Lincoln Electric 305D User's Manual

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IM730
Ranger 305 D
For use with machines having Code Numbers:
August, 2004
10926
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.
OPERATOR’S MANUAL
Copyright © 2004 Lincoln Global Inc.
• 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
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SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
FOR ENGINE
powered equipment.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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.
____________________________________________________
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.
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
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.
___________________________________________________
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.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
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SAFETY
ARC RAYS can burn.
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
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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 below Threshold Limit Values (TLV)
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. 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.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. 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.e. Also see item 1.b.
Mar ‘95
iii
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SAFETY
WELDING 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.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
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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!
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.
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.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
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.
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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
Additional Safety Precautions .......................................................................................A-2
High Altitude Operation .................................................................................................A-2
High Temperature Operation ........................................................................................A-2
Cold Weather Operation ...............................................................................................A-2
Towing...........................................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Oil ..................................................................................................................................A-3
Fuel ...............................................................................................................................A-3
Engine Coolant..............................................................................................................A-3
Battery Connections ......................................................................................................A-3
Muffler Outlet Pipe ........................................................................................................A-3
Spark Arrester ...............................................................................................................A-4
Remote Control .............................................................................................................A-4
Electrical Connections ..........................................................................................................A-4
Machine Grounding .......................................................................................................A-4
Welding Terminals ........................................................................................................A-4
Welding Output Cables .................................................................................................A-4
Cable Installation...........................................................................................................A-5
Auxiliary Power Receptacles and Plugs ...............................................................................A-5
Standby Power Connections ................................................................................................A-5
Premises Wiring ...................................................................................................................A-6
Connection of Lincoln Electric Wire Feeders .......................................................................A-7
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
For Auxiliary Power ..............................................................................................................B-1
Engine Operation..................................................................................................................B-1
Engine Break in ...................................................................................................................B-1
Add Fuel ...............................................................................................................................B-1
Fuel ......................................................................................................................................B-1
Welder Controls ............................................................................................................B-2
Engine Controls.............................................................................................................B-3
Starting and Stopping the Engine ...........................................................................B-3, B4
Stopping .......................................................................................................................B-4
Welding Operation................................................................................................................B-5
Duty Cycle .....................................................................................................................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
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ............................................................................................D-1
Engine Maintenance Components ........................................................................D-1
Kubota Diesel Engine ............................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Refill Capacities.............................................................................D-2
Engine Oil Filter Change.................................................................................D-2
Air Cleaner Service .........................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter .......................D-3
Cooling System .....................................................................................................D-4
Fan Belt...........................................................................................................D-4
Fuel .................................................................................................................D-4
Bleeding the Fuel System ...............................................................................D-4
Fuel Filter ........................................................................................................D-5
Engine Adjustment ..........................................................................................D-5
Battery Maintenance .......................................................................................D-5
Servicing Optional Spark Arrestor ...................................................................D-5
Welder / Generator Maintenance ........................................................................D-6
Storage ...........................................................................................................D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-6
________________________________________________________________________
Diagrams and Dimension Print ......................................................................Section F
________________________________________________________________________
Parts List ..................................................................................................................P417
________________________________________________________________________
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2)
INPUT - DIESEL ENGINE
Make/Model
Kubota**
D722
Description
Speed (RPM)
3 cylinder
4 stroke
18.8 HP
(14 KW)
Net intermittent
3600 RPM
naturally aspirated
water cooled engine
Displacement
cu. in. (cu. cm.)
43.88(789)
High Idle 3650
Bore x Stroke inch (mm)
Full Load 3500
2.64 x 2.68
(67 x 68 mm)
Low Idle 2450
Starting
System
Capacities
12VDC Battery &
starter
Fuel: 12 gal.
Oil: 3.4Qts. (3.2L)
(Group 58; 550 Radiator Coolant:
cold crank amps) 3.85Qts. (3.6L)
Battery Charger
(3.6L)
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
Max. Weld OCV
@Rated Load RPM
20 TO 305 AMPS
40 TO 300 AMPS
20 TO 250 AMPS
14 TO 29 VOLTS
60 Volts
RATED OUTPUT @ 104° F (40° C).- GENERATOR
Auxiliary Power 1
10,000 Watts Peak, / 9,500 Watts Continuous, 60 Hz 120/240 Volts
Sound Levels
Sound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m )
PHYSICAL DIMENSIONS
HEIGHT
30.00* in.
762.0 mm
WIDTH
21.50 in
546.0 mm
DEPTH
52.25 in.
WEIGHT
698 lbs. (317kg.)
1327.0 mm
ENGINE
LUBRICATION
EMISSIONS
FUEL SYSTEM
GOVERNOR
Full Pressure
Electric Fuel Pump, Auto air bleed system
with Full Flow Filter Certified to EPA Tier I
Electric shutoff solenoid
Mechanical Governor
Indirect fuel injector
AIR CLEANER
ENGINE IDLER
MUFFLER
ENGINE PROTECTION
Low noise Muffler:
Shutdown on low oil
Single Element
Automatic Idler
Top outlet can be rotated.
pressure & engine
Made from long life, aluminized steel.
temperature
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)
RECEPTACLES
(2) 120VAC Duplex (5-20R)
(1) 120/240VAC Dual Voltage
Full KVA (14-50R)
AUXILIARY POWER CIRCUIT BREAKER
OTHER CIRCUIT BREAKERS
Two 20AMP for Two Duplex Receptacle
Two 50AMP for Dual Voltage
25AMP 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
A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
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.
