584-9 2 X

NSS - Not Sold Separately

RANGER

305D (AU)

Oct-13

Page 62

Engine Assembly

14A

10G

11A

10F

10C

10A

10D

10E

P-646-HP-646-H

14A

10A

10C

11A

10G

10F

10D

10E

RANGER®305D (AU)

08-17-2012

Page 63

P-646-H.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Engine (M21504) (KUBOTA) NSS 1X 1B Fan Coupling Hub - Kubota S25211 1 X 1C Lock Washer (Not Shown) E106A-14 3 X 1D Metric Screw (M8 x 1.25 x 25) T14731-11 3 X 1E Fan, Pusher (350mm) (Supplied w/Engine) (Note 1) 1X 1F Lock Washer E106A-2 4 X 1G 1/4-20 x .75 HHCS CF000014 4 X 1H Flat Washer (Not Shown) S9262-98 4 X 2A Left Engine Foot L11885-2 1 X 2B Right Engine Foot L11885-1 1 X 2C Rubber Mounting T11991-3 2 X 2D Thread Forming Screw (Not Shown) S9225-26 4 X 2E 3/8-16 x 1.25 HHCS T8833-62 2 X 2F Lock Washer E106A-16 2 X 2G Plain Washer S9262-120 2 X 2H HHCS (M10 x 1.25 x 25) T14731-30 4 X 2J Lock Washer S17400-1 4 X 3A Muffler Asbly (Includes M20062-9 Gasket) G4247-1 1 X 3B Exhaust Gasket (Supplied w/Engine) (M20062-9) (Note 1)1X 3C M8 x 1.25 x 25mm Bolt (Supplied w/Engine) (Note 1) 4X 3D M8 Nut (Supplied w/Engine) (Not Shown) (Note 1) 4X 3E Spring Washer (M8) (Supplied w/Engine) (Not Shown) (Note 1) 4X 3F Flat Washer (Not Shown) S9262-121 4 X 3G Muffler Bracket S25496 1 X 3H Thread Forming Screw S9225-26 4 X 3J Spark Arrestor Clamp (Includes Fasteners) S20462 1 X 3K Outlet Pipe Elbow M16980-1 1 X 4A Inline Fuel Filter (Supplied w/Engine) (Note 1) 1X 6A Main Fuel Filter/Sedimenter (Supplied w/Engine) (Note 1) 1X 6B 5/16 -18 x 2.75 HHCS CF000073 1 X 6C Lock Washer (Not Shown) E106A-14 1 X 6D 5/16HN (Not Shown) CF000029 1 X 7A Solenoid & Fuel Pump Bracket L11898 1 X 7B Screw M8 x 1.25 20 HHCS (Not Shown) T14731-3 2 X 7C Lock Washer (Not Shown) E106A-14 2 X 7D Fuel Pump, Electric (Supplied w/Engine) (Note 1) 1• 7E 1/4-20 x .75 HHCS (Not Shown) CF000014 2 X 7F Plain Washer (Not Shown) S9262-98 2 X 7G Lock Washer (Not Shown) E106A-2 2 X 7H 1/4 x 20 HN (Not Shown) CF000017 2 X 7J Plain Washer (Not Shown) S9262-121 2 X 8A Adapter Fitting S25362-2 1 X 8B 5/8 ID Drain Hose T10642-264 1 X 8C Hose Clamp (Not Shown) S10888-27 2 X 8D Adapter Fitting S25362-1 1 X 8E Oil Drain Valve S24662 1 X 9A Air Cleaner Housing & Element M19801-1 1 X 9B Air Cleaner Mounting Band S25230 1 X 9C 5/16-18 x .875 HHCS (Not Shown) CF000168 2 X 9D Plain Washer (Not Shown) S9262-121 2 X 9E Lock Washer (Not Shown) E106A-14 2 X

NSS - Not Sold Separately

Note 1-See Kubota Parts List. Supplied by Engine Manufacturer.

RANGER

305D (AU)

08-17-2012

Page 64

P-646-H.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

9F 5/16-18 HN (Not Shown) CF000029 2 X 9G Air Intake Hose M20061 1 X 9H Hose Clamp S10888-29 2 X 9J Air Cleaner Decal (Supplied w/Air Cleaner) NSS 1 X 10A Solenoid Assembly, Idler S20140-3 1 X 10B 1/4-20 x .75 HHCS (Not Shown) CF000014 2 X 10C Plain Washer S9262-98 2 X 10D Lock Washer E106A-2 4 X 10E 1/4-20 HN CF000017 2 X 10F In-Line Swivel S22070 1 X 10G Governor Ball Joint S10623-2 1 X 10H 1/4-28 x .625 HHCS (Not Shown) T8833-51 1 X 10J 1/4-28 HN (Not Shown) CF000198 3 X 1 1A Governor Arm Bracket S25108 1 X 11B 1/4-20 x .75 HHCS (Not Shown) CF000014 1 X 11C Lock Washer (Not Shown) E106A-2 1 X 11D Plain Washer (Not Shown) S9262-98 1 X 11E 1/4-20 HN (Not Shown) CF000017 1 X 13 Shutdown Solenoid (Supplied w/Engine) (Note 1) 1X 14A Lift Bale Assembly L11880 1 X 14B 3/8-16 X .75 HHCS (Not Shown) CF000034 6 X 14C Lock Washer (Not Shown) E106A-16 6 X 15 Fuel Hose(9") (Not Shown) (Main Filter to Fuel Pump) T10642-256 2 X 15B Hose Clamp (Not Shown) T13777-5 4 X

NSS - Not Sold Separately

Note 1-See Kubota Parts List. Supplied by Engine Manufacturer.

