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 fumesoutdoors. ...
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
iii SAFETY 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 manufacturerʼsrecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Soudage A L...
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
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 9 - INSTALLATION; INPUT - DIESEL ENGINE; PHYSICAL DIMENSIONS
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:; SAFETY PRECAUTIONS; LOCATION AND VENTILATION; 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 (698 lbs. lessfuel). A lift bail is mounted to the machine and shouldalways be used when lifting the machine. HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary....
Page 11 - TOWING; VEHICLE MOUNTING
PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc-tions supplied with this machine. • Stop engine and allow to cool before fueling• Do not smoke when fueling.• Fill fuel tank at a moderate rate and do not over- fill. • Wipe up spilled fuel and allow fumes to clear before...
Page 12 - ELECTRICAL CONNECTIONS; • Be grounded to the frame of the welder using a; NOTE; CAUTION
A-4 INSTALLATION RANGER 305D A-4 REMOTE CONTROL The RANGER 305D is equipped with a 6-pin and a14-pin connector. The 6-pin connector is for connect-ing the K857 or K857-1 Remote Control or for TIGwelding, the K870 foot Amptrol or the K936-3 handAmptrol. When in the CC-STICK, DOWNHILL PIPE,or CV-WIRE ...
Page 13 - CABLE INSTALLATION; • Loose connections will cause the output termi-; WELDING TERMINALS; Cable Length
CABLE INSTALLATION Install the welding cables to your RANGER 305D asfollows. 1. The engine must be OFF to install welding cables. 2. Remove the flanged nuts from the output terminals.3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identifiedon the case...
Page 14 - AUXILIARY POWER RECEPTACLES; STANDBY POWER CONNECTIONS
AUXILIARY POWER RECEPTACLES Start the engine and set the “IDLER” control switch tothe “High Idle” mode. Voltage is now correct at thereceptacles for auxiliary power. This must be donebefore a tripped GFCI receptacle can be reset prop-erly. See the MAINTENANCE section for detailedinformation on testi...
Page 15 - CONNECTION OF RANGER 305D TO PREMISES WIRING
A-7 INSTALLATION RANGER 305D A-7 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 16 - Connection of LN-7 or LN-8 to the RANGER 305D
A-8 INSTALLATION RANGER 305D A-8 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 17 - • Shut the welder off.
A-9 INSTALLATION RANGER 305D A-9 Connection of LN-742, Spool Gun (K487-25) andCobramatic to RANGER 305D • Shut the welder off. • Connect per instructions on the appropriate connec- tion diagram in Section F. 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 t...
Page 18 - OPERATION; GENERAL DESCRIPTION; ENGINE OPERATION; • 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 youhave thoroughly read the engine manufacturerʼsmanual supplied with your welder. It includesi m p o r t a n t s a f e t y p r e c a u t i o n s , d e t a i l e d e n g i n estarting, operating and maintenan...
Page 19 - WELDING CONTROLS; D I G I TA L O U T P U T M E T E R S -
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 PIPEor CV-WIRE modes and when a remote control isconnected to the 6-Pin or ...
Page 20 - WELD OUTPUT TERMINALS WITH FLANGE; • AUTO BLEED FUNCTION; S TA R T P U S H B U T T O N
B-3 OPERATION B-3 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 isnot active in the TIG mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) durin...
Page 21 - STARTING THE ENGINE; TYPICAL RANGER 305D FUEL CONSUMPTION
B-4 OPERATION B-4 15. ELECTRIC FUEL GAUGE- The electric fuel gauge gives accurate and reliable indication as tohow much fuel is in the fuel tank. 16. ENGINE HOUR METER- Displays the total time that the engine has been running. This meteris useful for scheduling prescribed maintenance. 17. ENGINE PRO...
Page 22 - DOWNHILL PIPE Welding; TIG WELDING
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 23 - ARC GOUGING
RANGER 305D B-6 OPERATION B-6 RANGER 305 D settings when using the K930-2 TIG Module withan 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 "REM...
Page 24 - Simultaneous Welding and Auxiliary Power Loads; RANGER 305D Simultaneous Welding and Power Loads
Permissible AuxiliaryCurrent in -Amps @ 240 VAC 4431241912 3 B-7 OPERATION B-7 AUXILIARY POWER: If a GFCI receptacle is tripped, See the MAINTE-NANCE section for detailed information on testing andresetting the GFCI receptacle. Start the engine and set the IDLER control switch tothe desired operatin...
Page 25 - ACCESSORIES; REMOTE CONTROL
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, stateand local laws regarding requirements for brakes,lights, ...
Page 26 - MAINTENANCE; • Have qualified personnel do all maintenance
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 n e c e s s a r y t o perform maintenance and replace ...
Page 27 - 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 rm t oassure rapid and complete draining. It is recommend-ed that each time the oil is changed the oil filter bechanged as well. • Be sure the unit is off. Disconnect the negative bat- tery ca...
Page 28 - Service Instructions & Installation Tips; For Engine Air Filter
D-3 MAINTENANCE D-3 RANGER 305D Service Instructions & Installation Tips For Engine Air Filter F Release the 1 Seal Carefully Unlatch and remove the servicecover of the air cleaner. Makecertain the latches are foldedback against the cover so thatthey don t hinder filterremoval/installation. Most...
Page 29 - 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 30 - ENGINE ADJUSTMENT; GASES FROM BATTERY can explode.; • ALLOW ENGINE TO COOL BEFORE INSTALLING
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 31 - 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: Itʼs...
Page 32 - 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 33 - 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 34 - 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 38 - DIAGRAMS
Page 43 - WA
F-6 DIAGRAMS F-6 RANGER 305D o r s e rv ic e t h is equ ipm ent . 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 rds in p lac e. MO VING PART S ca n inj ure WA R N IN G Do not t ouc h e lec tr ic a lly liv e pa rt s . be fo re s e rvi c in g. Disco...
Page 50 - DIMENSION PRINT; ASE F
F-13 DIMENSION PRINT F-13 RANGER 305D M20334 B 21 .0 6 53 4. 9 51 .2 0 1 300 .5 17 .5 0 44 4. 5 19 .50 49 5.3 35. 77 908 .4 29 .8 3 75 7. 6 34. 24 869 .8 CI RCU IT B R E AKE RS 13 26 .4 52 .0 0 1 320 .8 29 .0 0 73 6. 6 11 .3 0 28 7. 0 21 .5 0 5 46. 1 CE N T E R OF GR AV IT Y NO T E : C ASE F RO N T ...
Page 51 - NOTES