LIFTING
The RANGER 305D weighs approximately
775lbs.(352kg.) with a full tank of 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
EQUIPMENT can
cause injury.
• Do not lift machine if lift bail is
damaged.
• Do not operate machine while
suspended from lift bail.
------------------------------------------------------
--------------------------------------------------------------------------------
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 operator’s manual.
Only qualified personnel should install,
use, or service this equipment.
LOCATION AND VENTILATION
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 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.).
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.
HIGH TEMPERATURE OPERATION
At temperatures above104°F (40°C), 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!
------------------------------------------------------------------------
RANGER 305D
A-3
A-3
INSTALLATION
TOWING
The recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. If
the user adapts a non-Lincoln trailer, he must assume 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 welding equipment so there will be no undue stress to the framework.
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 surface on which the trailer will be operated; environmental conditions; like maintenance.
5. Conformance with federal, state and local laws.(1)
The oil change interval is dependent on the quality of
the oil and the operating environment. Refer to the
Engine Operator’s Manual for more details on the
proper service and maintenance intervals.
FUEL
USE DIESEL FUEL ONLY
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.
NOTE: A fuel shut off valve is located on the prefilter/sediment filter. Which should be in
the closed position when the welder is not
ran for extended periods of time.
------------------------------------------------------------------------
ENGINE COOLING SYSTEM
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public high-
CAUTION
ways.
VEHICLE MOUNTING
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 manufacturer’s instructions.
------------------------------------------------------------------------
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instructions supplied with this machine.
OIL
The RANGER 305D 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 Operator’s Manual for specific oil recommendations and break-in information.
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 is shipped with the negative battery cable disconnected. Make certain that the RUNSTOP 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.
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.
RANGER 305D
A-4
INSTALLATION
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.
CAUTION
An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
REMOTE CONTROL
The RANGER 305D 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 K936-2 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
A-4
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must be grounded to the frame of the welder using a
grounded type plug or be double insulated.
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. Do not ground the
machine to a pipe that carries explosive or combustible material.
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 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.
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.)
RANGER 305D
A-5
INSTALLATION
TABLE A-1
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100Ft. (0-30meters)
Cable Size for
305 Amps
100% Duty Cycle
1 / 0 AWG
100-150 Ft. (30-46m meters)
2 / 0 AWG
150-200 Ft. (46-61 meters)
3 / 0 AWG
CABLE INSTALLATION
Install the welding cables to your RANGER 305D as
follows.
1. The diesel 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.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output terminals to overheat. The terminals may eventually
melt.
• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and
separate from one another.
------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The auxiliary power of the RANGER 305D consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles and
one 50 Amp 120/240 VAC (14-50R) receptacle. The
240 VAC receptacle can be split for single phase 120
VAC operation.
The auxiliary power capacity is 10,500 watts Peak,
10000 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 44 amps.
A-5
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 cannot be paralleled).
Output voltage is within ± 10% at all loads up to rated
capacity.
The 120 V 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 120 V circuits,
but are of opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
The RANGER 305D is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.
The RANGER 305D can be permanently installed as
a standby power unit for 240 VAC, 3 wire, single
phase, 44 amp service. Connections must be made
by a licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes.
• Install the double-pole, double-throw switch
between the power company meter and the premises disconnect. Switch rating must be the same or
greater than the customer’s premises disconnect
and service over current protection.
• Take necessary steps to assure load is limited to
the capacity of the RANGER 305D by installing a
50 amp, 240 VAC double pole circuit breaker.
Maximum rated load for each leg of the 240 VAC
auxiliary is 44 amperes. 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
engine and/or alternator windings.
• Install a 50 amp, 120/240 VAC plug (NEMA Type
14-50) to the double-pole circuit breaker using No.
6, 4 conductor cable of the desired length. (The 50
amp, 120/240 VAC plug is available in the optional
K802R plug kit or as part number T12153-9.)
• Plug this cable into the 50 Amp, 120/240 Volt
receptacle on the RANGER 305D case front.
RANGER 305D
A-6
A-6
INSTALLATION
CONNECTION OF RANGER 305D TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
GROUND
50AMP
240 VOLT
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
DOUBLE
POLE
CIRCUIT
BREAKER
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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-7
INSTALLATION
A-7
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
• Control Cable Model:
Connect Control Cable between Engine Welder and
Feeder.
Connection of LN-7 or LN-8 to the RANGER 305D
• Set the MODE switch to the "CV-WIRE " position.
• Shut the welder off.
• Across-The-Arc Model:
Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"
• Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F.
• Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being
used.
• Set the "MODE" switch to the "CV WIRE " position.
• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
• Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
• Set the "IDLE" switch to the "HIGH" position.
Connection of LN-742, Spool Gun(K487-25SG)and
Cobramatic to RANGER 305D
• Shut the welder off.