RANGER

305D (AU)

08-17-2012

Page 65

NOTES

RANGER®305D (AU)

Page 66

Radiator & Case Back

10D

10A

10B

P-646-JP-646-J

10B

10A

10D

RANGER

305D (AU)

08-17-2012

Page 67

P-646-J.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Radiator G3115-7 1 X 1B Thread Forming Screw (Not Shown) S9225-26 4 X 1C Plain Washer (Not Shown) S9262-121 4 X 1D Lock Washer (Not Shown) E106A-14 4 X 1E Thread Forming Screw (Not Shown) S9225-68 6 X 2 Fan Shroud G4245 1 X 3A Case Back G4243 1 X 3B Thread Forming Screw S9225-68 8 X 3C Fastener Button T14659-1 4 X 3D Foam M15045-40 1 X 4A Fan Guard (Right) G4058-1 1 X 4B Thread Forming Screw S9225-68 4 X 4C Thread Forming Screw (Not Shown) S9225-66 2 X 5A Fan Guard (Left) G4060-1 1 X 5B Thread Forming Screw S9225-68 4 X 5C Speed Nut (Not Shown) T11525-5 2 X 6A Lower Radiator Hose L11881 1 X 6B Hose Clamp S10888-44 4 X 6C Upper Radiator Hose M20064 1 X 6D Hose Fitting, Brass S25524 1 X 6E Flex Hose (Ref. Thermostat to Radiator) T10642-263 1 X 6F Clamps (Not Shown) S10888-35 2 X 10A Bracket, Coolant Recovery Bottle S25514 1 X 10B Thread Forming Screw S9225-68 2 X 10C Bushing (Not Shown) T12380-1 1 X 10D Coolant Recovery Bottle (Supplied w/Engine) (Note 1) 1X 10E PVC Coolant Drain Hose (Not Shown) (Note 1) 1X 10F

Flex Tube (Not Shown)

T10642-236 1 X 10G Hose Clamp (Not Shown) T13777-5 2 X 12 Country of Origin Decal S24727-1 1 X 13 Warning Decal T13086-62 1 X

RANGER

305D (AU)

08-17-2012

Page 68

Covers

21A21A

3030

20A20A

21C21C

2A2A

3030

1010

15A15A

3131

21B21B

2525

1A1A

2626

1818

2727

1919

2929

3B3B

2828

3A3A

3C3C

P-646-KP-646-K

RANGER®305D (AU)

08-17-2012

Page 69

P-646-K.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Roof G3926-3 1 X 1B Door Bumper (Not Shown) T14882-1 12 X 1C Thread Forming Screw (Not Shown) S9225-68 16 X 2A Case Side (Right) G3510 1 X 2B Thread Forming Screw (Not Shown) S9225-68 3 X 3A Engine Top Cover Assembly G3927 1 X 3B Door Bumper T14882 2 X 3C Latch S24694 1 X 3D Rivet (Not Shown) T12584-9 2 X 3E Rivet (Not Shown) T12584-6 2 X 5 Fuel Warning Decal T13086-205 1 X 6 Warning Label M16197 1 X 7 Engine Service Decal S25522 1 X 9 Wiring Diagram G4571-3 1 X 10 Logo Decal S23768-5 2 X 15A Case Side (Left) G3511 1 X 15B Thread Forming Screw (Not Shown) S9225-68 3 X 18 Cover Seal S12934-1 1 X 19 Fuel Trough L12084 1 X 20A Left Engine Cover L11879 1 X 20B Latch (Not Shown) S24694 1 X 20C Hinge (Not Shown) S24348 2 X 20D Rivet (Not Shown) T12584-9 6 X 21A Right Engine Cover L11878 1 X 21B Latch S24694 1 X 21C Hinge S24348 2 X 21D Rivet (Not Shown) T12584-9 6 X 25 Oil Drain Procedure Decal S25455 1 X 26 Warranty Decal Part of L12790-10 1 X 27 Warning Decal S25896 1 X 28 Warning Decal T13086-62 1 X 29 CO Warning Decal M21436 1 X 30 Green Initiative Decal S28039-3 1 X 31 Family Name Decal M21952-1 1 X

NSS - Not Sold Separately

RANGER

305D (AU)

08-17-2012

Page 70

WARNING

Spanish

AVISO DE

PRECAUCION

• Do not touch 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 mojada.

• Aislese del trabajo y de la tierra.

• Keep flammable materials away.

• Mantenga el material combustible

fuera del área de trabajo.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

• Ne laissez ni la peau ni des vêtements

mouillés entrer en contact avec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

• Isolieren Sie sich von den Elektroden

und dem Erdboden!

• Não toque partes elétricas e electro-

dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Gardez à l’écart de tout matériel

inflammable.

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-

dos.

• Protégez vos yeux, vos oreilles et

votre corps.

• Tragen Sie Augen-, Ohren- und Kör-

perschutz!

• Use proteção para a vista, ouvido e

corpo.

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 ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 71

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

• Turn power off before servicing.

• Do not operate with panel open or

guards off.

WARNING

• Los humos fuera de la zona de res-

piración.

• Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

• Gardez la tête à l’écart des fumées.

• Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

• Vermeiden Sie das Einatmen von

Schweibrauch!

• Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.

• Use ventilação e exhaustão para

remover fumo da zona respiratória.

• Desconectar el cable de alimentación

de poder de la máquina antes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-

tien.

• Strom vor Wartungsarbeiten abschal-

ten! (Netzstrom völlig öffnen; Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer serviço.

•

Não toque as partes elétricas nuas.

• No operar con panel abierto o

guardas quitadas.

• N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

• Anlage nie ohne Schutzgehäuse oder

Innenschutzverkleidung in Betrieb setzen!

• Mantenha-se afastado das partes

moventes.

• Não opere com os paineis abertos ou

guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 72

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any 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.

Lincoln Electric IM10053 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual