Lincoln K1727-4, K1727-3 User Manual

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Operator’s Manual

RANGER ®305D

For use with machines having Code Numbers:

11457, 11909

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM970-A | Issue D ate Sept- 13

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

For Service outside the USA:

Email: globalservice@lincolnelectric.com

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

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

CAUTION

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

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

READ and obey the Material Safety

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

USE ENOUGH VENTILATION or

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

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

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

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

face.

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

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

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

PROTECT your body from welding spatter and arc

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

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

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

DO NOT WELD OR CUT painted or plated parts unless special

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

PROTECT compressed gas cylinders from excessive heat, mechanical

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

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

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

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

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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

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

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

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

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

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

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

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

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

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

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

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

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

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

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

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

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

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

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

7.c. Cylinders should be located:

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

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

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

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

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

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

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

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

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

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

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

TABLE OF CONTENTS

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Premises Wiring ...................................................................................................................A-8

Connection of Lincoln Electric Wire Feeders...............................................................A-9,A-10

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ..............................................................................................................B-1

General Description..............................................................................................................B-1

For Auxiliary Power ..............................................................................................................B-1

Engine Operation..................................................................................................................B-1

Add Fuel ...............................................................................................................................B-1

Break in Period.....................................................................................................................B-1

Welder Controls .............................................................................................................B-2,B-3

Engine Controls....................................................................................................................B-3

Starting and Stopping the Engine .................................................................................B-4

Welding Operation................................................................................................................B-4

Duty Cycle ..............................................................................................................B-4,B-5

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

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

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

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

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

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

Auxiliary Power .............................................................................................................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

GFCI Testing and Resetting Procedure..........................................................D-6

________________________________________________________________________

Troubleshooting ..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-6

________________________________________________________________________

Diagrams and Dimension Print ......................................................................Section F

________________________________________________________________________

Parts List.................................................................................................................P-492

________________________________________________________________________

vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger® 305D (K1727-3, K1727-4)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

A-1

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

18.8 HP High Idle 3650

Kubota** (14 KW)

D722 Net intermittent Full Load 3500

3600 RPM

naturally aspirated Low Idle 2450 Battery Charger

water cooled (3.6L)

Diesel Engine

Bore x Stroke inch (mm)

2.64 x 2.68

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

12VDC Battery &

(Group 58; 550 Radiator Coolant:

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

Welding Process

DC Constant Current

DC Pipe Current

Touch-Start™TIG

DC Constant Voltage

Welding Output

Current/Voltage/Duty Cycle

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

Output Range

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

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

Auxiliary Power

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 WIDTH DEPTH WEIGHT

30.00* in. 21.50 in 52.25 in.

762.0 mm 546.0 mm 1327.0 mm

698 lbs. (317kg.)

Fuel: 12 gal.

Oil: 3.4Qts. (3.2L)

Max. Weld OCV

@Rated Load RPM

60 Volts

ENGINE

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

Full Pressure with Full Flow Filter

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

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

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

Certified to EPA Tier 4

Compliant

Mechanical Fuel Pump, Auto air bleed

system Electric shutoff solenoid Indirect fuel injector

Low noise Muffler: Shutdown on low oil

Made from long life, aluminized steel. temperature

Mechanical

Governor

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

(2) 120VAC GFCI Duplex (5-20R) Two 20AMP for Two Duplex Receptacle 15AMP for Battery Charging Circuit

(1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage(2-pole) 15AMP for 42V Wire Feeder Power

Full KVA (14-50R)

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

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

RANGER® 305D

A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

•

Use in open, well ventilated areas or vent exhaust outside.

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

MOVING PARTS can injure.

•

Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operatorʼs manual.

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

LOCATION AND VENTILATION

A-2

LIFTING

The RANGER® 305D weighs approximately 775lbs.(352kg.) with a full tank of fuel (698 lbs. less fuel). A lift bail is mounted to the machine and should always be used when lifting the machine.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

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HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 2.5% to 3.5% for every 1000 ft. (305m). Due to new EPA and other local emissions regulations, modifications to the engine for high altitude are restricted within the United States and some other European Countries. Use above 6000 ft.(1828 m) may be limited due to poor engine performance or excessive exhaust smoke. An authorized Kubota engine field service shop should be contacted to determine if any adjustments can be made for operation in higher elevations locally.

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

STACKING

RANGER® 305D machines cannot be stacked.

ANGLE OF OPERATION

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 20 degrees in all directions, 35 degrees Intermittent (less than 10 minutes continuous) in all directions. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase.

When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 12 gallons (45ltrs.).

RANGER® 305D

HIGH TEMPERATURE OPERATION

At temperatures above 104°F(40°C), Welder output derating is necessary. For maximum output ratings, derate the welder output 2 volts for every 18°F(-7.8°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!

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A-3

INSTALLATION

A-3

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincolnʼs K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the weld-

ing equipment so there will be no undue stress to the framework.

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)

Consult applicable federal, state and local laws regarding specific

requirements for use on public highways.

(1)

VEHICLE MOUNTING

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions supplied with this machine.

• Stop engine and allow to cool before fueling

• Do not smoke when fueling.

• Fill fuel tank at a moderate rate and do not overfill.

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

• Keep sparks and flame away from tank.

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

OIL

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 Operatorʼs Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operatorʼs Manual for more details on the proper service and

maintenance intervals.

WARNING

Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

• Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is stable under conditions of use.

• Do not exceed maximum rated loads for components such as suspension, axles and tires.

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

• Follow vehicle manufacturerʼs instructions.

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

FUEL

DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur fuel in U.S.A. and Canada.

WARNING

• Fill the fuel tank with clean, fresh fuel. The capacity of the tank is 12 gals. (45.4ltrs). When the fuel gauge reads empty the tank contains approximately 2 gals. (7.6ltrs.) of reserve fuel.

WARNING

NOTE: A fuel shut off valve is located on the pre-

filter/sediment filter. Which should be in the closed position when the welder is not ran for extended periods of time.

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

RANGER® 305D

A-4

INSTALLATION

A-4

ENGINE COOLING SYSTEM

WARNING

Air to cool the engine is drawn in the base sides and exhaust through radiator & case back. It is important that the intake and exhaust air is not restricted. Allow a minimum clearance of 2 feet (0.6m) from the case back and 16in.(406mm) from either side of the base to a vertical surface.

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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 RUN-STOP switch is in the STOP position. Remove the two screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench.

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

MUFFLER OUTLET PIPE

Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction. Tighten using a 9/16" socket or wrench.

SPARK ARRESTER

Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the K1898-1 must be installed and properly maintained.

WARNING

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

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

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 K936-3 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.

When in TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.

The 14-pin connector is used to directly connect a wire feeder control cable. In the CV-WIRE mode, when the control cable is connected to the 14-pin connector, the auto-sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active

WARNING

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

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

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.)

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:

WARNING

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

• Be double insulated.

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

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

RANGER® 305D

A-5

INSTALLATION

A-5

When this welder is mounted on a truck or trailer, its frame must be electrically bonded to the metal frame of the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section entitled "Standby Power Connections" as well as the article on grounding in the latest National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded.

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.

CABLE INSTALLATION

Install the welding cables to your RANGER® 305D as follows.

1. The engine must be OFF to install welding cables.

2. Remove the flanged nuts from the output terminals .

3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identified on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the “work”) is properly connected to the work clamp and cable.

CAUTION

6. Check and tighten the connections periodically.

• Loose connections will cause the output termi-

nals to overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output ter-

minal connection. Keep the cables isolated and separate from one another.

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

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.

TABLE A.1

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30 meters)

100-150 Ft. (30-46 meters)

150-200 Ft. (46-61 meters)

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

3 / 0 AWG

RANGER® 305D

A-6

ELECTRICAL DEVICE USE WITH THE RANGER® 305D

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

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

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

appliances with electrical control. regulation can cause the capaci-

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting. refrigerators, weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain

INSTALLATION

TABLE lll

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

ation. DO NOT RUN THESE

DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS.

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

A-6

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

complicated electrical equipment. er along with transient and

surge protection is required, and

liabilities still exist. DO NOT

USE THESE DEVICES WITH A RANGER® 305D

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

RANGER 305D

A-7

INSTALLATION

AUXILIARY POWER RECEPTACLES

Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI receptacle can be reset properly. See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle.

The auxiliary power of the RANGER® 305D consists of two 20 Amp-120 VAC (5-20R) duplex receptacles with GFCI protection 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, 9,500 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 40 amps. The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 40 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. All auxiliary power is protected by circuit breakers.

A-7

• 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 customerʼs 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 40 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.

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 manufacturerʼs recommended maintenance schedule.

The RANGER® 305D can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 40 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.

RANGER® 305D

A-8

240 Volt

60 Hz. 3-Wire

Service

INSTALLATION

CONNECTION OF RANGER® 305D TO PREMISES WIRING

240 VOLT

POWER



COMPANY



METER

DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT

PROTECTION.

120 VOLT

50AMP

240 VOLT

GROUNDED CONDUCTOR

NEUTRAL BUS

GROUND

DISCONNECT AND

OVERCURRENT

PREMISES

SERVICE

PROTECTION

A-8

LOAD

DOUBLE

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

240 VOLT

POLE

CIRCUIT

BREAKER

GND

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-9

INSTALLATION

CONNECTION OF LINCOLN ELECTRIC WIRE 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" switch to either "+" or "-" as required by the electrode being used.

A-9

• Across The-Arc Model:

Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

• Control Cable Model:

Connect Control Cable between Engine Welder and Feeder.

• Set the "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-15 to the Ranger® 305D

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.

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

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

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

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

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

RANGER® 305D

A-10

INSTALLATION

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.

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.

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

A-10

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

• Shut the welder off.

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

Connection of PRINCE XL SPOOL GUN to the Ranger® 305D

Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module.

• Shut the Welder off.

• Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder.

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.

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

• 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.

RANGER® 305D

B-1

OPERATION

SAFETY PRECAUTIONS

WARNING

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door closed and the side panels in place.

• Read carefully the Safety Precautions page before operating this machine. Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual.

GENERAL DESCRIPTION

B-1

• Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

• Check radiator for proper coolant level. (Fill if necessary).

• See Engine Ownerʼs Manual for specific oil and coolant recommendations.

ADD FUEL

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

DIESEL FUEL

can cause fire.

DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur fuel in U.S.A. and Canada.

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

• Remove the fuel tank cap.

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

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

The RANGER® 305D is a diesel engine powered DC multi-process 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.

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.

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.

• Fill the tank approximately 4 inches (100mm) from the top of the filler neck to allow for fuel expansion . DO NOT FILL THE TANK TO THE POINT OF OVERFLOW.

• Replace the fuel cap and tighten securely.

• See Engine Ownerʼs Manual for specific fuel recommendations.

BREAK-IN PERIOD

Any engine will use a small amount of oil during its “break-in” period. For the diesel engine on the RANGER® 305D, break-in is about 50 running hours.

Check the oil every four hours during break-in. Change the oil after the first 50 hours of operation,every 100 hours thereafter. Change the oil filter at the second oil change.

CAUTION

During break-in, subject the RANGER® 305D to moderate loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several minutes.

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

RANGER® 305D

B-2

OPERATION

B-2

WELDING CONTROLS (Figure B.1)

1. OUTPUT CONTROL-

used to preset the output voltage or current as displayed on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control.

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

When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.

The OUTPUT dial is

FIGURE B.1

2. DIGITAL OUTPUT METERS-The digital

3. WELD MODE SELECTOR SWITCH-

meters allow the output voltage (CV-WIRE mode) or current (CC-STICK,DOWN HILL PIPE and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on for seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior to when welding was ceased.

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

(Provides four selectable welding modes)

CV-WIRE DOWNHILL PIPE CC-STICK TOUCH START TIG

RANGER® 305D

B-3

OPERATION

B-3

4. ARC CONTROL

the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, and has different functions in these modes. This control is not active in the TIG mode.

- The ARC CONTROL dial is active in

10. WIRE FEEDER VOLTMETER SWITCH:

ENGINE CONTROLS:

CC-STICK mode: In this mode, the ARC CONTROL dial

sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the dial from –10 (soft) to +10 (crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with a setting at 0.

DOWNHILL PIPE mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or a more forceful digging arc (crisp). Increasing the number from –10 (soft) to +10 (crisp) increases the short circuit current which results in a more forceful digging arc. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition ("stacking" of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROL clock wise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with a setting of 0.

5. WELD OUTPUT TERMINALS WITH FLANGE NUT-

Provides a connection point for the electrode and

work cables.

6. GROUND STUD-

connecting the machine case to earth ground.

7. 14-PIN CONNECTOR-

trol cables to the RANGER® 305D. Includes contactor closure circuit, auto-sensing remote control circuit, and 120V and 42V power. The remote control circuit operates the same as the 6 Pin Amphenol.

8. 6-PIN CONNECTOR-

control equipment. Includes auto-sensing remote control circuit.

Provides a connection point for

For attaching wire feeder con-

For attaching optional remote

11. RUN/STOP SWITCH

12. GLOW PLUG PUSH BUTTON

13. START PUSH BUTTON

14. IDLER SWITCH

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

(Figure B.2)

- RUN position energizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating.

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

- Energizes the starter motor to crank the engine.

- Has two positions as follows:

1) In the HIGH position, the engine runs at the high

idle speed controlled by the engine governor.

2) In the AUTO position, the idler operates as follows:

• When switched from HIGH to AUTO or after starting the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.

• When the electrode touches the work or power is drawn for lights or tools (approximately 100 Watts minimum), the engine accelerates and operates at full speed.

• When welding ceases or the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

• The engine will automatically return to high idle speed when there is welding load or AC power load reapplied.

9. WELD TERMINALS CONTROL SWITCH-

WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is

depressed.

In the

RANGER® 305D

B-4

OPERATION

15. ELECTRIC FUEL GAUGE- The electric fuel

gauge gives accurate and reliable indication as to how much fuel is in the fuel tank.

16. ENGINE HOUR METER- Displays the total

time that the engine has been running. This meter is useful for scheduling prescribed maintenance.

17. ENGINE PROTECTION LIGHT- A warning

indicator light for Low Oil Pressure and/or Coolant Over Temperature. The light is off when the systems are functioning properly. The light turns on when the RUN-STOP switch is in the “ON” position prior to starting the engine. If the Engine Protection or Battery Charging Lights do “not” turn off shortly after starting the engine shut off the engine immediately and determine the cause.

STARTING THE ENGINE

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

2. Set IDLER switch to AUTO.

3. Set the RUN/STOP switch to RUN.

4. Press Glow Plug Button and hold 5 to 10 seconds.

5. Press and hold both the “Glow Plug” Button and

START button together until the engine starts or for up to 10 seconds.

6. Release the engine START button immediately

when the engine starts.

7. Release the glow plug button after the Engine

Protection Light turns off or after an additional 5 seconds maximum.

8. The engine will run at high idle speed for approxi-

mately 12 seconds and then drop to low idle speed. Allow the engine to warm up at low idle for several minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

B-4

NOTE: If the unit fails to start repeat step 4 through

step 7 after waiting 30 seconds

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.

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.

TABLE B.1

TYPICAL RANGER® 305D FUEL CONSUMPTION

Kubota D722 Running time for

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

9,500 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

OPERATION

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

B-5

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

Constant Current (CC-STICK) Welding

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The output CONTROL dial adjusts the full output range for stick welding.

TIG WELDING

The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little volt-

The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the number from -10(soft) to +10(crisp)

age or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a

rocking motion, which establishes the arc. increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

DOWNHILL PIPE Welding

This slope controlled setting is intended for "out-of-position" and "down hill" pipe welding where the operator would like to control the current level by changing the arc length. The output CONTROL dial adjusts the full output range for pipe welding. The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or more forceful digging arc (crisp).

When in the TOUCH START TIG mode and when a

Amptrol is connected to the 6-Pin connector the OUT-

PUT dial is used to set the maximum current range of the

current control of the Amptrol.

The ARC CONTROL is not active in the TIG mode. To

STOP a weld, simply pull the TIG torch away from the

work. When the arc voltage reaches approximately 30

Volts the arc will go out and the machine will reset the

current to the Touch Start level. To reinitiate the arc,

retouch the tungsten to the work and lift. Alternatively,

the weld can be stopped by releasing the Amptrol or arc

start switch. Increasing the number from -10(soft) to +10(crisp) increases the short circuit current which results in a more forceful digging arc.Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds. This can also increase spatter.

TABLE B.2

TYPICAL CURRENT RANGES

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

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

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

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

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

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

The RANGER® 305 D can be used in a wide variety of

DC TIG welding applications. In general the ʻTouch Startʼ

feature allows contamination free starting without the use

of a Hi-frequency unit. If desired, the K930-2 TIG Module

can be used with the RANGER® 305 D. The settings are

for reference.

(1)

FOR TUNGSTEN ELECTRODES

(2)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases. (2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP

1% Thoriated EWTh-1

2% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications. (3) DCEP is not commonly used in these sizes. (4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures

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

and high duty cycles.

RANGER® 305D

B-6

OPERATION

B-6

RANGER® 305 D 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® 305 D is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.

ARC GOUGING

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.

Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table.

Carbon Diameter

WIRE WELDING-CV

Connect a wire feeder to the RANGER® 305 D according to the instructions in INSTALLATION INSTRUCTIONS Section.

The RANGER® 305 D 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.

Current Range (DC, electrode

positive)

1/8" 60-90 Amps

5/32" 90-150 Amps

3/16" 200-250 Amps

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

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

• Outershield - 0S-70, 0S-71M, 0S-71 ELITE.

• Solid wires for MIG welding - .035 (0.9 mm), and

.045 (1.1 mm), Super Arc L-50 and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max MIG 308 LS.

Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain applications with this machine.

RANGER® 305D

B-7

OPERATION

B-7

AUXILIARY POWER:

If a GFCI receptacle is tripped, See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle.

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

The auxiliary power of the RANGER® 305D consists of two 20 Amp-120 VAC GFCI (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. 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. All auxiliary power is protected by circuit breakers.

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).

Current (Amps)

15 20 15 20 44

RANGER® 305D Simultaneous Welding and Power Loads

Welding

Output-Amps

Permissible Power-Watts

(Unity Power Factor)

Permissible Auxiliary Current in -Amps

@ 240 VAC

0 100 150

200 250 300

9500 7100 5600 4200 2300

40 30 23 18 10

* 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.)

Voltage

Volts

120 120 240 240 240

Load

(Watts)

1800 2400 3600 4800 9500

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

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

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

40 30 75 60

(12)

(9) (23) (18)

50 150 100

(23) (15) (46) (30) (15)

125

88 225 175

(38) (27) (69) (53) (27)

175 138 350 275 150

(53) (42)

(107)

(84) (46)

300 225 600 450 225

(91)

(69) (183) (137)

(69)

RANGER® 305D

C-1

ACCESSORIES

C-1

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 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-2 Fender & Light Kit K965-1 Cable Storage Rack

K1789-1 ROLL CAGE - Gives added damage protection.

K1898-1 SPARK ARRESTOR

K704 ACCESSORY SET - Includes 35 ft. (10m) of

electrode cable and 30 ft. (9.1m) of work cable, headshield, work clamp electrode holder. Cables are rated at 400 amps, 100% duty cycle.

K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE CONTROL

Portable control provides same dial range as the output control on the welder. Has a convenient 6 pin plug for easy connection to the welder.

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.

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.

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.

T12153-9 50 AMP, 120/240 V POWER PLUG

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.

TIG Welding K1783-9 TIG Torch PTA-26V (25ft.) K963-3 Hand Amptrol K870 Foot Amptrol

KP509 Magnum Parts Kit

Spool Gun K1692-2 Prince XL Spool Gun (25ft.)

K487-25 Magnum Spool Gun K488 Magnum Control Module

K691-10 Input Cable)

RANGER® 305D

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance and troubleshooting work.

• Turn the engine off before working inside the machine or servicing the engine.

• Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. If guards are missing from the machine, obtain replacements from a Lincoln Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this manual and in the Engine Ownerʼs Manual before working on this machine.

D-1

KUBOTA D722 DIESEL ENGINE

FREQUENCY

DAILY OR BEFORE STARTING ENGINE

Service Intervals Observe the following for service and maintenance. The lubricating oil change intervals listed in the table below are for Classes CF,CE and CD lubricating oils of API classification with a low sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition.

MAINTENANCE REQUIRED

• FILL FUEL TANK.

• CHECK OIL LEVEL.

• CHECK COOLANT LEVEL.

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

• CHECK AIR INTAKE HOSE FOR CRACKS OR LOOSE CONNECTIONS.

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

• CHECK ALTERNATOR BELT TENSION AND WEAR.

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, clothing, and tools away from the gears, fans, and all other moving parts when starting, operating, or repairing the equipment.

Routine Maintenance

At the end of each dayʼs use, refill the fuel tank to minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated.

ENGINE MAINTENANCE COMPONENTS

KUBOTA D722 DIESEL ENGINE

ITEM

OIL FILTER KUBOTA 70000-15241

AIR FILTER ELEMENT DONALDSON P822686

FUEL FILTER ELEMENT KUBOTA 15231-43560

BATTERY KUBOTA GROUP 58, 550 CCA

BELT KUBOTA 15881-97011

GLOW PLUGS KUBOTA 16851-65512

INLINE FUEL FILTER KUBOTA 12581-43012

MAKE AND PART NUMBER

Intervals

Every 50 hours Every 75 hours

Every 100 hours

Every 150 hours

Every 200 hours Every 400 hours Every 500 hours

Every 1 or 2 months Every 800 hours Every 1500 hours

Every 3000 hours

Every 2 years

IMPORTANT

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

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

Replacement of fan belt.

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

Items

•

*1,*2

*3 *3

@ @ @

@ @

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

*1 Air cleaner should be inspected/cleaned more often in dusty conditions than

the normal conditions.

*2 Follow Service Instructions and Installation Tips for air cleaner in

Section D. *3 Consult your local KUBOTA Dealer for this service. *4 Replace only if necessary. @ All these markings are registered as emission related critical parts by KUB-

OTA in the U.S. EPA nonroad emission regulation. As the engine owner,

you are responsible for the performance of the required maintenance on

the according to the above instruction. Please see Engine Owners Manual for Warranty Statement in detail.

RANGER® 305D

D-2

MAINTENANCE

D-2

Engine Oil Change

Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well.

• Be sure the unit is off. Disconnect the negative battery cable to ensure safety.

• Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder.

• Remove the cap from the drain valve. Push valve in and twist counterclockwise. Pull to open and drain the oil into a suitable container for disposal.

• Close the drain valve by pushing in and twisting clockwise. Replace the cap.

• Re-fill the crankcase to the upper limit mark on the dipstick with the recommended oil (see engine operation manual OR engine service items decal OR below). Replace and tighten the oil filler cap securely.

Oil Filter Change

• Drain the oil.

• Remove the oil filter with an oil filter wrench and drain the oil into a suitable container. Discard the used filter. Note: Care should be taken during filter removal to not disrupt or damage in any way the fuel lines.

• Clean the filter mounting base and coat the gasket

of the new filter with clean engine oil.

• Screw the new filter on by hand until the gasket con-

tacts the mounting base. Using an oil filter wrench, tighten the filter an additional 1/2 to 7/8 of a turn.

• Refill the crankcase with the specified amount of the

recommended engine oil. Reinstall the oil filler cap and tighten securely.

• Start the engine and check for oil filter leaks.

• Stop the engine and check the oil level. If neces-

sary, add oil to the upper limit mark on the dipstick.

• Push oil drain hose and valve back into unit, re-connect negative battery cable, and close doors and engine top cover before restarting unit.Wash your hands with soap and water after handling used motor oil. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station or recycling center for reclamation. DO NOT throw it in the trash; pour it on the ground or down a drain.