• Connect per instructions on the appropriate connection diagram in Section F.
Connection of LN-15 to the Ranger 305D
Control Cable Model:
Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED"
• 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 "High" position
Connection of an LN-23P Wire Feeder to the
RANGER 305D
• Shut the welder off.
• Connect the LN-23P as per instructions on the
appropriate connection diagram in Section F.
(NOTE): When connecting an LN-23P to the
RANGER 305D, a K350-1 adapter kit must be used.
• Set the "VOLTMETER" switch to "-".
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.
• 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 "MODE" switch to "CV WIRE " position.
• Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED".
• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
• 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-23P with the
K350-1 adapter kit, the electrode is not energized
until the gun trigger is closed. When the gun trigger
is closed, the current sensing circuit will cause the
RANGER 305D engine to go to the high idle speed,
the wire will begin to feed and the welding process
can be started. When welding is stopped, the engine
will revert to low idle speed after approximately 12
seconds unless welding is resumed.
RANGER 305D
A-8
INSTALLATION
A-8
Connection of PRINCE XL SPOOL GUN to the
Ranger 305D
WARNING
Connection of the LN-25 to the RANGER 305D
Shut off welder before making any electrical connections.
-----------------------------------------------------------------------The LN-25 with or without an internal contactor may
be used with the RANGER 305D. See the appropriate
connection diagram in Section F.
NOTE: The LN-25 (K431) Remote Control Module
and (K432) Remote Cable are not recommended for
use with the RANGER 305D.
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.
Connection of the Prince XL Spool Gun requires the
use of the K1849-1 Adapter Module.
• Shut the Welder off.
• For electrode Positive, connect the electrode cable
to the "+" terminal of the welder and work cable to
the "-" terminal of the welder. For electrode
Negative, connect the electrode cable "-" terminal of
the welder and work cable to the "+" terminal of the
welder.
• Connect the Control Cable of the Spool Gun to the
Adapter Module and connect the Control Cable of
the Adapter Module to the Welder.
• Connect the Gas Hose.
• Set the MODE switch to the "CV-WIRE " position.
• Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON".
• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
• Set the “IDLE” switch to the “HIGH” position.
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 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 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
If you are using an LN-25 without an internal contactor, the electrode will be energized when the
Ranger 305D is started.
-----------------------------------------------------------------------RANGER 305D
B-1
B-1
OPERATION
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s 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.
ADD FUEL
• Remove the fuel tank cap.
• Fill the tank approximately 4 inches (100mm) from the top
of the filler neck to allow for fuel expansion (observe the
fuel gauge while filling). DO NOT FILL THE TANK TO THE
POINT OF OVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recommendations.
WARNING
• 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.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
DIESEL FUEL fumes to clear before starting
can cause fire. engine.
• Do not overfill tank, fuel
expansion may cause overflow.
GENERAL DESCRIPTION
-----------------------------------------------------------------------
The RANGER 305D is a diesel engine powered DC multiprocess welding power source and 120 / 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.
BREAK-IN PERIOD
• Always operate the welder with the hinged door closed
and the side panels in place.
DIESEL FUEL ONLY
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 consists of two
20 Amp-120 VAC (5-20R) duplex receptacles and one 50
Amp 120/240 VAC (14-50R) receptacle. The 240 VAC
receptacle can be split for single phase 120 VAC operation.
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.
• 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 Owner’s Manual for specific oil and coolant
recommendations.
Lincoln Electric selects high quality, heavy-duty industrial
engines for the portable welding machines we offer. While it is
normal to see a small amount of crankcase oil consumption
during initial operation, excessive oil use, wetstacking (oil or tar
like substance at the exhaust port), or excessive smoke is not
normal.
Larger machines with a capacity of 350 amperes and higher,
which are operated at low or no-load conditions for extended
periods of time are especially susceptible to the conditions
described above. To accomplish successful engine break-in,
most diesel-powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some
period of time during the engine’s early life. However, if the
welder is subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a
diesel/generator unit.
1. Connect the welder output studs to a suitable resistive load
bank. Note that any attempt to short the output studs by
connecting the welding leads together, direct shorting of the
output studs, or connecting the output leads to a length of
steel will result in catastrophic damage to the generator and
voids the warranty.
2. Set the welder controls for an output current and voltage
within the welder rating and duty cycle. Note that any
attempt to exceed the welder rating or duty cycle for any
period of time will result in catastrophic damage to the generator and voids the warranty.
3. Periodically shut off the engine and check the crankcase oil
level.
RANGER 305D
B-2
B-2
OPERATION
16
1
15
14
2
17
3
13
12
11
4
10
9
8
7
5
FIGURE B.1
WELDING CONTROLS (Figure B.1)
1. OUTPUT CONTROL: The OUTPUT dial is
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 autosensing 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 autosensing 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.
6
2. DIGITAL OUTPUT METERS
The digital meters allow the output voltage (CV-WIRE
mode) or current (CC-STICK, PIPE and TIG modes)
to be set prior to welding using the 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
B-3
B-3
OPERATION
4. ARC CONTROL : The ARC CONTROL dial is
active in the CV-WIRE, CC-STICK and DOWNHILL PIPE
modes, and has different functions in these modes. This
control is not active in the TIG mode.
