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Manual Motosoldadora Ranger 305 D 2
Manual Motosoldadora Ranger 305 D 2
Manual Motosoldadora Ranger 305 D 2
For use with machines having Code Numbers: 11121, 11188, 11275
OPERATORS MANUAL
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
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
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
AUG 06
iii iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to Safety in Welding and Cutting (ANSI Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically hot parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been cleaned. For information, purchase Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders, available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturers
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturers recommendations.
6.I. Read and follow NFPA 51B Standard for Fire Prevention Jan 07
During Welding, Cutting and Other Hot Work, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
Sret Pour Soudage A LArc 7. Quand on ne soude pas, poser la pince une endroit isol de
1. Protegez-vous contre la secousse lectrique: la masse. Un court-circuit accidental peut provoquer un
chauffement et un risque dincendie.
a. Les circuits llectrode et la pice sont sous tension
quand la machine souder est en marche. Eviter toujours 8. Sassurer que la masse est connecte le plus prs possible
tout contact entre les parties sous tension et la peau nue de la zone de travail quil est pratique de le faire. Si on place
ou les vtements mouills. Porter des gants secs et sans la masse sur la charpente de la construction ou dautres
trous pour isoler les mains. endroits loigns de la zone de travail, on augmente le risque
b. Faire trs attention de bien sisoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, cbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques dincendie ou dechauffement des chaines et des
les positions assis ou couch pour lesquelles une cbles jusqu ce quils se rompent.
grande partie du corps peut tre en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-lectrode, la pince de masse, le cble Ceci est particulirement important pour le soudage de tles
de soudage et la machine souder en bon et sr tat galvanises plombes, ou cadmies ou tout autre mtal qui
defonctionnement. produit des fumes toxiques.
d.Ne jamais plonger le porte-lectrode dans leau pour le
refroidir. 10. Ne pas souder en prsence de vapeurs de chlore provenant
e. Ne jamais toucher simultanment les parties sous tension doprations de dgraissage, nettoyage ou pistolage. La
des porte-lectrodes connects deux machines soud- chaleur ou les rayons de larc peuvent ragir avec les
er parce que la tension entre les deux pinces peut tre le vapeurs du solvant pour produire du phosgne (gas forte-
total de la tension vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sret,
pour le porte-lectrode sapplicuent aussi au pistolet de voir le code Code for safety in welding and cutting CSA
soudage. Standard W 117.2-1974.
Mar. 93
v v
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
as much pride as we have in bringing this product to you!
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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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.
vi TABLE OF CONTENTS vi
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
Auxiliary Power Receptacles and Plugs ...............................................................................A-6
Standby Power Connections ................................................................................................A-6
Premises Wiring ...................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders.................................................................A-8,A-9
________________________________________________________________________________
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 .............................................................................................................B-7
Simultaneous Welding and Auxiliary Power Loads .......................................................B-7
Extension Cord Recommendations...............................................................................B-7
________________________________________________________________________________
Accessories .....................................................................................................Section C
Field Installed Options / Accessories ...............................................................................C-1
________________________________________________________________________________
vii TABLE OF CONTENTS vii
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 ..................................................................................................................P492
________________________________________________________________________
A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2)
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
cu. in. (cu. cm.) System
(2) 120VAC GFCI Duplex (5-20R) Two 20AMP for Two Duplex Receptacle 15AMP for Battery Charging Circuit
(1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage(2-pole) 15AMP for 42V Wire Feeder Power
Full KVA (14-50R) Below code 11275 two 50AMP Below code 11275 Battery
cicuit breakers were used for Charging Circuit Breaker was
Dual Voltage 25 amps
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
A-2 INSTALLATION A-2
SAFETY PRECAUTIONS LIFTING
The RANGER 305D weighs approximately
WARNING 775lbs.(352kg.) with a full tank of fuel (698 lbs. less
fuel). A lift bail is mounted to the machine and should
Do not attempt to use this equipment until you always be used when lifting the machine.
have thoroughly read the engine manufacturers
manual supplied with your welder. It includes WARNING
important safety precautions, detailed engine
Lift only with equipment of ade-
starting, operating and maintenance instructions,
and parts lists. quate lifting capacity.
------------------------------------------------------------------------ Be sure machine is stable when lift-
ELECTRIC SHOCK can kill. ing.
Do not touch electrically live parts or Do not lift this machine using lift
electrode with skin or wet clothing. bail if it is equipped with a heavy
Insulate yourself from work and accessory such as trailer or gas
ground cylinder.
Always wear dry insulating gloves.
------------------------------------------------------------------------ FALLING Do not lift machine if lift bail is
ENGINE EXHAUST can kill. EQUIPMENT can damaged.
Use in open, well ventilated areas or cause injury. Do not operate machine while
vent exhaust outside.
suspended from lift bail.
------------------------------------------------------------------------ --------------------------------------------------------------------------------
MOVING PARTS can injure.
Do not operate with doors open or HIGH ALTITUDE OPERATION
guards off. At higher altitudes, output derating may be necessary. For max-
Stop engine before servicing. imum rating, derate the machine 2.5% to 3.5% for every 1000 ft.
Keep away from moving parts.
------------------------------------------------------------------------ (305m). Due to new EPA and other local emissions regulations,
See additional warning information at modifications to the engine for high altitude are restricted within
the United States and some other European Countries. Use
front of this operators manual.
above 6000 ft.(1828 m) may be limited due to poor engine per-
Only qualified personnel should install, formance or excessive exhaust smoke. An authorized Kubota
use, or service this equipment. engine field service shop should be contacted to determine if
any adjustments can be made for operation in higher elevations
LOCATION AND VENTILATION locally.
RANGER 305D
A-3 INSTALLATION A-3
WARNING FUEL
USE DIESEL FUEL ONLY
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other WARNING
components to fail.