Engine Oil Refill capacities

Without oil filter replacement:

• 3.3 U.S. Quart. (2.7 Imp Quart, 3.2 liter)

With oil filter replacement:

• 3.4 U.S. Quart. (3.0 Imp Quart, 3.2 liter)

Use motor oil designed for diesel engines that meets requirements for API service classification CC/CD/CE/CF/CF-4/CG-4 or CH-4. ACEA E1/E2/E3. Always check the API service label on the oil container to be sure it includes the letters indicated. (Note: An S-grade oil must not be used in a diesel engine or damage may result. It IS permissible to use an oil that meets S and C grade service classifications.) SAE 10W30 is recommended for general, all temperature use, 5F to 104F (-15C to 40C). See engine ownerʼs manual for more specific information on oil viscosity recommendations.

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

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

Remove the Filter

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

Inspect the Old Filter for Leak Clues

Inspect the New Filter for Damage

Insert the New Radial Seal Filter Properly

Check Connectors for Tight Fit

NEVER use the service cover to push the filter into place! Using the cover to push the filter in could cause damage to the housing, cover fasteners and will void the warranty.

Caution

Service Instructions

Single- and Two-Stage Engine Air Cleaners

MAINTENANCE

Service Instructions

Single- and Two-Stage Engine Air Cleaners

D-3

Remove the Filter

Unfasten or unlatch the service cover. Because the filter fits tightly over the outlet tube to create the critical seal, there will

Rotate the filter while pulling straight out.

If your air cleaner has a safety filter, replace it every third primary filter change. Remove the safety filter as you would the primary filter. Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine.

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

Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube. Contaminant on the sealing surface could hinder an effective seal and cause leakage. Make sure that all contaminant is removed before the new filter is inserted. Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear. Engine manufacturers say that it takes only a few grams of dirt to "dust" an engine! Be careful not to damage the sealing area on the tube.

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

Wipe both sides of the outlet tube clean.

Inspect the New Filter for Damage

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

Insert the New Radial Seal Filter Properly

If you're servicing the safety filter, this should be seated into position before installing the primary filter.

Insert the new filter carefully. Seat the filter by hand, making certain it is completely into the air cleaner housing before securing the cover in place.

The critical sealing area will stretch slightly, adjust itself and distribute the sealing pressure evenly. To complete a tight seal, apply pressure by hand at the outer rim of the filter, not the flexible center. (Avoid pushing on the center of the urethane end cap.) No cover pressure is required to hold the seal. NEVER use the service cover to push the filter into place! Using the cover to push the filter in could cause damage to the housing, cover fasteners and will void the warranty.

If the service cover hits the filter before it is fully in place, remove the cover and push the filter (by hand) further into the air cleaner and try again. The cover should go on with no extra force.

Once the filter is in place, secure the service cover.

Outer edge of the outlet tube

If your air cleaner is equipped with a Vacuator Valve

Visually check and physically squeeze to make sure the valve is flexible and not inverted, damaged or plugged.

Inspect the Old Filter for Leak Clues

Visually inspect the old filter for any signs of leaks. A streak of dust on the clean side of the filter is a telltale sign. Remove any cause of leaks before installing new filter.

Inner edge of the outlet tube

Caution

NEVER use the service cover to push the filter into place! Using the cover to push the filter in could cause damage to the housing, cover fasteners and will void the warranty.

Check Connectors for Tight Fit

Make sure that all mounting bands, clamps, bolts, and connections in the entire air cleaner system are tight. Check for holes in piping and repair if needed. Any leaks in your intake piping will send dust directly to the engine!

RANGER® 305D

D-4

COOLING SYSTEM

MAINTENANCE

FUEL

D-4

WARNING

HOT COOLANT

• Do not remove cap if radiator is hot.

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

Check the coolant level by observing the level in the radiator and recovery bottle. Add 50/50 antifreeze / water solution if the level is close to or below the "LOW" mark. do not fill above the "FULL" mark. Remove radiator cap and add coolant to radiator. Fill up to the top of the tube in the radiator filler neck which includes a connecting hose coming from the thermostat housing.

To drain the coolant, open the petcock at the bottom of the radiator. Open the radiator cap to allow complete drainage. (Tighten the petcock and refill with a 50/50 antifreeze/water solution.) Use an automotive grade (low silicate) ethylene glycol antifreeze. The cooling system capacity is 3.85 quarts (3.6L.). Squeeze upper and lower radiator hoses while filling to bleed air from system coolant. Replace and tighten the radiator cap.

can burn skin.

At the end of each dayʼs use, refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the fuel to expand.

Use only fresh, No. 2 grade DIESEL fuel. Do not use kerosene.

See the Engine Operator's Manual for instructions on replacing the fuel filter.

BLEEDING THE FUEL SYSTEM

You may need to bleed air from the fuel system if the fuel filter or fuel lines have been detached, the fuel tank has been ran empty or after periods of long storage. It is recommended that the fuel shutoff valve be closed during periods of non-use.

The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that helps purge the air from the mechanical fuel pump system. It is generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system. Operate the priming lever on the pump to assist starting after extended periods of non-use or out of fuel conditions.

CAUTION

Always premix the antifreeze and clean tap water before adding to the radiator. It is very important that a precise 50/50 solution be used with this engine year round. This gives proper cooling during hot weather and freezing protection to -34° F (37° C).

Cooling solution exceeding 50% ethylene glycol can result in engine overheating and damage to the engine. Coolant solution must be premixed before adding to radiator.

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

Periodically remove the dirt from the radiator fins.

Periodically check the fan belt and radiator hoses. Replace if signs of deterioration are found.

TIGHTENING THE FAN BELT

If the fan belt is loose, the engine can overheat and the battery lose its charge. Check tightness by pressing on the belt midway between the pulleys. It should deflect about .25 in. under a load of 20 lbs. (9 Kg) (6 mm).

WARNING

To avoid personal injury, do not bleed a hot engine. This could cause fuel to spill onto a hot exhaust manifold, creating a danger of fire.

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

Bleed the fuel system as follows:

1. Fill the fuel tank with fuel.

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

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

seconds.

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

filters

5. Follow the normal STARTING procedures.

RANGER® 305D

D-5

MAINTENANCE

D-5

FUEL FILTER

1. Check the fuel filter and fuel pre-filter for water accumulation or sediment.

2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre-fil-

ter.

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for this machine is 3650 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum.

ENGINE ADJUSTMENT

Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop.

BATTERY MAINTENANCE

To access the battery, Disconnect the Negative and then Positive battery cables. Remove the 2 screws from the battery door using a screwdriver or a 3/8" socket. Remove the 2 nuts from the battery bracket using a 7/16” wrench or socket. Slide the battery out and remove from welder

WARNING

GASES FROM BATTERY can explode.

Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

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

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

USING A BOOSTER — connect positive lead to battery first then connect negative lead to neg-

ative battery lead at engine foot. BATTERY ACID can burn eyes and skin.

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

Follow instructions printed on battery.

RANGER® 305D

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 kg) of baking soda and 1 quart (0.9461) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells. After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petroleum jelly or a non-conductive grease to retard corrosion. Keep the battery clean and dry. Moisture accumulation on the battery can lead to more rapid discharge and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The RANGER® 305D 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!

D-6

MAINTENANCE

D-6

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

CAUTION

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

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.

GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE

The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully remove any load and check it for damage.

• If the equipment has been shut down, it must be restarted.

• The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI receptacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other product (such as a lamp) into the GFCI receptacle and turn the product "ON".

• Push the "Test" button located on the GFCI receptacle. The night-light or other product should go "OFF".

• Push the "Reset" button, again. The light or other product should go "ON" again.

If the light or other product remains "ON" when the "Test" button is pushed, the GFCI is not working properly or has been incorrectly installed (miswired). If your GFCI is not working properly, contact a qualified, certified electrician who can assess the situation, rewire the GFCI if necessary or replace the device.