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
10. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to
the polarity of the electrode.
ENGINE CONTROLS: (Figure B.2)
FIGURE B.2
11. RUN/STOP SWITCH - 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.
12. GLOW PLUG PUSH BUTTON When pushed activates the glow plugs as well as the
electric fuel pump for quick starting. Glow plug should
not be activated for more then 20 seconds continuously.
AUTO BLEED FUNCTION – Air will automatically
bleed from the fuel system by simply pushing the
GLOW PLUG BUTTON. It is generally not required
to crack open fittings in the fuel system to bleed air
from the fuel system.
13. START PUSH BUTTON Energizes the starter motor to crank
the engine.
electrode and work cables.
6. GROUND STUD: (graphic)
Provides a connection point for connecting the
machine case to earth ground.
7. 14-PIN CONNECTOR: For attaching wire
feeder control cables to the RANGER 305D. 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: For attaching optional
remote control equipment. Includes auto-sensing
remote control circuit.
9. WELD TERMINALS CONTROL SWITCH: In
the WELD TERMINALS ON position, the output is
electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire
feeder or amptrol device, and is electrically off until a
remote switch is depressed.
14. IDLER SWITCH- 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.
RANGER 305D
B-4
B-4
OPERATION
15. ENGINE ALTERNATOR TROUBLE
LIGHT-The engine alternator light is off when battery
charging system is functioning normally. If light turns
on, the alternator or the voltage regulator may not be
operating correctly. The light may also come on due
to the battery not holding a charge. It is normal for the
light to be on while initially starting the engine.
8. The engine will run at high idle speed for approximately 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
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.
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.
CAUTION
• 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.
----------------------------------------------------------------------NOTE: When starting a RANGER 305D 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.
TABLE B.1
TYPICAL RANGER 305D FUEL CONSUMPTION
Kubota D722
Gal./Hr (Liters/Hr)
Low Idle - No Load
2450 R.P.M.
High Idle - No Load
3650 R.P.M.
DC Weld Output
250 Amps @ 28 Volts
DC Weld Output
300 Amps @ 29 Volts
Running time for
12 gallons-hours
.29 (1.09)
41.77
.54 (2.06)
22.02
1.03 (3.91)
11.62
1.18 (4.47)
10.16
10,000 Watts
1.16 (4.38)
10.37
7,000 Watts
.96 (3.63)
12.50
3,000 Watts
.70 (2.67)
17.03
RANGER 305D
B-5
B-5
OPERATION
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.
The Ranger 305D can be used with a broad range of DC
stick electrodes. The MODE switch provides two stick welding settings as follows:
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.
The ARC CONTROL dial sets the short circuit current (arcforce) 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.
The OUTPUT CONTROL dial adjusts the full output range
for stick welding. The ARC CONTROL dial sets the short
circuit current (arc-force) during stick welding to adjust for
a soft or 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.
TIG WELDING
The TOUCH START TIG setting of the MODE switch is for
DC TIG (Tungsten Inert Gas) welding. To initiate a weld,
the OUTPUT 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
voltage 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.
To stop the arc, simply lift the TIG torch away from the
work piece. When the arc voltage reaches approximately
30 volts, the arc will go out and the machine will automatically reset to the touch start current level. The tungsten
may then be retouched to the work piece to restrike the
arc. The arc may also be started and stopped with an
Amptrol or Arc Start Switch. See the following paragraphs.
DOWNHILL PIPE (STICK) Welding
The DOWNHILL PIPE position of the MODE switch is a
slope controlled setting intended for "out-of-position" and
"down hill" pipe welding where the operator would like to
TABLE B.2
control the current level by changing the arc length.
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN
Tungsten Electrode
DCEN (-)
DCEP (+)
Diameter in. (mm)
(.25)
(.50)
(1.0)
Approximate Argon Gas Flow
TIG TORCH
Flow Rate C.F.H. ( l /min.)
1%, 2% Thoriated
Tungsten
.010
0.020
0.040
ELECTRODES(2)
2-15
5-20
15-80
1%, 2% Thoriated
Tungsten
(3)
(3)
(3)
Aluminum
3-8
5-10
5-10
Nozzle Size (4), (5)
Stainless Steel
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
1/16
(1.6)
70-150
10-20
5-10
(3-5)
9-13
(4-6)
#5, #6
3/32
1/8
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#8, #10
(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
B-6
OPERATION
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.
ARC GOUGING
The ARC CONTROL is not active in the TIG mode.
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 B.3.
TABLE B.3
The Ranger 305D can be used in a wide variety of DC
TIG welding applications. In general the ‘Touch Start’
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. The settings are for reference.
The RANGER 305D can be used for limited arc gouging. For optimal performance, set the MODE switch to
CC-STICK and the ARC CONTROL to +10.
Electrode Diameter
Ranger 305D 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 is used to set the maximum range of
the CURRENT CONTROL on the TIG module or an
Amptrol if connected to the TIG Module. (See Table
B.2.)
WIRE WELDING-CV
Connect a wire feeder to the Ranger 305D according to
the instructions in INSTALLATION INSTRUCTIONS
Section.