Fill the fuel tank with clean, fresh fuel. The
Only transport this Equipment on serviceable capacity of the tank is 12 gals. (45.4ltrs). When
vehicles which are rated and designed for such the fuel gauge reads empty the tank contains
loads. approximately 2 gals. (7.6ltrs.) of reserve fuel.
Distribute, balance and secure loads so vehicle
is stable under conditions of use. WARNING
Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires. NOTE: A fuel shut off valve is located on the pre-
Mount equipment base to metal bed or frame of filter/sediment filter. Which should be in
vehicle. the closed position when the welder is not
Follow vehicle manufacturers instructions. ran for extended periods of time.
------------------------------------------------------------------------ ------------------------------------------------------------------------
RANGER 305D
A-4 INSTALLATION A-4
Use caution as the electrolyte is a strong acid that The 14-pin connector is used to directly connect a
can burn skin and damage eyes. wire feeder control cable. In the CV-WIRE mode,
------------------------------------------------------------------------ when the control cable is connected to the 14-pin con-
nector, the auto-sensing circuit automatically makes
The RANGER 305D is shipped with the negative bat- the Output Control inactive and the wire feeder volt-
tery cable disconnected. Make certain that the RUN- age control active
STOP switch is in the STOP position. Remove the two
screws from the rear battery tray using a screwdriver WARNING
or a 3/8" socket. Attach the negative battery cable to
the negative battery terminal and tighten using a 1/2"
NOTE: When a wire feeder with a built in welding
socket or wrench.
voltage control is connected to the 14-pin connec-
tor, do not connect anything to the 6-pin connec-
NOTE: This machine is furnished with a wet charged
tor.
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat- ------------------------------------------------------------------------
tery with the correct polarity. ELECTRICAL CONNECTIONS
MUFFLER OUTLET PIPE
Using the clamp provided secure the outlet pipe to the MACHINE GROUNDING
outlet tube with the pipe positioned such that it will Because this portable engine driven welder creates its
direct the exhaust in the desired direction. Tighten own power, it is not necessary to connect its frame to
using a 9/16" socket or wrench. an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)
SPARK ARRESTER
Some federal, state or local laws may require that
To prevent dangerous electric shock, other equipment
gasoline or diesel engines be equipped with exhaust
to which this engine driven welder supplies power
spark arresters when they are operated in certain
must:
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 WARNING
local regulations, a suitable spark arrester, such as
Be grounded to the frame of the welder using a
the K1898-1 must be installed and properly main-
grounded type plug.
tained.
Be double insulated.
WARNING Do not ground the machine to a pipe that carries
explosive or combustible material.
An incorrect spark arrestor may lead to damage to
------------------------------------------------------------------------
the engine or adversely affect performance.
------------------------------------------------------------------------
RANGER 305D
A-5 INSTALLATION A-5
When this welder is mounted on a truck or trailer, its CABLE INSTALLATION
frame must be electrically bonded to the metal frame Install the welding cables to your RANGER 305D as
of the vehicle. Use a #8 or larger copper wire connect- follows.
ed between the machine grounding stud and the
frame of the vehicle. When this engine driven welder 1. The engine must be OFF to install welding cables.
is connected to premises wiring such as that in a
home or shop, its frame must be connected to the sys- 2. Remove the flanged nuts from the output terminals
tem earth ground. See further connection instructions .
in the section entitled "Standby Power Connections" 3. Connect the electrode holder and work cables to the
as well as the article on grounding in the latest weld output terminals. The terminals are identified
National Electrical Code and the local code. on the case front.
In general, if the machine is to be grounded, it should 4. Tighten the flanged nuts securely.
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the 5. Be certain that the metal piece you are welding (the
ground for at least ten feet and having no insulated work) is properly connected to the work clamp and
joints, or to the metal framework of a building which cable.
has been effectively grounded.
6. Check and tighten the connections periodically.
The National Electrical Code lists a number of alter-
nate means of grounding electrical equipment. A CAUTION
machine grounding stud marked with the symbol
is provided on the front of the welder. Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
WELDING TERMINALS melt.
The RANGER 305D is equipped with a toggle switch Do not cross the welding cables at the output ter-
for selecting "hot" welding terminal when in the "WELD minal connection. Keep the cables isolated and
TERMINALS ON" position or "cold" welding terminal separate from one another.
when in the "REMOTELY CONTROLLED" position. ------------------------------------------------------------------------
TABLE A.1
RANGER 305D
A-6 INSTALLATION A-6
AUXILIARY POWER RECEPTACLES Install the double-pole, double-throw switch
between the power company meter and the premis-
Start the engine and set the IDLER control switch to es disconnect. Switch rating must be the same or
the High Idle mode. Voltage is now correct at the greater than the customers premises disconnect
receptacles for auxiliary power. This must be done and service over current protection.
before a tripped GFCI receptacle can be reset prop-
erly. See the MAINTENANCE section for detailed Take necessary steps to assure load is limited to
information on testing and resetting the GFCI recep- the capacity of the RANGER 305D by installing a 50
tacle. amp, 240 VAC double pole circuit breaker.
Maximum rated load for each leg of the 240 VAC
The auxiliary power of the RANGER 305D consists of auxiliary is 40 amperes. Loading above the rated
two 20 Amp-120 VAC (5-20R) duplex receptacles output will reduce output voltage below the allow-
with GFCI protection and one 50 Amp 120/240 VAC able - 10% of rated voltage which may damage
(14-50R) receptacle. The 240 VAC receptacle can be appliances or other motor-driven equipment and
split for single phase 120 VAC operation. may result in overheating of the RANGER 305D
engine and/or alternator windings.
The auxiliary power capacity is 10,000 watts Peak,
9,500 Watts Continuous of 60 Hz, single phase Install a 50 amp, 120/240 VAC plug (NEMA Type
power. The auxiliary power capacity rating in watts is 14-50) to the double-pole circuit breaker using No.
equivalent to volt-amperes at unity power factor. The 6, 4 conductor cable of the desired length. (The 50
max permissible current of the 240 VAC output is 40 amp, 120/240 VAC plug is available in the optional
amps. The 240 VAC output can be split to provide K802R plug kit or as part number T12153-9.)
two separate 120 VAC outputs with a max permissi-
ble current of 40 Amps per output to two separate Plug this cable into the 50 Amp, 120/240 Volt recep-
120 VAC branch circuits (these circuits cannot be tacle on the RANGER 305D case front.
paralleled). Output voltage is within 10% at all loads
up to rated capacity. All auxiliary power is protected
by circuit breakers.
RANGER 305D
A-7 INSTALLATION A-7
240 VOLT
GROUNDED CONDUCTOR
240 Volt POWER
120 VOLT
60 Hz.
3-Wire COMPANY
120 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
240 VOLT PROTECTION
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
WARNING
Only a licensed, certified, trained electrician should install the machine to a premises or residential
electrical system. Be certain that:
The installation complies with the National Electrical Code and all other applicable electrical codes.
The premises is isolated and no feedback into the utility system can occur. Certain state and local
laws require the premises to be isolated before the generator is linked to the premises. Check your
state and local requirements.
A double pole, double throw transfer switch in conjunction with the properly rated double throw
circuit breaker is connected between the generator power and the utility meter.
RANGER 305D
A-8 INSTALLATION A-8
Across The-Arc Model:
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS Attach the single lead from the front of the LN-15 to
work using the spring clip at the end of the lead. This
Connection of LN-7 or LN-8 to the RANGER 305D is a control lead to supply current to the wire feeder
motor; it does not carry welding current.
Shut the welder off.
Set the "WELD TERMINALS" switch to "WELD TER-
Connect the LN-7 or LN-8 per instructions on the MINALS ON"
appropriate connection diagram in Section F.
Control Cable Model:
Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being Connect Control Cable between Engine Welder and
used. Feeder.
Set the "MODE" switch to the "CV WIRE " position. Set the "WELD TERMINALS" switch to "REMOTELY
Set the "ARC CONTROL" knob to "0" initially and CONTROLLED".
adjust to suit.
Set the MODE switch to the "CV-WIRE " position.
Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode polarity
Set the "IDLE" switch to the "HIGH" position. being used.
Connection of LN-15 to the Ranger 305D Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
These connections instructions apply to both the LN-
15 Across The-Arc and Control Cable models. The Set the "IDLE" switch to the "AUTO" position
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.
RANGER 305D
A-9 INSTALLATION A-9
Connection of the LN-25 to the RANGER 305D Connection of LN-742, Spool Gun (K487-25) and
Cobramatic to RANGER 305D
WARNING
Shut the welder off.
Shut off welder before making any electrical con-
nections. Connect per instructions on the appropriate connec-
------------------------------------------------------------------------ tion diagram in Section F.
The LN-25 with or without an internal contactor may
be used with the RANGER 305D. See the appropriate Connection of PRINCE XL SPOOL GUN to the
connection diagram in Section F. Ranger 305D
NOTE: The LN-25 (K431) Remote Control Module Connection of the Prince XL Spool Gun requires the
and (K432) Remote Cable are not recommended for use of the K1849-1 Adapter Module.
use with the RANGER 305D.
Shut the Welder off.
1. Shut the welder off.
For electrode Positive, connect the electrode cable
2. For electrode Positive, connect the electrode to the "+" terminal of the welder and work cable to
cable from the LN-25 to the "+" terminal of the the "-" terminal of the welder. For electrode
welder and work cable to the "-" terminal of the Negative, connect the electrode cable "-" terminal of
welder. For electrode Negative, connect the elec- the welder and work cable to the "+" terminal of the
trode cable from the LN-25 to the "-" terminal of welder.
the welder and work cable to the "+" terminal of
the welder. Connect the Control Cable of the Spool Gun to the
Adapter Module and connect the Control Cable of
3. Attach the single lead from the front of the LN-25 the Adapter Module to the Welder.
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire Connect the Gas Hose.
feeder motor; it does not carry welding current.
Set the MODE switch to the "CV-WIRE " position.
4. Set the MODE switch to the "CV-WIRE " position.
Set the "WELD TERMINALS" switch to "WELD
5. Set the "WELD TERMINALS" switch to "WELD TERMINALS ON".
TERMINALS ON"
Set the "ARC CONTROL" knob to "0" initially and
6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
adjust to suit.
Set the IDLE switch to the HIGH position.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the RANGER 305D 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.
CAUTION
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
Ranger 305D is started.
------------------------------------------------------------------------
RANGER 305D
B-1 OPERATION B-1
SAFETY PRECAUTIONS Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
Check radiator for proper coolant level. (Fill if nec-
WARNING essary).
See Engine Owners Manual for specific oil and
Do not attempt to use this equipment until you coolant recommendations.
have thoroughly read the engine manufacturers
manual supplied with your welder. It includes ADD FUEL
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists. WARNING
------------------------------------------------------------------------
ELECTRIC SHOCK can kill. Stop engine while fueling.
Do not touch electrically live parts or Do not smoke when fueling.
electrode with skin or wet clothing.
Insulate yourself from work and Keep sparks and flame away
ground from tank.
Always wear dry insulating gloves. Do not leave unattended while
fueling.
Always operate the welder with the hinged door
Wipe up spilled fuel and allow
closed and the side panels in place. DIESEL FUEL
can cause fire. fumes to clear before starting
Read carefully the Safety Precautions page
before operating this machine. Always follow engine.
these and any other safety procedures included Do not overfill tank, fuel
in this manual and in the Engine Instruction expansion may cause over-
Manual. flow.