RANGER® 305D

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RANGER® 305D

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Major Physical or Electrical Damage is Evident.

Engine will not "crank".

Engine will "crank" but not start.

1. Contact your local Lincoln Authorized Field Service Facility.

1. Battery is low,

2. Loose battery cable connections.

Inspect, clean and tighten terminals.

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

1. Fuel shut off valve on Main Fuel Filter in the OFF position. Open valve (vertical) position of handle.

2. Fuel Filters dirty/clogged. Check and replace main filter element and/or Inline Fuel Filter.

3. Out of fuel. Fill tank and bleed fuel system.

4. High coolant temperature or low oil pressure. (indictor lights lit) Check oil and coolant levels. Fill if required. Check for loose or broken fan belt.

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

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

Charge Battery.

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

Contact your local Lincoln Authorized Field Service Facility.

Engine shuts down shortly after starting.

1. High coolant temperature or low oil pressure. (indictor light lit) Change oil and oil filters and fill to proper level. Check and fill coolant level. Check for loose or broken fan belt. Start engine and look for leaks.

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

3. Faulty engine protection relay.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RANGER® 305D

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Engine shuts down while under a load.

Engine runs rough.

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

Engine will not idle down to low speed.

1. High radiator coolant temperature. Reduce load if it is exceeding machine rating. Add coolant to system if low. Clean fins on radiator if dirty. Tighten fan belt if loose. Remove objects blocking or close to intake openings on both sides of base and exhaust end (case back).

1. Dirty fuel or air filters. Inspect and clean/replace filters as needed. Inspect and clean/replace filters as needed.

2. Water in fuel. If water found in tank. Empty fuel tank and refill then purge fuel lines.

1. Faulty battery. Replace.

2. Loose connections at battery or alternator. Clean and tighten connections.

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

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

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

3. Faulty PC board or idler solenoid.

Remove all external

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

your local Lincoln Authorized Field Service Facility.

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

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

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

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

connected to clean base

Set to "Welding On" when

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RANGER® 305D

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

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

Engine will not go to high idle under weld or auxiliary loading.

Engine does not develop full power. Engine runs rough.

Engine will not go to high idle when attempting to weld or using auxiliary power. Switching to manual high idle does not work.

Engine will not shut off.

1. Auxiliary power load is less than 100 watts. with less than a 100 watt load. Set idler to "High".

2. Faulty PC board.

1. Faulty idler solenoid. Check for bent linkage or broken spring

1. Fuel filter clogged,

2. Air filter clogged,

3. High idle setting incorrect, check and adjust if required.

4. Valves out of adjustment.

5. Fuel contaminated with water or sediment. Check fuel pre-filter and empty of water, bleed fuel system. Replace fuel in tank if needed.

1. Broken spring on Idle Solenoid, solenoid linkage binding, Faulty PC board, low idle speed set too low on idle solenoid.

1. Fuel Shutdown solenoid not functioning properly / linkage binding. Stop engine by shutting off valve located on main fuel filter. Contact authorized local Engine Service Shop.

Idler may not respond

Replace.

clean or replace.

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

Contact your local Lincoln Authorized Field Service Facility.

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

1. Fuel filter dirty/clogged. Replace.

2. Air filter dirty/clogged. Replace Air Filter Element.

3. Fouled fuel injector(s). Contact authorized Engine Service Shop.

4. Fuel contaminated with water. Check Main Filter Bowl and Inline Fuel filters for water. Clean and replace as needed. Replace fuel in tank.

5. Cracked or loose fuel hose. Replace hose and tighten clamps.

6. Valves out of adjustment. Contact authorized local Engine Service Shop.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RANGER® 305D

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

No welding power output.

Welder has output but no control.

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

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

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

3. Faulty PC board or welder alternator.

1. Poor remote/control cable connection to 6-pin or 14-pin connector. Check connections.

2. Faulty remote cable or faulty wire feeder or wire feeder cable. Replace if necessary.

3. Faulty control potentiometer or PC board.

1. Wire Feeder Power circuit breaker open. Check 42V and 120V beakers and reset if tripped.

2. Faulty control cable. Repair or replace cable.

3. Faulty wire feeder. Replace wire feeder.

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

Contact your local Lincoln Authorized Field Service Facility.

No auxiliary power.

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

2. Faulty connections to auxiliary receptacles. Check connections.

GFCI Receptacle may have tripped. Follow “GFCI Receptacle Testing and Resetting Procedure” in the MAINTENANCE section of this manual.

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

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-6

The welding arc is “cold.” The welding arc is not stable or is not satisfactory. the engine runs normally. The auxiliary power is normal.

1. Make sure the MODE selector switch is in the correct position for the process being used. (For example, CV-WIRE, PIPE, CC-STICK.)

2. Make sure the electrode (wire, gas, voltage, current etc.) is correct for the process being used.

3. Check for loose or faulty 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

F-1

RANGER® 305D

F-2

DIAGRAMS

F-2

RANGER® 305D

F-3

DIAGRAMS

F-3

RANGER® 305D

F-4

DIAGRAMS

F-4

RANGER® 305D

F-5

DIAGRAMS

F-5

S24787-6

TO W O R K

or servi ce thi s equipment.

Only qualified per sonnel should install,use

Keep guards in place.

Keep away f rom moving part s.

MO VI NG P ART S c an i njure

WARNING

ELECTRI C SHOC K can ki l l

Do not operate wi th panel s open.

Di sc onnect NEGATIVE ( -) Battery lead

before servi cing.

C ABLE PL U G

TO LN- 8 INPUT

K595 CONTROL CABLE

ELECTRODE CABLE

TO WIR E FEED UNI T

Do not touch elect ri cal ly live part s.

MATCH THE POLARI TY OF THE ELECTRODE CABLE.

14 PIN

AN I NCREASE I N THE AC WI RE FEEDER VOLTAGE, WHI CH CAN DAMAGE THE CONTROL CI RCUI T. THE ENGI NE GOVERNOR SETTI NG I S

AT THE FACTORY — DO NOT ADJUST ABOVE RPM SPECI FI CATI ONS LI STED I N THE ENGI NE WELDER OPERATI NG MANUAL.

N. A. WELDI NG CABLES MUST BE OF PROPER CAPACI TY FOR THE CURRENT AND DUTY CYCLE OF I MMEDI ATE AND FUTURE

AMPHENOL

CAUTI ONANY I NCREASE OF THE HI GH I DLE ENGI NE RPM BY CHANGI NG THE GOVERNOR SETTI NG OR OVERRI DI NG THE THROTTLE LI NKAGE WI

APPLI CATI ONS. SEE OPERATI NG MANUAL.

N. B. CONNECT WELDI NG CABLES TO OUTPUT STUDS FOR DESI RED POLARI TY. POSI TI ON THE WI RE FEEDER VOLTMETER SWI TCH T

N. C. PLACE I DLER SWI TCH I N HI GH POSI TI ON.

RANGER® 305D

F-6

DIAGRAMS

F-6

RANGER® 305D

F-7

DIAGRAMS

F-7

RANGER® 305D

F-8

DIAGRAMS

F-8

9/03

RANGER® 305D

F-9

DIAGRAMS

F-9

RANGER® 305D

F-10

ENHANCED DIAGRAM

DIAGRAMS

F-10

RANGER® 305D

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-11

DIMENSION PRINT

35.77908 .4

F-11

M20334

34. 24

869 .8

29.83757.

6. 33

160. 9

11.0 3

280. 2

21.50

546.

CIRCUIT

BREAKERS

21.06534.

19.50

11.30287.

29.00736.

52.00

1320

51.20

1300

26.64

676.7

29.5 7

751.

1326 .4

495.3

NOTE: CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES.

17.5 0

444. 5

CENTER OF GRAVIT

RANGER® 305D

PARTS LIST FOR

RANGER

P-492P-492

305D

This parts list is provided as an informative guide only.

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

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

RANGER®305D

ILLUSTRATION OF SUB-ASSEMBLIES

P-492-AP-492-A

RANGER®305D

08-03-2009

P-492-A.1P-492-A.1

RANGER®305D

For Codes: 11121, 11188, 11275, 11457 & 11909

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

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

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

Optional Equipment

PAGE NO.