The Ranger 305D 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.
Contact your local authorized Lincoln Electric
Distributor or the Lincoln Electric Company for specific
wires used on certain applications with this machine.
Also
for
additional
information
contact
WWW.Lincolnelectric.com
RANGER 305D
Current Range (DC, electrode
positive)
1/8" (3.2)
30-60 Amps
5/32"(4.0)
90-150 Amps
3/16"(4.8)
150-250 Amps
B-7
B-7
OPERATION
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 consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles and
one 50 Amp 120/240 VAC (14-50R) receptacle. The
240 VAC receptacle can be split for single phase 120
VAC operation.
The auxiliary power capacity is 10,000 watts Peak,
9500 Watts continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 44 Amps.
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. The permissible currents shown assume that current is being drawn from
either the 120 VAC or 240 VAC supply (not both at the
same time).
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 cannot be paralleled).
Output voltage is within ± 10% at all loads up to rated
capacity.
The 120 V 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.
RANGER 305D Simultaneous Welding and Power Loads
Welding
Output-Amps
Permissible Power-Watts
(Unity Power Factor)
Permissible Auxiliary
Current in -Amps
@ 240 VAC
10000
0
44
7500
100
31
5800
150
24
4500
200
19
2800
250
12
700
300
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
(Amps) Volts (Watts)
15
120
1800
20
120
2400
15
240
3600
20
240
4800
44
240
9500
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG
10 AWG
8 AWG
6 AWG
40
(12)
75
(23)
125
(38)
175
(53)
30
(9)
50
(15)
88
(27)
138
(42)
(18)
75
(23)
150
(46)
225
(69)
350
(107)
60
(18)
100
(30)
175
(53)
275
(84)
50
(15)
90
(27)
150
(46)
Conductor size is based on maximum 2.0% voltage drop.
14 AWG
30
(9)
60
RANGER 305D
4 AWG
300
(91)
225
(69)
600
(183)
450
(137)
225
(69)
C-1
ACCESSORIES
FIELD INSTALLED OPTIONS /
ACCESSORIES
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
K958-1
K958-2
K959-2
K965-1
Trailer
Ball Hitch
Lunette Eye Hitch
Fender & Light Kit
Cable Storage Rack
C-1
K1690-1 GFCI RECEPTACLE KIT
Includes one UL approved 120V ground fault circuit
interrupter duplex type receptacle with cover and
installation instructions. Replaces the factory installed
120V duplex receptacle. Each receptacle of the GFCI
Duplex is rated at 20 Amps, the maximum total current from the GFCI Duplex is limited to the 20 Amps.
Two kits are required.
K802-N POWER PLUG KIT
Provides four 120 volt plugs rated at 20 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K1789-1 ROLL CAGE - Gives added damage protection.
K802-R POWER PLUG KIT
Provides four 120 volt plugs rated at 15 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K1898-1 SPARK ARRESTOR
T12153-9 50 AMP, 120/240 V POWER PLUG
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 300 amps, 100% duty cycle.
K1816-1 FULL KVA ADAPTER KIT
Plugs into the 120/240V NEMA 14-50R receptacle on
the case front (which accepts 4-prong plugs) and
converts it to a NEMA 6-50R receptacle, (which
accepts 3-prong plugs.) For connection of Lincoln
equipment with NEMA 6-50R plug.
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 OPTIONS
K963-2 HAND AMPTROL
K870 FOOT AMPTROL
K2174-1 COLD WEATHER OPERATIONS KITProvides starting aid and enhancement in extreme cold
weather. Includes radiator grill cover, oil pan heater,
coolant Lester and all hardware required for installation.
RANGER 305D
D-1
D-1
MAINTENANCE
KUBOTA D722 DIESEL ENGINE
SAFETY PRECAUTIONS
FREQUENCY
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 Owner’s Manual before
working on this machine.
• 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.
At the end of each day’s 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
OIL FILTER
MAKE AND PART NUMBER
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
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.
Intervals
Every 50 hours
Every 75 hours
Items
Check of fuel pipes and clamp bands.
Change of engine oil
Every 100 hours
Routine Maintenance
ITEM
DAILY OR BEFORE
STARTING ENGINE
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.
Inspect/Clean air cleaner element
and Vacuator™ valve.
Cleaning of fuel filter.
Check the battery electrolyte level.
Check the fan belt tightness.
Every 150 hours
Check the radiator and hose clamps.
Replacement of oil filter cartridge
Check the intake air lines.
Every 200 hours
Replacement of Air Filter element.
Every 400 hours
Replacement of fuel filter element.
Every 500 hours
Removal of of sediment in fuel tank.
Cleaning of water jacket (radiator
interior).
Replacement of fan belt.
Every 1 or 2 months Recharging of Battery.
Every 800 hours
Check of valve clearance.
Every 1500 hours
Check the fuel injection nozzle injection pressure.
Every 3000 hours Check of injection pump.
Check of fuel injector timer.
Every 2 years
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.
@
•
*1
@
•
*1,*2
@
@
@
*3
*3
@
@
*3
*3
@
@
*4
@
IMPORTANT
• 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 KABOTA 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
D-2
D-2
MAINTENANCE
Engine Oil Change
Drain the engine oil while the engine is warm to
assure rapid and complete draining.