DIESEL FUEL ONLY
GENERAL DESCRIPTION ------------------------------------------------------------------------
Remove the fuel tank cap.
The RANGER 305D is a diesel engine powered DC
Fill the tank approximately 4 inches (100mm) from
multi-process welding power source and 120 / 240
the top of the filler neck to allow for fuel expansion .
volt AC power generator. The engine drives a genera-
DO NOT FILL THE TANK TO THE POINT OF
tor that supplies three phase power for the DC weld-
OVERFLOW.
ing circuit and single phase power for the AC auxiliary
outlets. The DC welding control system uses state of
Replace the fuel cap and tighten securely.
the art Chopper Technology (CT tm) for superior weld-
ing performance.
See Engine Owners Manual for specific fuel recom-
mendations.
FOR AUXILIARY POWER:
Start the engine and set the IDLER control switch to BREAK-IN PERIOD
the desired operating mode. Full power is available
regardless of the welding control settings providing no Any engine will use a small amount of oil during its
welding current is being drawn. break-in period. For the diesel engine on the
RANGER 305D, break-in is about 50 running hours.
The auxiliary power of the RANGER 305D consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles with Check the oil every four hours during break-in.
GFCI protection and one 50 Amp 120/240 VAC (14- Change the oil after the first 50 hours of
50R) receptacle. The 240 VAC receptacle can be split operation,every 100 hours thereafter. Change the oil
for single phase 120 VAC operation. Also refer to the filter at the second oil change.
AUXILIARY POWER OPERATION section later in this
chapter.
CAUTION
ENGINE OPERATION During break-in, subject the RANGER 305D to
Before Starting the Engine: moderate loads. Avoid long periods running at
Be sure the machine is on a level surface. idle. Before stopping the engine, remove all loads
Open top & side engine doors and remove the and allow the engine to cool several minutes.
engine oil dipstick and wipe it with a clean cloth. ------------------------------------------------------------------------
Reinsert the dipstick and check the level on the dip-
stick.
RANGER 305D
B-2 OPERATION B-2
16
1
15
14
2 17
13
3
12
11
4
10
5 7
FIGURE B.1 6
WELDING CONTROLS (Figure B.1) 2. DIGITAL OUTPUT METERS- The digital
meters allow the output voltage (CV-WIRE mode)
1. OUTPUT CONTROL- The OUTPUT dial is or current (CC-STICK,DOWN HILL PIPE and TIG
used to preset the output voltage or current as dis- modes) to be set prior to welding using the OUT-
played on the digital meters for the four welding PUT control dial. During welding, the meter dis-
modes. When in the CC-STICK, DOWNHILL PIPE play the actual output voltage (VOLTS) and cur-
or CV-WIRE modes and when a remote control is rent (AMPS). A memory feature holds the display
connected to the 6-Pin or 14-Pin Connector, the of both meters on for seven seconds after welding
auto-sensing circuit automatically switches the is stopped. This allows the operator to read the
OUTPUT CONTROL from control at the welder to actual current and voltage just prior to when weld-
the remote control. ing was ceased.
In the CV-WIRE mode, when the wire feeder con- While the display is being held the left-most deci-
trol cable is connected to the 14-Pin Connector, the mal point in each display will be flashing. The
auto-sensing circuit automatically makes OUTPUT accuracy of the meters is +/- 3%.
CONTROL inactive and the wire feeder voltage
control active. 3. WELD MODE SELECTOR SWITCH-
(Provides four selectable welding modes)
CV-WIRE
When in the TOUCH START TIG mode and when a
DOWNHILL PIPE
Amptrol is connected to the 6-Pin Connector, the
CC-STICK
OUTPUT dial is used to set the maximum current
TOUCH START TIG
range of the CURRENT CONTROL of the Amptrol.
RANGER 305D
B-3 OPERATION B-3
4. ARC CONTROL- The ARC CONTROL dial is active in 10. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to
the CV-WIRE, CC-STICK and DOWNHILL PIPE modes,
the polarity of the electrode.
and has different functions in these modes. This control is
not active in the TIG mode.
ENGINE CONTROLS: (Figure B.2)
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 11. RUN/STOP SWITCH - RUN position energizes
electrode sticking. Start with a setting at 0. the engine prior to starting. STOP position stops the
engine. The oil pressure interlock switch prevents
DOWNHILL PIPE mode: In this mode, the ARC CONTROL battery drain if the switch is left in the RUN position
dial sets the short circuit current (arc-force) during stick and the engine is not operating.
welding to adjust for a soft or a more forceful digging arc
(crisp). Increasing the number from 10 (soft) to +10 (crisp) 12. GLOW PLUG PUSH BUTTON -
increases the short circuit current which results in a more When pushed activates the glow plugs as well as
forceful digging arc. Typically a forceful digging arc is pre- the electric fuel pump for quick starting. Glow plug
ferred for root and hot passes. A softer arc is preferred for fill should not be activated for more than 20 seconds
and cap passes where weld puddle control and deposition continuously.(For Code 11121)
("stacking" of iron) are key to fast travel speeds. It is recom- AUTO BLEED FUNCTION Air will automatically
mended that the ARC CONTROL be set initially at 0. bleed from the fuel system by simply pushing the
GLOW PLUG BUTTON. It is generally not required
CV-WIRE mode: In this mode, turning the ARC CONTROL to crack open fittings in the fuel system to bleed air
clock wise from 10 (soft) to +10 (crisp) changes the arc from the fuel system.(For Code 11121)
from soft and washed-in to crisp and narrow. It acts as an
inductance/pinch control. The proper setting depends on the When pushed activates the glow plugs. Glow plug
procedure and operator preference. Start with a setting of 0. should not be activated for more than 20 seconds
continuously.(For Code 11188, 11275)
5. WELD OUTPUT TERMINALS WITH FLANGE
NUT- Provides a connection point for the electrode and 13. START PUSH BUTTON -
work cables. Output stud covers provided on code 11275 Energizes the starter motor to crank the engine.
and above.