CODE NO.

11121 1111111

11188 1111122

11275 2111123

P-492-B.1

Case Front Assembly

P-492-C

Control Panel Assembly

P-492-D

Stator Rotor Assembly

P-492-E

Blower Baffle Assembly

P-492-F

Base, Fuel Tank, Battery

P-492-G

Assembly

Engine Assembly

P-492-H

Covers & Case Back Assembly

P-492-J

11457 3212133

11909 3 2 1 2143

RANGER®305D

02-06-2013

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Accessory Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K703

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1898-1

Aux. Power Plug Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K802N

Aux. Power Plug Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K802-R

4-Wire Grounding Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order T12153-9

Remote Output Control (25 ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857

Remote Output Control (100 ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857-1

Roll Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1789-1

Full KVA Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1816-1

2 Wheel Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2635-1

Cold Weather Operation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2174-1

P-492-B.1P-492-B.1

RANGER®305D

08-03-2009

NOTES

RANGER®305D

Case Front Assembly

18A

24A

18B

15A

31A

31B

31C

16A

23B

20A

22A

23A

20A

20B

Below Code 11200

20A

P-492-CP-492-C

Above Code 11200

22A

23A

23B

20B

20A

18A

18B

24A

16A

31C

31B

31A

15A

RANGER®305D

04-12-2010

P-492-C.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Case Front G3860-4 1 X • • 1 Case Front G3860-8 1 • X X 2A Output Terminal Kit, Includes: T14166-9 2 X X X

Self Tapping Screw (Not Shown) S8025-91 4 X X X

Output Stud Nut T3960 2 X X X 3 Circuit Breaker Cover M19161 1 X • • 4 Receptacle Cover M18861 1 X X X 5A Receptacle, Single S18907-2 1 X X X 5B Lock Washer (Not Shown) T9695-3 4 X X X 5C #8-32 HN (Not Shown) CF000042 4 X X X 6 Receptacle, Gasket S21088 2 X X X 7 Cover Receptacle M16996 2 X X X 8A Receptacle, Duplex, GFCI S24410-1 2 X X X 8B Thread Forming Screw (Cutting) S9225-63 4 X • • 8B Thermoplastic Screw S24738-3 4 • X X 8C Speed Nut T11525-1 4 X X X 8D GFCI Cover L13286 2 X X X 8E Mounting Bracket S27167 2 X X X 8G Receptacle Seal (Not Shown) S27176 2 X X X 9 1/4-20 HJLN T9187-1 1 X X X 10 1/4-20 HN CF000017 1 X X X 11 Self Tapping Screw S8025-96 4 X X X 12 Connector Cap S17062-11 1 X X X 13 Circuit Breaker Decal S24672-2 1 X • • 14 Connector Cap S17062-10 1 X X X 15A Shunt & Lead Assembly S24097-3 1 X X X 15B 1/2-13 x .875 HHCS (Not Shown) CF000344 2 X X X 15C Plain Washer (Not Shown) S9262-1 2 X X X 15D Lock Washer (Not Shown) E106A-15 2 X X X 16A RF-Bypass Filter Assembly S24982 1 X X X 16B Flat Washer (Not Shown) S9262-27 1 X X X 16C Lock Washer (Not Shown) E106A-1 1 X X X 16D #10-24 HN (Not Shown) CF000010 1 X X X 17 Harness Assembly (Not Shown) G4244-2 1 X X • 17 Harness Assembly (Not Shown) G4244-4 1 • • X 18 Connector & Lead Assembly, Includes: M19685-3 1 X X X 18A Receptacle S12021-70 1 X X X 18B Receptacle S12021-68 1 X X X 20A Circuit Breaker - 50A,250VAC T12287-19 2 X • • 20B Circuit Breaker - 20A,250VAC, 50VDC T12287-38 2 X X X 20C Sealing Boot (Not Shown) S22061-2 2 • X X 21 Circuit Breaker-15A,250VAC,50VDC T12287-22 2 X • • 22A Circuit Breaker-15A, 250VAC, 50VDC T12287-37 2 • X X 22B Sealing Boot (Not Shown) S22061-2 2 • X X 23A Circuit Breaker-50A, 2-Pole, Includes 28B M20585 1 • X X 23B Circuit Breaker Cover Seal S24911-2 1 • X X 23C Sems Screw (Not Shown) T10082-30 4 • X X 23D Lock Washer (Not Shown) T4291-A 4 • X X 24A Thread Forming Screw S9225-76 3 X X X 24B Plain Washer (Not Shown) S9262-27 6 X X X 24C #10-24 HN (Not Shown) CF000010 6 X X X

NSS - Not Sold Separately

RANGER

305D

04-12-2010

P-492-C.2

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

24D Lock Washer (Not Shown) E106A-1 3 X X X 24E Lock Washer (Not Shown) T9695-1 3 X X X 28 Rating Plate L11812-4 1 X • • 28 Rating Plate L12790-2 1 • X X 29 Thread Forming Screw (Not Shown) S9225-68 4 X X X 31A Output Stud Cover M20007 2 • X X 31B Output Stud Cover Plate S25669 2 • X X 31C Thread Forming Screw S9225-68 4 • X X

RANGER

305D

04-12-2010

NOTES

RANGER®305D

Control Panel Assembly

20A

22A

27A

14A

14B

27C

27B

P-492-DP-492-D

20A

27C

27B

14A

14B

27A

22A

RANGER®305D

04-12-2010

P-492-D.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

2A Top Bezel G3593 1 X X 2B Self Tapping Screw (Not Shown) S24738-1 4 X X 3A Right Bezel G3594-1 1 X X 3B Self Tapping Screw (Not Shown) S24738-1 2 X X 4A Left Bezel G3594-2 1 X X 4B Self Tapping Screw (Not Shown) S24738-1 2 X X 5 Switch, Push-Button S13146-4 1 X X 6 Start Button S13146-1 1 X X 7 Hour Meter-Miniature S17475-3 1 X X 12 Knob T10491-1 1 X X 13 “O” Ring (Not Shown) T13483-7 2 X X 14 Connector & Lead Assembly (Includes) M19685-4 1 X X 14A Potentiometer (10K) T10812-112 2 X X 14B Potentiometer Spacer S18280 2 X X 14C Rotary Switch (Not Shown) S16670-10 1 X X 15 Switch, Toggle, SPST (Idle Switch) T10800-38 1 X X 15A Sealing Boot (Not Shown) S22061-4 1 • X 16 Nameplate-Ranger®305D G4577 1 X X 17 Switch, Toggle, DPDT T10800-36 1 X X 17A Sealing Boot (Not Shown) S22061-4 1 • X 18 Knob T10491 2 X X 19 Front Door Nameplate L11746-2 1 X X 20A Door Welded Assembly L11185 1 X X 20B Rivet (Not Shown) T12584-6 2 X X 21 Latch S21033 1 X X 22A Catch Bracket S24659 1 X X 22B Self Tapping Screw (Not Shown) S8025-98 2 X X 23 Fuel Gauge S17585-1 1 X X 24 Plug & Lead Asbly (Not Shown) S18250-889 1 X X 25 Operation Decal M19452-3 1 X X 26 Pilot Light T13534-11 1 X X 27 Digital Weld Meter Kit, Includes: (27A thru 27E) K2467-1 1 X X 27A Meter Housing Asbly (L11160) NSS 2XX 27B Meter Housing Seal S24630 2 X X 27C Meter Bezel M19368 2 X X 27D Lens (Not Shown) T14807-9 2 X X 27E #4-40 x .375 SS-PPNHS (Not Shown) CF000389 4 X X 27F #6-32 HN (Not Shown) CF000005 4 X X 27G Plain Washer (Not Shown) S9262-3 4 X X 28 Toggle Switch T10800-39 1 X X 28A Sealing Boot (Not Shown) S22061-4 1 • X 29 Switch, Toggle, SPST T10800-38 1 X X 29A Sealing Boot (Not Shown) S22061-4 1 • X