• 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)
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 contacts 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 necessary, 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.
CAUTION
• Never run the engine without the air cleaner.
Rapid engine wear will result from contaminants,
such as dust and dirt being drawn into the
engine.
------------------------------------------------------------------------
AIR CLEANER
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 owner’s manual for more specific information on oil viscosity recommendations.
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
D-3
D-3
MAINTENANCE
Service Instructions & Installation Tips
For Engine Air Filter
1
Release the
Seal Carefully
Unlatch and remove the service
cover of the air cleaner. Make
certain the latches are folded
back against the cover so that
they donít hinder filter
removal/installation. Most latches
are spring loaded to fold back when open.
The filter fits tightly over the outlet tube,
creating the critical seal on the inside
diameter of the filter endcap. The filter
should be removed gently to reduce the
amount of dust dislodged. There will 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.
2
3
5
Check the Old
Filter for Leak Clues
6
Inspect the New
Filter for Damage
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.
Avoid Dislodging
Dust from the Filter
Gently pull the
filter off the outlet
tube and out of the
housing. Avoid
knocking the filter
against the housing.
Clean Sealing Surface
of the Outlet Tube
Use a clean cloth to wipe the sealing
surface. Dust on the outside diameter of the
outlet tube could hinder
an effective seal
and cause leakage.
Make sure that all
contaminant is
removed before the
new filter is inserted.
4
Clean the Inside of
the Outlet Tube
Carefully wipe the inside
of the outlet tube
with a clean cloth.
Dirt accidently
transferred to the
inside of the outlet
tube will reach the
engine and cause wear.
(Engine manufacturers says that it takes
only a few grams of dirt to ëdustí an
engine!) Be careful not to damage the
sealing area on the tube.
Inspect the new filter carefully,
paying attention to the inside of
the open end,
which is the
sealing area.
NEVER install
a damaged filter.
7
Insert the New
RadialSealô Filter
by Hand
Insert carefully. Seat the new filter by hand,
making certain it is completely into the air
cleaner housing before latching the cover in
place. If the cover hits the filter before it is
fully in place, remove the cover and push
(by hand) the
filter further into
the air cleaner
and try again.
The cover
should go on
with no extra force.
Never use the latches on the cover to force
the filter into the air cleaner! It is tempting
to assume the cover will do the job of
seating the filter ñ but it will not! Using the
latches to push the filter in could cause
damage to the housing and will void the
warranty.
RANGER 305D
Donaldson filters with RadialSeal™ Sealing
Technology are self-aligning, self-centering,
and self-sealing. A new filter has a dry
lubricant to aid installation. The critical
sealing area will stretch slightly, adjust
itself and distribute the sealing pressure
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. Again, do NOT use the service
cover to push the filter into place!
When the filter in is place, put the service
cover back on, making sure the Vacuator™
Valve points down. Inspect the Vacuator ™
Valve for cracks or dust hang-ups to insure
that it is functioning properly. Re-fasten
the latches.
8
Check Connections
for Tight Fit
Make sure that all clamps, bolts, and
connections in the entire air intake system
are tight. Check for holes in piping, and
repair if needed.
D-4
D-4
MAINTENANCE
FUEL
COOLING SYSTEM
WARNING
HOT COOLANT can burn skin.
• 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.
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.
At the end of each day’s 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
functions when the electric fuel pump is actuated. It is
generally not necessary to open a vent screw or fuel
line fitting to bleed the fuel system.
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. Press and hold the glow plug button for 10 to 20
seconds
4. Check to see that fuel is flowing through both fuel
filters
5. Follow the normal STARTING procedures.
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).
RANGER 305D
D-5
CLEANING THE BATTERY
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-filter.
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.
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.
●
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
BATTERY MAINTENANCE
●
D-5
MAINTENANCE
USING A BOOSTER — connect positive lead to
battery first then connect negative lead to negative 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.
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 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
Clean every 100 hours.
WARNING
• MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
RANGER 305D
D-6
MAINTENANCE
WELDER / GENERATOR
MAINTENANCE
STORAGE: Store the RANGER 305D 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: It’s 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.
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
D-6
E-1
TROUBLESHOOTING
E-1
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.
__________________________________________________________________________
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 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.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your local Lincoln
is Evident.
Authorized Field Service
Facility.
Engine will not "crank".
1. Battery is low, Charge Battery.
2. Loose battery cable connections.
Inspect, clean and tighten terminals.
3. Faulty engine starter motor.
Contact authorized local Engine
Service Shop.
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)
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 electric fuel pump. Check
for fuel flow through filters.
Contact authorized local Engine
Service Shop.
Engine shuts down shortly after
starting.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
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
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Engine shuts down while under a 1. High radiator coolant temperaload.
ture. 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).
Engine runs rough.
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.
Battery does not stay charged.
Engine alternator trouble light is on 2. Loose connections at battery or
alternator. Clean and tighten conwhile machine is running.
nections.
3. Faulty engine alternator or charger module. Consult authorized
Engine Service Shop.
Engine will not idle down to low
speed.
1. Idler switch in High idle position.
Set switch to Auto.