14. IDLER SWITCH- Has two positions as follows:
6. GROUND STUD- Provides a connection point for 1) In the HIGH position, the engine runs at the high
connecting the machine case to earth ground. idle speed controlled by the engine governor.
2) In the AUTO position, the idler operates as follows:
7. 14-PIN CONNECTOR- For attaching wire feeder con- When switched from HIGH to AUTO or after starting
trol cables to the RANGER 305D. Includes contactor clo- the engine, the engine will operate at full speed for
sure circuit, auto-sensing remote control circuit, and 120V approximately 12 seconds and then go to low idle
and 42V power. The remote control circuit operates the speed.
same as the 6 Pin Amphenol. When the electrode touches the work or power is
drawn for lights or tools (approximately 100 Watts
8. 6-PIN CONNECTOR- For attaching optional remote minimum), the engine accelerates and operates at
full speed.
control equipment. Includes auto-sensing remote control
When welding ceases or the AC power load is
circuit.
turned off, a fixed time delay of approximately 12
seconds starts. If the welding or AC power load is
9. WELD TERMINALS CONTROL SWITCH- In the not restarted before the end of the time delay, the
WELD TERMINALS ON position, the output is electrically idler reduces the engine speed to low idle speed.
hot all the time. In the REMOTELY CONTROLLED posi- The engine will automatically return to high idle
tion, the output is controlled by a wire feeder or amptrol speed when there is welding load or AC power load
device, and is electrically off until a remote switch is reapplied.
depressed.
RANGER 305D
B-4 OPERATION B-4
15. ELECTRIC FUEL GAUGE- The electric fuel NOTE: If the unit fails to start repeat step 4 through
gauge gives accurate and reliable indication as to step 7 after waiting 30 seconds
how much fuel is in the fuel tank.
CAUTION
16. ENGINE HOUR METER- Displays the total
time that the engine has been running. This meter Do not allow the starter motor to run continuously
is useful for scheduling prescribed maintenance. for more than 20 seconds.
Do not push the START button while the engine
is running because this can damage the ring
17. ENGINE PROTECTION LIGHT- A warning
gear and/or the starter motor.
indicator light for Low Oil Pressure and/or Coolant
IF the Engine Protection or Battery Charging
Over Temperature. The light is off when the sys-
Lights do not turn off shortly after starting the
tems are functioning properly. The light turns on
engine shut off the engine immediately and deter
when the RUN-STOP switch is in the ON posi-
mine the cause.
tion prior to starting the engine. If the Engine
-----------------------------------------------------------------------
Protection or Battery Charging Lights do not
NOTE: When starting a RANGER 305D for the first
turn off shortly after starting the engine shut off
time, or after and extended period of time of not oper-
the engine immediately and determine the cause.
ating, it will take longer than normal because the fuel
pump has to fill the fuel system.
STARTING THE ENGINE
1. Remove all plugs connected to the AC power STOPPING THE ENGINE
receptacles. Remove all welding and auxiliary power loads and
2. Set IDLER switch to AUTO. allow the engine to run at low idle speed for a few
3. Set the RUN/STOP switch to RUN. minutes to cool the engine.
4. Press Glow Plug Button and hold 5 to 10 seconds.
5. Press and hold both the Glow Plug Button and STOP the engine by placing the RUN-STOP switch in
START button together until the engine starts or for the STOP position.
up to 10 seconds.
6. Release the engine START button immediately NOTE: A fuel shut off valve is located on the fuel pre-
when the engine starts. filter.
7. Release the glow plug button after the Engine
Protection Light turns off or after an additional 5 WELDER OPERATION
seconds maximum.
DUTY CYCLE
8. The engine will run at high idle speed for approxi-
mately 12 seconds and then drop to low idle speed. Duty Cycle is the percentage of time the load is being
Allow the engine to warm up at low idle for several applied in a 10 minute period. For example a 60% duty
minutes before applying a load and/or switching to cycle, represents 6 minutes of load and 4 minutes of no
high idle. Allow a longer warm up time in cold load in a 10 minute period.
weather.
TABLE B.1
TYPICAL RANGER 305D 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
RANGER 305D
B-5 OPERATION B-5
The Ranger 305D can be used with a broad range of DC It is recommended that the ARC CONTROL be set to the
stick electrodes. The MODE switch provides two stick minimum number without electrode sticking. Start with
welding settings as follows: the dial set at 0.
DOWNHILL PIPE Welding The ARC CONTROL is not active in the TIG mode. To
This slope controlled setting is intended for "out-of-posi- STOP a weld, simply pull the TIG torch away from the
tion" and "down hill" pipe welding where the operator work. When the arc voltage reaches approximately 30
would like to control the current level by changing the arc Volts the arc will go out and the machine will reset the
length. The output CONTROL dial adjusts the full output current to the Touch Start level. To reinitiate the arc,
range for pipe welding. The ARC CONTROL dial sets the retouch the tungsten to the work and lift. Alternatively,
short circuit current (arc-force) during stick welding to the weld can be stopped by releasing the Amptrol or arc
adjust for a soft or more forceful digging arc (crisp). start switch.
Increasing the number from -10(soft) to +10(crisp)
increases the short circuit current which results in a more The RANGER 305 D can be used in a wide variety of DC
forceful digging arc.Typically a forceful digging arc is pre- TIG welding applications. In general the Touch Start
ferred for root and hot passes. A softer arc is preferred for feature allows contamination free starting without the use
fill and cap passes where weld puddle control and deposi- of a Hi-frequency unit. If desired, the K930-2 TIG Module
tion (stacking of iron) are key to fast travel speeds. This can be used with the RANGER 305 D. The settings are
can also increase spatter. TABLE B.2 for reference.
.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)
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)
(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:
# 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)
(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
and high duty cycles.
RANGER 305D
B-6 OPERATION B-6
RANGER 305 D settings when using the K930-2 TIG Module with ARC GOUGING
an Amptrol or Arc Start Switch: The RANGER 305D can be used for limited arc goug-
Set the MODE Switch to the TOUCH START TIG setting. ing. For optimal performance, set the MODE switch to
CC-STICK and the ARC CONTROL to +10.
Set the "IDLER" Switch to the "AUTO" position.
Set the OUTPUT CONTROL knob to adjust output
Set the "WELDING TERMINALS" switch to the "REMOTELY current to the desired level for the gouging electrode
CONTROLLED" position. This will keep the "Solid State" con- being used according to the ratings in the following
tactor open and provide a "cold" electrode until the Amptrol or Table.
Arc Start Switch is pressed.
Carbon Diameter Current Range (DC, electrode
When using the TIG Module, the OUTPUT control on the positive)
RANGER 305 D is used to set the maximum range of the CUR-
RENT CONTROL on the TIG Module or an Amptrol if connected 1/8" 60-90 Amps
to the TIG Module.
5/32" 90-150 Amps
WIRE WELDING-CV
Connect a wire feeder to the RANGER 305 D according to the 3/16" 200-250 Amps
instructions in INSTALLATION INSTRUCTIONS Section.
Listed below are some wires suitable for use on this machine:
RANGER 305D
B-7 OPERATION B-7
AUXILIARY POWER: The 120 V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
If a GFCI receptacle is tripped, See the MAINTE- double insulated tools with two wire plugs. The current
NANCE section for detailed information on testing and rating of any plug used with the system must be at
resetting the GFCI receptacle. least equal to the current capacity of the associated
receptacle.
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 NOTE: The 240 V receptacle has two circuits, each of
welding current is being drawn. which measure 120 V to neutral but are of opposite
polarities and cannot be paralleled.
The auxiliary power of the RANGER 305D consists of
two 20 Amp-120 VAC GFCI (5-20R) duplex recepta- Simultaneous Welding and Auxiliary Power Loads
cles and one 50 Amp 120/240 VAC (14-50R) recepta- The above auxiliary power ratings are with no welding
cle. The 240 VAC receptacle can be split for single load. Simultaneous welding and power loads are
phase 120 VAC operation. The auxiliary power capac- specified in the following table. The permissible cur-
ity is 10,000 watts Peak, 9500 Watts continuous of 60 rents shown assume that current is being drawn from
Hz, single phase power. The auxiliary power capacity either the 120 VAC or 240 VAC supply (not both at the
rating in watts is equivalent to volt-amperes at unity same time).
power factor. The max permissible current of the 240
VAC output is 44 Amps. The 240 VAC output can be
split to provide two separate 120 VAC outputs with a
max permissible current of 44 Amps per output to two
separate 120 VAC branch circuits (these circuits can-
not be paralleled). Output voltage is within 10% at
all loads up to rated capacity. All auxiliary power is
protected by circuit breakers.
@ 240 VAC
0 9000 44
100 7500 31
150 5800 24
200 4500 19
250 2800 12
300 700 3
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 44A per 120 VAC branch circuit when splitting the 240 VAC output.
RANGER 305D Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current Voltage Load Maximum Allowable Cord Length in ft. (m) for Conductor Size
(Amps) Volts (Watts) 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
44 240 9500 50 (15) 90 (27) 150 (46) 225 (69)
Conductor size is based on maximum 2.0% voltage drop.
RANGER 305D
C-1 ACCESSORIES C-1
RANGER 305D
D-1 MAINTENANCE D-1
RANGER 305D
D-2 MAINTENANCE D-2
Locate oil drain hose and valve in bottom of base Clean the filter mounting base and coat the gasket
and pull through the hole in the battery access panel of the new filter with clean engine oil.
on the welder.
Screw the new filter on by hand until the gasket con-
Remove the cap from the drain valve. Push valve in tacts the mounting base. Using an oil filter wrench,
and twist counterclockwise. Pull to open and drain tighten the filter an additional 1/2 to 7/8 of a turn.
the oil into a suitable container for disposal. Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap
Close the drain valve by pushing in and twisting and tighten securely.
clockwise. Replace the cap.
Start the engine and check for oil filter leaks.
Re-fill the crankcase to the upper limit mark on the
dipstick with the recommended oil (see engine oper- Stop the engine and check the oil level. If neces-
ation manual OR engine service items decal OR sary, add oil to the upper limit mark on the dipstick.
below). Replace and tighten the oil filler cap secure-
ly.
Push oil drain hose and valve back into unit, re-con-
nect negative battery cable, and close doors and WARNING
engine top cover before restarting unit.Wash your
hands with soap and water after handling used Never use gasoline or low flash point solvents
motor oil. Please dispose of used motor oil in a for cleaning the air cleaner element. A fire or
manner that is compatible with the environment. explosion could result.
We suggest you take it in a sealed container to your
local service station or recycling center for reclama-
CAUTION
tion. DO NOT throw it in the trash; pour it on the Never run the engine without the air cleaner.
ground or down a drain. Rapid engine wear will result from contaminants,
such as dust and dirt being drawn into the
Engine Oil Refill capacities engine.
Without oil filter replacement: ------------------------------------------------------------------------
3.3 U.S. Quart. (2.7 Imp Quart, 3.2 liter) AIR CLEANER
With oil filter replacement: The diesel engine is equipped with a dry type air filter.
3.4 U.S. Quart. (3.0 Imp Quart, 3.2 liter) Never apply oil to it. Service the air cleaner as follows:
Use motor oil designed for diesel engines that meets Replace the element at least every 200 hours of
requirements for API service classification operation and sooner under dusty conditions.
CC/CD/CE/CF/CF-4/CG-4 or CH-4.
ACEA E1/E2/E3. Always check the API service label
on the oil container to be sure it includes the letters
indicated. (Note: An S-grade oil must not be used in a
diesel engine or damage may result. It IS permissible
to use an oil that meets S and C grade service classifi-
cations.)
SAE 10W30 is recommended for general, all tempera-
ture use, 5F to 104F (-15C to 40C).
See engine owners manual for more specific informa-
tion on oil viscosity recommendations.
RANGER 305D
D-3 MAINTENANCE D-3
1 Release the
5 Check the Old Donaldson filters with RadialSeal Sealing
Technology are self-aligning, self-centering,
Seal Carefully Filter for Leak Clues and self-sealing. A new filter has a dry
Unlatch and remove the service Visually inspect the old filter for any signs
lubricant to aid installation. The critical
cover of the air cleaner. Make of leaks. A streak of dust on
sealing area will stretch slightly, adjust
certain the latches are folded the clean side of the filter
itself and distribute the sealing pressure
back against the cover so that is a telltale sign.
evenly. To complete a tight seal, apply
they don t hinder filter Remove any cause
pressure by hand at the outer rim of the
removal/installation. Most latches of leaks before
filter, not the flexible center. (Avoid
are spring loaded to fold back when open. installing new
pushing on the center of the urethane end
The filter fits tightly over the outlet tube, filter. cap.) No cover pressure is required to hold
creating the critical seal on the inside
the seal. Again, do NOT use the service
diameter of the filter endcap. The filter
should be removed gently to reduce the
amount of dust dislodged. There will be
6 Inspect the New
Filter for Damage
Inspect the new filter carefully,
cover to push the filter into place!
7 Insert the New Make sure that all clamps, bolts, and
housing. Avoid
connections in the entire air intake system
knocking the filter RadialSeal Filter are tight. Check for holes in piping, and
against the housing. by Hand repair if needed.
Insert carefully. Seat the new filter by hand,
RANGER 305D
D-4 MAINTENANCE D-4
COOLING SYSTEM FUEL
WARNING At the end of each days use, refill the fuel tank to min-
imize moisture condensation and dirt contamination in
HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to
expand.
Do not remove cap if radiator is
hot. Use only fresh, No. 2 grade DIESEL fuel. Do not use
kerosene.
RANGER 305D
D-5 MAINTENANCE D-5
CLEANING THE BATTERY
FUEL FILTER
Keep the battery clean by wiping it with a damp cloth
1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon-
accumulation or sediment. nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
2. Replace the fuel filter if it is found with excessive kg) of baking soda and 1 quart (0.9461) of water. Be
water accumulation or sediment. Empty fuel pre-fil- sure the battery vent plugs (if equipped) are tight so
ter. that none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat-
OVERSPEED IS HAZARDOUS tery compartment, and surrounding areas with clear
The maximum allowable high idle speed for this water. Coat the battery terminals lightly with petroleum
machine is 3650 RPM, no load. Do NOT tamper jelly or a non-conductive grease to retard corrosion.
with governor components or setting or make any Keep the battery clean and dry. Moisture accumula-
other adjustments to increase the maximum tion on the battery can lead to more rapid discharge
speed. Severe personal injury and damage to the and early battery failure.
machine can result if operated at speeds above
maximum.
CHECKING THE ELECTROLYTE LEVEL
ENGINE ADJUSTMENT If battery cells are low, fill them to the neck of the filler
Adjustments to the engine are to be made only by a hole with distilled water and recharge. If one cell is
Lincoln Service Center or an authorized Field Service low, check for leaks.
Shop.
CLEANING: Blow out the generator and controls peri- If the receptacle has tripped, first carefully remove
odically with low pressure air. Do this at least once a any load and check it for damage.
week in particularly dirty areas. If the equipment has been shut down, it must be
restarted.
BRUSH REMOVAL AND REPLACEMENT: Its nor- The equipment needs to be operating at high idle
mal for the brushes and slip rings to wear and darken speed and any necessary adjustments made on the
slightly. Inspect the brushes when a generator over- control panel so that the equipment is providing at
haul is necessary. least 80 volts to the receptacle input terminals.
The circuit breaker for this receptacle must not be
tripped. Reset if necessary.
CAUTION Push the "Reset" button located on the GFCI recep-
tacle. This will assure normal GFCI operation.
Plug a night-light (with an "ON/OFF" switch) or other
Do not attempt to polish slip rings while the product (such as a lamp) into the GFCI receptacle
engine is running. and turn the product "ON".
Push the "Test" button located on the GFCI recepta-
cle. The night-light or other product should go
"OFF".
WARNING Push the "Reset" button, again. The light or other
product should go "ON" again.
Service and Repair should only be performed by
Lincoln Electric Factory Trained Personnel. If the light or other product remains "ON" when the
Unauthorized repairs performed on this equip- "Test" button is pushed, the GFCI is not working prop-
ment may result in danger to the technician and erly or has been incorrectly installed (miswired). If
machine operator and will invalidate your factory your GFCI is not working properly, contact a qualified,
warranty. For your safety and to avoid Electrical certified electrician who can assess the situation,
Shock, please observe all safety notes and pre- rewire the GFCI if necessary or replace the device.
cautions.
RANGER 305D
E-1 TROUBLESHOOTING E-1
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS). This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
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
E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your local Lincoln
is Evident. Authorized Field Service
Facility.
Engine will "crank" but not start. 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) If all recommended possible areas
Check oil and coolant levels. Fill if of misadjustment have been
required. Check for loose or bro- checked and the problem persists,
ken fan belt. Contact your local Lincoln
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.
Check that shutdown solenoid is
functioning properly and not bind-
ing/ contact authorized engine
service shop.
6. Faulty fuel pump. Check for fuel
flow through filters. Contact autho-
rized 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
E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Engine shuts down while under a 1. High radiator coolant tempera-
load. ture. Reduce load if it is exceed-
ing 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).
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Contactor" switch is in wrong
position. Set to "Welding On" when
welding without a control cable.
Refer to Operations chapter for prop-
er use of this switch.
3. Faulty PC board. Low idle speed
set to low.
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
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power. 100 watts. Idler may not respond
with less than a 100 watt load. Set
idler to "High".
2. Faulty PC board.
Engine will not go to high idle 1. Faulty idler solenoid. Check for
under weld or auxiliary loading. bent linkage or broken spring
Engine will not go to high idle when 1. Broken spring on Idle Solenoid,
attempting to weld or using auxil- solenoid linkage binding, Faulty
iary power. Switching to manual PC board, low idle speed set too If all recommended possible areas
high idle does not work. low on idle solenoid. of misadjustment have been
checked and the problem persists,
Engine will not shut off. 1. Fuel Shutdown solenoid not Contact your local Lincoln
functioning properly / linkage Authorized Field Service Facility.
binding. Stop engine by shutting
off valve located on main fuel fil-
ter. Contact authorized local
Engine Service Shop.
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace
Engine runs rough. 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
E-5 TROUBLESHOOTING E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
No welding power output. 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 alterna-
tor.
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
E-6 TROUBLESHOOTING E-6
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
The welding arc is cold. The weld- 1. Make sure the MODE selector
ing arc is not stable or is not satis- switch is in the correct position for
factory. the engine runs normally. the process being used. (For exam-
The auxiliary power is normal. ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,
voltage, current etc.) is correct for
the process being used.
3. Check for loose or faulty connec-
tions at the weld output terminals
and welding cable connections.
4. The welding cables may be too long
or coiled, causing an excessive
voltage drop. If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
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
F-1 DIAGRAMS F-1
RANGER 305D
F-2 DIAGRAMS F-2
RANGER 305D
F-3 DIAGRAMS F-3
RANGER 305D
F-4 DIAGRAMS F-4
RANGER 305D
F-5 DIAGRAMS F-5
RANGER 305D
F-6
WARNING
ELECTRIC SHOCK can kill MOVING PARTS can injure
Do not operate with panels open. Keep guards in place.
Disconnect NEGATIVE (-) Battery lead Keep away from moving parts.
before servicing. Only qualified personnel should install,use
Do not touch electrically live parts. or service this equipment.
14 PI
N
AMPHENOL TO NL-8NPUT
I
CABLE PLUG
K595CONTROL CABLE
+ _
TO W ORK
RANGER 305D
ELECTRODE CABLE
DIAGRAMS
TO WIRE F
EED UNIT
CAUTION
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WIL
AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS
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.
N.C. PLACE IDLER SWITCH IN HIGH POSITION.
4-14-2000
S24787-6
F-6
F-7 DIAGRAMS F-7
RANGER 305D
F-8 DIAGRAMS F-8
RANGER 305D
F-9 DIAGRAMS F-9
9/03
2
RANGER 305D
F-10 DIAGRAMS F-10
RANGER 305D
F-11
RANGER 305D
DIAGRAMS
ENHANCED
WIRING DIAGRAM
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.
F-11
FOR CODES 11188, 11275
F-12
RANGER 305D
DIAGRAMS
ENHANCED
WIRING DIAGRAM
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.
F-12
11.0 3
F-13
280. 2
1326.4
29.5 7 6. 33
751. 0 160. 9
26.64
676.7
29 .0 0 35. 77
736. 6 34. 24 908 .4
869 .8
CENTER OF GRAVIT Y
29.8 3
CIRCUIT 757. 6
BREAKERS
11.3 0
287. 0
52.0 0
RANGER 305D
1320 .8
51.2 0 21.5 0
1300 .5 546. 1
DIMENSION PRINT
17.5 0 21.0 6
444. 5 534. 9
19.50
495.3
CS MAY NOT
NOTE: CASE FRONTGRAPHI MATCH ALL CODES.
B
F-13
M20334
NOTES
RANGER 305D
Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection.
French Ne laissez ni la peau ni des vte- Gardez lcart de tout matriel Protgez vos yeux, vos oreilles et
ments mouills entrer en contact inflammable. votre corps.
ATTENTION avec des pices sous tension.
Isolez-vous du travail et de la terre.
German Berhren Sie keine stromfhrenden Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kr-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Krper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
No toque partes eltricas e elec- Mantenha inflamveis bem guarda- Use proteo para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENO da.
Isole-se da pea e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYERS 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 HER-
STELLERS. DIE UNFALLVERHTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or
Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
Los humos fuera de la zona de res- Spanish
Desconectar el cable de ali- No operar con panel abierto o
piracin.
Mantenga la cabeza fuera de los
mentacin de poder de la mquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilacin o
aspiracin para gases.
PRECAUCION
Gardez la tte lcart des fumes. Dbranchez le courant avant lentre- Noprez pas avec les panneaux French
Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ter les fumes des zones
de travail.
protection enlevs. ATTENTION
Vermeiden Sie das Einatmen von Strom vor Wartungsarbeiten Anlage nie ohne Schutzgehuse German
Schweibrauch! abschalten! (Netzstrom vllig ff- oder Innenschutzverkleidung in
Sorgen Sie fr gute Be- und
Entlftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
Mantenha seu rosto da fumaa. No opere com as tampas removidas. Mantenha-se afastado das partes
Use ventilao e exhausto para Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratria. servio. No opere com os paineis abertos ATENO
No toque as partes eltricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRTICAS DE SEGURANA DO EMPREGADOR.
World's Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com