RANGER

305D

04-12-2010

Stator Rotor Assembly

P-492-EP-492-E

RANGER®305D

08-03-2009

P-492-E.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

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

Brush Holder Cartridge G2114 1 X

Brush Assembly S19480 2 X

Brush Assembly Retainer M16157 1 X 11 Brush Holder Bracket M18336 1 X 12 Self Tapping Screw S8025-91 2 X 13 1/4-20 x 1.00 HHCS CF000015 2 X 14 Lock Washer E106A-2 2 X 14A Flat Washer (Not Shown) S9262-98 2 X 15 1/4-20 HN CF000017 2 X 16 Firewall G3404 1 X 17 Bushing T12380-1 1 X 18 Door Bumper T14882-1 2 X

RANGER

305D

08-03-2009

Blower Baffle Assembly

18C

14A

18A

11A

11G

11H

11B

11H

11K

11J

11F

11E

11D

12A

12C

13A

6B 6C

13A

P-492-FP-492-F

11H

11F

11J

11E

11K

11D

11B

11A

14A

18C

11H

18A

11G

12A

12C

13A

6B 6C 6D

RANGER®305D

08-03-2009

P-492-F.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

Blower Baffle Assembly, Includes: G4097-9 1 X •

Blower Baffle Assembly, Includes: G4097-10 1 • X 1 Baffle G3862-1 1 X X 2 Warning Decal T13086-163 1 X X 3 Baffle S24624 1 X X 4 Heat Sink Holder S22168 3 X X 5 Thread Forming Screw (Cutting) S9225-17 3 X X 6A Thread Forming Screw (Cutting) S9225-17 3 X X 6B Plain Washer S9262-98 3 X X 6C Lock Washer E106A-2 3 X X 6D 1/4-20 HN CF000017 3 X X 7A Weld Control PC Board Assembly G4107-[ ] 1 X • 7A Weld Control PC Board Assembly G5507-[ ] 1 • X 7B Self Tapping Screw S8025-100 4 X X 8 Chopper Board Assembly L11845-[ ] 1 X X 9A Capacitor S13490-114 1 X X 9B Capacitor Bracket L9250 1 X X 10 Bushing T14614-1 1 X X 11A Resistor S10404-138 1 X X 11B Heat Sink Holder S22168 2 X X 11C Thread Forming Screw (Cutting) S9225-17 2 X X 11D Plain Washer S9262-98 2 X X 11E Lock Washer E106A-2 2 X X 11F 1/4-20 HN CF000017 2 X X 11G #10-24 x 7.50 RHS CF000191 1 X X 11H Plain Washer S9262-27 2 X X 11J Lock Washer E106A-1 1 X X 11K #10-24 HN CF000010 1 X X 12A Relay, DPDT 12-VDC AG-C100 S14293-14 1 X • 12A Relay, SPDT 12-VDC S14293-20 1 • X 12B Self Tapping Screw S8025-91 2 X X 12C Socket, Relay S14531-5 1 • X 13A Diode Bridge, 35A, 400V, FW 1PH T13637-6 2 X X 13B #10-24 x .75 RHS CF000072 2 X X 13C #10-24 HN CF000010 2 X X 13D Lock Washer E106A-1 2 X X 13E Plain Washer S9262-27 2 X X 14A Pull Coil PC Board Assembly L11768-[ ] 1 X X 14B Self Tapping Screw S8025-100 4 X X 15A Thread Forming Screw S9225-76 1 X X 15B Plain Washer S9262-27 2 X X 15C #10-24 HN CF000010 2 X X 15D Lock Washer E106A-1 1 X X 15E Lock Washer T9695-1 1 X X 16 Grommet S18543-5 1 X X 17 Thread Forming Screw (Cutting) S9225-68 1 X X 18A Resistor S10404-132 1 X X 18B #10-24 x 3.00 RHS CF000009 1 X X 18C Insulating Washer T4479-A 2 X X 18D Plain Washer S9262-27 1 X X

RANGER

305D

08-03-2009

P-492-F.2

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

18E Lock Washer E106A-1 1 X X 18F #10-24 HN CF000010 1 X X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates.

RANGER

305D

08-03-2009

NOTES

RANGER®305D

Base, Fuel Tank, Battery Assembly

11B

11A

10B

10A

P-492-GP-492-G

10A

RANGER®305D

10B

11A

11B

Oct-13

P-492-G.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

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

NSS - Not Sold Separately

RANGER

305D

Oct-13

Engine Assembly

P-492-HP-492-H

14A

3F 3E

14C

14B

10B

10H

10J

10F

10A

10G

10E

10C

11B

11A

11E

10D

11C

11D

4A 2H

RANGER®305D

08-03-2009

P-492-H.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Engine (M20062) (KUBOTA) NSS 1 X••• 1A Engine (M20502) (KUBOTA) NSS 1•X•• 1A Engine (M21504) (KUBOTA) NSS 1 ••X• 1A Engine (M22868) (KUBOTA) NSS 1 •••X 1B Fan Coupling Hub - Kubota S25211 1 XXXX 1C Lock Washer E106A-14 3 XXXX 1D Metric Screw (M8 X 1.25 X 25) T14731-11 3 XXXX 1E Fan, Pusher (350mm) (Supplied w/Engine) (Note 1) 1 XXXX 1F Lock Washer E106A-2 4 XXXX 1G 1/4-20 x .75 HHCS CF000014 4 XXXX 1H Flat Washer (Not Shown) S9262-98 4 XXXX 2A Left Engine Foot L11885-2 1 XXXX 2B Right Engine Foot L11885-1 1 XXXX 2C Rubber Mounting T11991-3 2 XXXX 2D Thread Forming Screw S9225-26 4 XXXX 2E 3/8-16 x 1.25 HHCS T8833-62 2 XXXX 2F Lock Washer E106A-16 2 XXXX 2G Plain Washer S9262-120 2 XXXX 2H HHCS (M10 X 1.25 X 25) T14731-30 4 XXXX 2J Lock Washer S17400-1 4 XXXX 3A Muffler Asbly (Includes M20062-9 Gasket) G4247-1 1 XXXX 3B Exhaust Gasket (Supplied w/Engine) (M20062-9) (Note 1) 1 XXXX 3C M8 x 1.25 x 25mm Bolt (Supplied w/Engine) (Note 1) 4 XXXX 3D M8 Nut (Supplied w/Engine) (Note 1) 4 XXXX 3E Spring Washer (M8) (Supplied w/Engine) (Note 1) 4 XXXX 3F Flat Washer S9262-121 4 XXXX 3G Muffler Bracket S25496 1 XXXX 3H Thread Forming Screw S9225-26 4 XXXX

3J Spark Arrestor (Includes Fasteners) S20462 1 XXXX

3K Outlet Pipe Elbow M16980-1 1 XXXX 4A Inline Fuel Filter (Supplied w/Engine) (Note 1) 1 XXXX 6A Main Fuel Filter/Sedimenter (Supplied w/Engine) (Note 1) 1 XXXX 6B 5/16 -18 X 2.50 HHCS CF000187 1 XXXX 6C Lock Washer E106A-14 1 XXXX 6D 5/16HN CF000029 1 XXXX 7A Solenoid & Fuel Pump Bracket L11898 1 XXXX 7B Screw M8 X 1.25 20 HHCS T14731-3 2 XXXX 7C Lock Washer E106A-14 2 XXXX 7D Fuel Pump, Electric (Supplied w/Engine) (Note 1) 1 X••• 7E 1/4-20 x .75 HHCS CF000014 2 XXXX 7F Plain Washer S9262-98 2 XXXX 7G Lock Washer E106A-2 2 XXXX 7H 1/4 x 20 HN CF000017 2 XXXX 7J Plain Washer S9262-121 2 XXXX 8A Adapter Fitting S25362-2 1 XXXX 8B 5/8 ID Drain Hose T10642-264 1 XXXX 8C Hose Clamp S10888-27 2 XXXX 8D Adapter Fitting S25362-1 1 XXXX 8E Oil Drain Valve S24662 1 XXXX 9A Air Cleaner Housing & Element M19801-1 1 XXXX 9B Air Cleaner Mounting Band S25230 1 XXXX