2. External load on welder or auxiliary power. Remove all external
loads.
3. Faulty PC board or idler solenoid.
Engine will not go to high idle when
attempting to weld.
1. Poor work lead connection to
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 proper use of this switch.
3. Faulty PC board. Low idle speed
set to low.
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
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
Engine will not go to high idle when
using auxiliary power.
1. Auxiliary power load is less than
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
under weld or auxiliary loading.
1. Faulty idler solenoid. Check for
bent linkage or broken spring
Engine does not develop full
power. Engine runs rough.
1. Fuel filter clogged, Replace.
2. Air filter clogged, clean or replace.
3. High idle setting incorrect, check
and adjust if required.
4. Valves out of adjustment.
5. Fuel contaminated with water or
sediment. Check fuel pre-filter
and empty of water, bleed fuel
system. Replace fuel in tank if
needed.
Engine will not go to high idle when
attempting to weld or using auxiliary power. Switching to manual
high idle does not work.
1. Broken spring on Idle Solenoid,
solenoid linkage binding, Faulty
PC board, low idle speed set too If all recommended possible areas
low on idle solenoid.
of misadjustment have been
checked and the problem persists,
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 filter. Contact authorized local
Engine Service Shop.
Engine will not shut off.
RECOMMENDED
COURSE OF ACTION
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace
Air Filter Element.
Engine runs rough.
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
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT (S)
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 alternator.
Welder has output but no control.
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.
Wire feeder does not work when 1. Wire Feeder Power circuit breaker
control cable is connected to 14 pin open. Check 42V and 120V
beakers and reset if tripped.
connector.
2. Faulty control cable. Repair or
replace cable.
3. Faulty wire feeder. Replace wire
feeder.
No auxiliary power.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
1. Open circuit breakers. Reset
breakers. If breakers keep tripping, reduce power draw.
2. Faulty connections to auxiliary
receptacles. Check connections.
3. GFCI tripped (if installed). Clear
any ground fault and reset GFCI
circuit by pressing "Reset" button
on the 120 V receptacle.
4. Faulty PC board or welder alternator.
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
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
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 examThe 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 connections 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
RANGER 305D
F-1
F-2
DIAGRAMS
RANGER 305D
F-2
F-3
DIAGRAMS
RANGER 305D
F-3
F-4
DIAGRAMS
RANGER 305D
F-4
F-5
DIAGRAMS
RANGER 305D
F-5
RANGER 305D
+
_
ELECTRODE CABLE
TO WIRE FEED UNIT
K595 CONTROL CABLE
TO LN-8 INPUT
CABLE PLUG
TO WORK
Keep guards in place.
Keep away from moving parts.
Only qualified personnel should install,use
or service this equipment.
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead
before servicing.
Do not touch electrically live parts.
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.
DIAGRAMS
S24787-6
4-14-2000
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.
CAUTION:
14 PIN
AMPHENOL
MOVING PARTS can injure
ELECTRIC SHOCK can kill
WARNING
ENGINE WELDERS /LN-8 CONNECTION DIAGRAM
F-6
F-6
F-7
DIAGRAMS
RANGER 305D
F-7
F-8
DIAGRAMS
RANGER 305D
F-8
F-9
DIAGRAMS
RANGER 305D
F-9
F-10
DIAGRAMS
RANGER 305D
F-10
F-11
DIAGRAMS
RANGER 305D
F-11
W7
208
208C
206B
208C
5N
42A
CB8
15A
41A
41
A
B
C
D
E
F
9
12
7
8
4
42A
41A
76A
75A
2A
4A
6
1
GND-B
77B
76B
75B
2B
4B
77A
GND-A
4B
2B
75B
76B
77B
21
16
8
10
5
GND-K
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
GND-B
FRAME GND.
GND-G
GND-D
GND-C
GND-R
GND-E
GND-B
GND-A
31
GND-N
GND-N
C9
PCB 1
B5
C8
B4
B1
B7
B8
WHITE
TERM.
3E
GND-C
GND-D
GND-G
SHOWN IN
"WELDING ON"
POSITION
CONTACTOR
CONTROL
S3
GND-E 5
STATOR AUX. WINDING 6
3
B6
B2
C11
300 AMP
MODULE
14
13
C10
301
2A
2
4A
4
5C
J100
115/230V
6F
SILVER
J101
SILVER
J102
W11
WHITE
32
5G
50A
CB2
50A
CB5
CB6
3E
BLACK
6E
6B
3A
20A
CB1
20A
W6
5H
BLACK
3D
BLACK
BLACK
5B
5A
5B
5C
TOP GND. SCREW ON
INSIDE OF CASE FRONT
5K
5
42 VAC
9
5N
7
FIELD WINDING
5A
FRAME GND.
W5
25
W6
23
3A
3
5C
3A
6B
6
GND SCREW ON
FAN BAFFLE.
6
3
6B
3
W3
GND-J
GND-K
D3
GLOW
PLUGS
223
H2O
TEMP
SW
229
209B
229A
15A
CB7
ROTOR
201
212
IGN
BAT
228
209A
209
210D
200N
210E
STARTER
S1
212A
210H
211
210
Engine Protection
Light PL1
228
229B
229A
210D
R3
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
210C
200
ALTERNATOR
L
W3
200A
C3
800uf
150vdc
ENGINE COMPONENTS
OIL
PRES
SW
223A
S7
GLOW
PLUG
BUTTON
5H
201A
200B
WINDINGS
WELD
STATOR
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
7
9
W2
W1
D1 - THREE PHASE BRIDGE RECTIFIER
GND-J
ENGINE
GROUND
-
4
1
FRAME
GROUND
GND-M
J74
P74
10K
278
279
FUEL
PUMP
blk red
225
HOLD
COIL
red
9
blk
B
3
6
5G
S4
223A
PULL
COIL
wht
10K
76 75
252
251
D4
J72
P72
blk
3 4
PULL
COIL
wht
IDLE SOLENOID
HOLD
COIL
red
1 2
224
210A
215
HOUR METER
+
77
R1 OUTPUT CONT. POT
CCW
SHOWN IN
"AUTO" POSITION
210G
225B
AMPS
IDLER CONTROL
224A
224B
FUEL SOLENOID
J73
P73
A
7
1
4
CR1
GND-R 5K
277
R2 ARC CONTROL
CCW
(LOCATED BELOW
TERMINAL 2)
A
210F
231
GND-L
210B
GND-H
12 VOLT
BATTERY
+
S2
START
BUTTON
210A
3
2
CV
TIG
CC
PIPE
Battery Charge
Light PL2
220
222
214
218
S6 MODE SELECTOR SWITCH
VOLTS
232
76A
14
4
2
23
25
260
261
13
208B
252 251
75A
77A
215
210H
224B
200N
5K
404
Key
77
75
76
Key
277
278
279
M10
M5
M9 M4
M3
M2
M1
M6
M10
M5
M9 M4
M3
M2
M1
M6
206S
204S
305
214
222
220
218
B1
210B
1
P43-J43
A.03
P3-J3
Sense/
Idler/
PWM
P1 - J1
Amphenol,
Model
Select,
Hot Start
P2 - J2
Engine &
Battery
Function
P7 - J7
Output &
Arc Cont.
Mode
Select
P5 - J5
Meter
P54 - J4
Meter
P6-J6
Shunt
G4250
5
B4
8
B3
4
GND-R
PCB3
PULL COIL BD.
404
B2
PCB2 WELD CONTROL PC BOARD
L3
ENHANCED DIAGRAM
L2
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..
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
W8
B3
BOTTOM GND INSIDE CASEFRONT
GND. SCREW ON LEFT
INSIDE CASEFRONT
L2, L3: RF CHOKES
SHOWN IN
POSITIVE (+)
POSITION
ELECTRICAL SYMBOLS PER E1537
CONNECTORS VIEWED FROM INSERTION END
1
6
5
2
1
1
1
AMPHENOL 2
GROUND
CONTACTOR
31
32
21
206A
206C
3
W9
302
HEATSINK
W10
W5
DIAGRAMS
REMOTE
CONTROL
AMPHENOL 1
115VAC
J
A
I
42VAC
K
WORK
H
E
REMOTE
CONTROL
F
G
CONTACTOR
D
C
GROUND
B
BYPASS
FILTER
ASSEMBLY
206C
42
6
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
3 SHOWN THROUGH
TOROID
6
TWISTED PAIR
L1 CHOKE
260
S5
VOLTMETER
WIRE FEED POWER
POLARITY
WINDING
SWITCH
208A
42 VAC
208B
206B
206A
50MV=400 AMPS
SHUNT
206S 204S
W10
261
W4
WHITE
WHITE
R4
Twisted
Pair
BLACK
M1
M2
M3
M4
M5
M6
M9
M10
RANGER 305D- KUBOTA - WIRING DIAGRAM
BLACK
10
6
M1
M2
M3
M4
M5
M6
M9
M10
1
2
5
1
5
6
10
6
8
1
1
16
9
12
1
8
7
16
1
8
9
16
1
RANGER 305D
9
F-12
F-12
RANGER 305D
51.20
52.00
52.2
*29.0
26.64
29.57
DIMENSION PRINT
17.50 19.50
*11.3
21.06
21.5
11.03
6.33
*CENTER OF GRAVITY
RANGER 305D
5.57
29.83 30.71
35.77
DIAGRAMS
M19772
A.05
34.24
F-13
F-13
NOTES
RANGER 305D
NOTES
RANGER 305D
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
● Do not touch electrically live parts or
● Keep flammable materials away.
● Wear eye, ear and body protection.
● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
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.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
fuera del área de trabajo.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
cuerpo.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Mantenha inflamáveis bem guarda-
dos.
● Use proteção para a vista, ouvido e
corpo.
Japanese
Chinese
Korean
Arabic
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.
● Keep your head out of fumes.
● Use ventilation or exhaust to
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
remove fumes from breathing zone.
● 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-
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
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.
● Strom vor Wartungsarbeiten
● 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
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
● Mantenha-se afastado das partes
serviço.
● Não toque as partes elétricas nuas.
● Não opere com os paineis abertos
moventes.
ou guardas removidas.
WARNING
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.
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com