Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS; Field Installed
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 8 - vii
vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ...................
Page 9 - INSTALLATION; INPUT - DIESEL ENGINE
RANGER 305D 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 outsi...
Page 10 - Cold weather starting:; Extreme cold weather starting may require; SAFETY PRECAUTIONS; LOCATION AND VENTILATION; RANGER 305D machines cannot be stacked.; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t
LIFTING T h e R A N G E R 3 0 5 D w e i g h s a p p r o x i m a t e l y775lbs.(352kg.) with a full tank of fuel. A lift bail ismounted to the machine and should always be usedwhen lifting the machine. • Lift only with equipment of ade- quate lifting capacity. • Be sure machine is stable when lift- i...
Page 11 - Design capacity of trailer vs. weight of Lincoln equipment and; CAUTION
A-3 INSTALLATION RANGER 305D A-3 TOWING The recommended trailer for use with this equipment for road,in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. Ifthe user adapts a non-Lincoln trailer, he must assume responsi-bility that the method of attachment and usage does not resultin a safet...
Page 12 - SPARK ARRESTER; ELECTRICAL CONNECTIONS; MACHINE GROUNDING
A-4 INSTALLATION RANGER 305D A-4 SPARK ARRESTER Some federal, state or local laws may require thatgasoline or diesel engines be equipped with exhaustspark arresters when they are operated in certainlocations where unarrested sparks may present a firehazard. The standard muffler included with this we...
Page 13 - STANDBY POWER CONNECTIONS; CABLE INSTALLATION; AUXILIARY POWER RECEPTACLES; Cable Length
The 240 VAC output can be split to provide two sepa-rate 120 VAC outputs with a max permissible currentof 44 Amps per output to two separate 120 VACbranch circuits (these circuits cannot be paralleled).Output voltage is within ± 10% at all loads up to ratedcapacity. The 120 V auxiliary power recepta...
Page 14 - CONNECTION OF RANGER 305D TO PREMISES WIRING
A-6 INSTALLATION RANGER 305D A-6 CONNECTION OF RANGER 305D TO PREMISES WIRING 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 ot...
Page 15 - Connection of LN-7 or LN-8 to the RANGER 305D
A-7 INSTALLATION RANGER 305D A-7 C O N N E C T I O N O F L I N C O L N E L E C T R I CWIRE FEEDERS Connection of LN-7 or LN-8 to the RANGER 305D • Shut the welder off. • Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. • Set the "WIRE FEEDER VOLTMETER...
Page 16 - NOTE
A-8 INSTALLATION RANGER 305D A-8 C o n n e c t i o n o f P R I N C E X L S P O O L G U N t o t h eRanger 305D Connection of the Prince XL Spool Gun requires theuse of the K1849-1 Adapter Module. • Shut the Welder off. • For electrode Positive, connect the electrode cable to the "+" terminal ...
Page 17 - OPERATION; GENERAL DESCRIPTION; ENGINE OPERATION; Before Starting the Engine:; • Do not leave unattended while; DIESEL FUEL ONLY; DIESEL FUEL
B-1 OPERATION RANGER 305D B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read the engine manufacturer ’ s manual sup- plied with your welder. It includes important safety pre-cautions, detailed engine starting, operating and main-tenance instructions, and parts ...
Page 18 - WELDING CONTROLS; The OUTPUT dial is; DIGITAL OUTPUT METERS
B-2 OPERATION B-2 WELDING CONTROLS (Figure B.1) 1. OUTPUT CONTROL: The OUTPUT dial is used to preset the output voltage or current as dis-played on the digital meters for the four weldingmodes. When in the CC-STICK, DOWNHILL PIPE orCV-WIRE modes and when a remote control is con-nected to the 6-Pin o...
Page 19 - GLOW PLUG PUSH BUTTON; AUTO BLEED FUNCTION; START PUSH BUTTON
B-3 OPERATION B-3 4. ARC CONTROL : The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPEmodes, and has different functions in these modes. Thiscontrol is not active in the TIG mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) durin...
Page 20 - ENGINE HOUR METER; TYPICAL RANGER 305D FUEL CONSUMPTION
B-4 OPERATION B-4 1 5 . E N G I N E A LT E R N AT O R T R O U B L ELIGHT -The engine alternator light is off when battery charging system is functioning normally. If light turnson, the alternator or the voltage regulator may not beoperating correctly. The light may also come on dueto the battery not...
Page 21 - WELDER OPERATION; DUTY CYCLE
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5) 1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel Tungsten Tungsten .010 (.25) 2-15 (3) 3-8 (2-...
Page 22 - The ARC CONTROL is not active in the TIG mode.; ARC GOUGING; Electrode Diameter
RANGER 305D B-6 OPERATION B-6 When in the TOUCH START TIG mode and when aAmptrol is connected to the 6-pin Connector the OUT-PUT dial is used to set the maximum current range ofthe CURRENT CONTROL of the Amptrol. The ARC CONTROL is not active in the TIG mode. The Ranger 305D can be used in a wide va...
Page 23 - : The 240 V receptacle has two circuits, each of; Simultaneous Welding and Auxiliary Power Loads; Welding; RANGER 305D Simultaneous Welding and Power Loads
Permissible AuxiliaryCurrent in -Amps @ 240 VAC 4431241912 3 B-7 OPERATION B-7 AUXILIARY POWER: Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn. The auxiliary ...
Page 24 - ACCESSORIES; REMOTE; TIG OPTIONS
C-1 ACCESSORIES C-1 FIELD INSTALLED OPTIONS /ACCESSORIES K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS F o r r o a d , o f f - r o a d a n d i n - p l a n t a n d y a r d t o w i n g .(For highway use, consult applicable federal, state andlocal laws regarding requirements for brakes, lights,...
Page 25 - MAINTENANCE; OIL FILTER
D-1 MAINTENANCE D-1 RANGER 305D SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • R e m o v e g u a r d s o n l y w h e n necessary to perform maintenanceand replace them when ...
Page 26 - Engine Oil Change; AIR CLEANER
D-2 MAINTENANCE D-2 Engine Oil Change D r a i n t h e e n g i n e o i l w h i l e t h e e n g i n e i s w a r m t oassure rapid and complete draining. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Locate oil drain hose and valve in bottom of base and pull thr...
Page 27 - Service Instructions & Installation Tips; For Engine Air Filter
D-3 MAINTENANCE D-3 RANGER 305D Service Instructions & Installation Tips For Engine Air Filter Release the 1 Seal Carefully Unlatch and remove the servicecover of the air cleaner. Makecertain the latches are foldedback against the cover so thatthey donít hinder filterremoval/installation. Most l...
Page 28 - COOLING SYSTEM; Do not remove cap if radiator is; TIGHTENING THE FAN BELT; Bleed the fuel system as follows:
D-4 MAINTENANCE D-4 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in theradiator and recovery bottle. Add 50/50 antifreeze /water solution if th...
Page 29 - ENGINE ADJUSTMENT
D-5 MAINTENANCE D-5 FUEL FILTER 1. Check the fuel filter and fuel pre-filter for water accumulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre-fil-ter. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by aLincol...
Page 30 - Store the RANGER 305D in clean, dry; BRUSH REMOVAL AND REPLACEMENT:; Service and Repair should only be performed by
D-6 MAINTENANCE D-6 RANGER 305D WELDER / GENERATORMAINTENANCE STORAGE: Store the RANGER 305D in clean, dry protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once aweek in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It ’...
Page 31 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 RANGER 305D If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Gu...
Page 32 - PROBLEMS; C o n t a c t y o u r l o c a l L i n c o l n
E-2 TROUBLESHOOTING E-2 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting ...
Page 33 - Observe all Safety Guidelines detailed throughout this manual; for technical troubleshooting assistance before you proceed.; Dirty fuel or air filters. Inspect and; Contact
E-3 TROUBLESHOOTING E-3 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting ...
Page 36 - The welding arc is
E-6 TROUBLESHOOTING E-6 RANGER 305D Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting ...
Page 37 - DIAGRAMS
Page 42 - ARN; INE
F-6 DIAGRAMS F-6 RANGER 305D o r s e rvice t his e q u ip m e n t. O n ly qualified pe rs onne l s hou ld ins tall, u s e Keep aw ay from m ovi ng pa rt s . Keep gua rd s in p lac e. MO VING PART S ca n injure W ARN ING Do not touch e lectricall y liv e pa rt s . be fo re s e rvici ng. Disconnect NE...
Page 48 - RANGER 3
F-12 DIAGRAMS F-12 RANGER 305D NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departme...
Page 50 - NOTES
Page 52 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...