NSS - Not Sold Separately

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

RANGER

305D

02-06-2013

P-492-H.2

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

9C 5/16-18 x 1.00 HHCS CF000062 2 XXXX 9D Plain Washer S9262-121 2 XXXX 9E Lock Washer E106A-14 2 XXXX 9F 5/16-18 HN CF000029 2 XXXX 9G Air Intake Hose M20061 1 XXXX 9H Hose Clamp S10888-29 2 XXXX 10A Solenoid Assembly, Idler S20140-3 1 XXXX 10B 1/4-20 x .75 HHCS CF000014 2 XXXX 10C Plain Washer S9262-98 2 XXXX 10D Lock Washer E106A-2 4 XXXX 10E 1/4-20 HN CF000017 2 XXXX 10F In-Line Swivel S22070 1 XXXX 10G Governor Ball Joint S10623-2 1 XXXX 10H 1/4-28 x .625 HHCS T8833-51 1 XXXX 10J 1/4-28 HN CF000198 3 XXXX 11A Governor Arm Bracket S25108 1 XXXX 11B 1/4-20 x .75 HHCS CF000014 1 XXXX 11C Lock Washer E106A-2 1 XXXX 11D Plain Washer S9262-98 1 XXXX 11E 1/4-20 HN CF000017 1 XXXX 13 Shutdown Solenoid (Supplied w/Engine) (Note 1) 1 XXXX 14A Lift Bale Assembly L11880 1 XXXX 14B 3/8-16 X .75 HHCS CF000034 6 XXXX 14C Lock Washer E106A-16 6 XXXX 15 Fuel Hose(9") (Not Shown) (Main Filter to Fuel Pump) T10642-256 1 X • • •

Hose Clamp (Not Shown) T13777-5 2 X • • • 16 Fuel Hose (4") (Not Shown) (Pump to In-Line Filter) T10642-67 1 X • • •

Hose Clamp (Not Shown) T13777-5 2 X • • • 17 Fuel Hose (9") (In-line Filter to Engine) (Not Shown) T10642-256 1 XXXX

Hose Clamp (Not Shown) T13777-5 2 XXXX 18 Fuel Hose (17”) (Not Shown) T10642-65 1 • X X X

(Main Filter to Mechanical Fuel Pump) Hose Clamp (Not Shown) T13777-5 2 • X X X Fuel Hose (9”) (Not Shown) (Mechanical Pump to in-line Filter)

T10642-256 1 • X X X

Hose Clamp (Not Shown) T13777-5 2 • X X X

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

RANGER

305D

02-06-2013

NOTES

RANGER®305D

Covers & Case Back Assembly

1A1A

2929

3737

2424

2525

3A3A

3D3D

3B3B

3C3C

3333

3434

11B11B

1B1B

26A26A

26B26B

2B2B

27C27C

2828

12A12A

23A23A

2A2A

11A11A

19D19D

19C19C

19B19B

19A19A

18B18B

18A18A

14B14B

14C14C

14D14D

1313

31D31D

31A31A

31B31B

14E14E

22C22C

22B22B

3030

22A22A

1515

2020

2121

17A17A

17B17B

17C17C

3636

3535

22G22G

22H22H

22E22E

1616

14A14A

27B27B

26C26C

27A27A

P-492-JP-492-J

07-26-2010

RANGER®305D

P-492-J.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Roof G3926-3 1 X X X 1B Door Bumper T14882-1 12 X X X 1C Thread Forming Screw (Cutting) (Not Shown) S9225-68 16 X X X 2A Case Side - Right G3510 1 X X X 2B Thread Forming Screw (Cutting) S9225-68 3 X X X 3A Engine Top Cover Assembly G3927 1 X X X 3B Door Bumper T14882 2 X X X 3C Latch S24694 1 X X X 3D Rivet T12584-9 2 X X X 3E Rivet (Not Shown) T12584-6 2 X X X 5 Fuel Warning Decal T13086-26 1 X X X 6 Warning Label M16197 1 X X X 7 Engine Service Decal S25522 1 X X X 8 Warning Decal T13086-62 3 X X X 9 Wiring Diagram G4571 1 X • • 9 Wiring Diagram G4571-1 1 • X • 9 Wiring Diagram G4571-2 1 • • X 10 Logo Decal S11893-4 2 X X X 11A Hinge Assembly S24295-1 2 X X X 11B Rivet (Not Shown) T12584-9 4 X X X 12A Hinge Assembly S24295-2 2 X X X 12B Rivet (Not Shown) T12584-9 2 X X X 13 Fan Shroud G4245 1 X X X 14A Radiator G3115-1 1 X X X 14B Thread Forming Screw S9225-26 4 X X X 14C Plain Washer S9262-121 4 X X X 14D Lock Washer E106A-14 4 X X X 14E Thread Forming Screw S9225-68 6 X X X 15 Radiator Cap S9970-2 1 X X X 16 Drain Cock T9956 1 X X X 17A Case Back G4243 1 X X X 17B Thread Forming Screw S9225-68 8 X X X 17C Fastener Button T14659-1 4 X X X 18A Fan Guard (Right) G4058-1 1 X X X 18B Thread Forming Screw S9225-68 4 X X X 19A Fan Guard (Left) G4060-1 1 X X X 19B Thread Forming Screw S9225-68 4 X X X 19C Speed Nut T11525-5 2 X X X 19D Thread Forming Screw S9225-66 2 X X X 20 Over Flow Hose (Radiator to Coolant Bottle) T10642-236 1 X X X 21 Hose Clamp (Over Flow Hose) T13777-5 2 X X X 22A Lower Radiator Hose L11881 1 X X X 22B Hose Clamp S10888-16 4 X X X 22C Upper Radiator Hose M20064 1 X X X 22E Hose Fitting, Brass S25524 1 X X X 22G Flex Hose (Ref. Thermostat to Radiator) T10642-263 1 X X X 22H Clamps S10888-35 2 X X X 23A Case Side-Left G3511 1 X X X 23B Thread Forming Screw (Cutting) (Not Shown) S9225-68 3 X X X 24 Cover Seal (Codes 11121 & 11188) S12934 1 X X • 24 Cover Seal (Codes 11275 & 11457) S12934-1 1 • X X

RANGER

305D

08-03-2009

P-492-J.2

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

25 Fuel Trough L12084 1 X X X 26A Left Engine Cover L11879 1 X X X 26B Latch S24694 1 X X X 26C Hinge S24348 2 X X X 26D Rivet (Not Shown) T12584-9 6 X X X 27A Right Engine Cover L11878 1 X X X 27B Latch S24694 1 X X X 27C Hinge S24348 2 X X X 27D Rivet (Not Shown) T12584-9 6 X X X 28 Oil Drain Procedure Decal S25455 1 X X X 29 Warranty Decal (Part of L11812-4) NSS 1 XXX 30 Foam M15045-40 1 X X X 31A Bracket, Coolant Recovery Bottle S25514 1 X X X 31B Thread Forming Screw S9225-68 2 X X X 31C Bushing (Not Shown) T12380-1 1 X X X 31D Coolant Recovery Bottle (Supplied w/Engine) (Note 1) 1 XXX 31E PVC Coolant Drain Hose (Not Shown) (Note 1) 1 XXX 32 Cover & Snap Assembly (Optional Part) (Not Shown) L11990-1 1 X X X 33 Warning Decal S25896 1 X X X 34 Instruction Tag M17238 1 X X X 35 Country of Origin Decal S24727-1 1 X X X 36 CCC Decal (Code 11457 Only) T13086-91 1 • • X 37 Decal, Product Name (Code 11457 Only) M21952-1 2 • • X

# # #

NSS - Not Sold Separately

Note 1- Supplied by Engine Manufacturer.

RANGER

305D

07-26-2010

NOTES

RANGER® 305D

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Lincoln K1727-4, K1727-3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual